Boumatic HD2 Rapid Exit User manual

9e1075
Operator Manual
HD2
Milking system
www.boumatic.com
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08-2018

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CONTENTS
1. PREFACE
1.1 MANUFACTURER’S ADRESS ......................................................................................................................................................... 3
1.2 CUSTOMER SERVICE........................................................................................................................................................................ 3
1.3 GUIDELINES, LAWS, STANDARDS............................................................................................................................................... 3
1.3.1 DECLARATION OF CONFORMITY ............................................................................................................................................... 4
1.4 SUCCESSFUL MILKING.................................................................................................................................................................... 5
2. SAFETY
2.1 OWNER’S DUTY OF CARE.............................................................................................................................................................. 6
2.2 BASIC SAFETY INSTRUCTIONS.................................................................................................................................................... 7
2.3 PERSONNEL QUALIFICATION....................................................................................................................................................... 8
2.4 PROTECTIVE EQUIPMENT.............................................................................................................................................................. 9
2.5 SAFETY SIGNS, STICKERS AND LABELS ................................................................................................................................... 9
2.6 PACKAGING MATERIALS ................................................................................................................................................................ 9
2.7 CORRECT APPLICATION................................................................................................................................................................. 9
3. DESCRIPTION
3.1 INSTALLATION CONDITIONS......................................................................................................................................................11
3.2 NOISE LEVEL .....................................................................................................................................................................................11
3.3 DELIVERY............................................................................................................................................................................................12
3.4 STORAGE............................................................................................................................................................................................12
3.5 RECOMMENDATIONS....................................................................................................................................................................13
3.6 SYMBOLS ...........................................................................................................................................................................................13
4. CONTROL AND OPERATING UNIT
4.1 CONTROL UNIT................................................................................................................................................................................14
4.2 OPERATION OF THE HD2.............................................................................................................................................................14
5. CLEANING
5. CLEANING..........................................................................................................................................................................................15
6. MAINTENANCE
6. MAINTENANCE................................................................................................................................................................................15
7. DECOMMISSIONING
7.1 SPECIAL PERSONNEL QUALIFICATION REQUIRED FOR DECOMMISSIONING .......................................................19
7.2 SAFETY INSTRUCTIONS FOR DECOMMISSIONING...........................................................................................................19
7.3 SPECIAL DANGERS INVOLVED IN DECOMMISSIONING..................................................................................................19
7.4 FINAL DECOMMISSIONING / DISPOSAL................................................................................................................................19

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These instructions are supplied with the product.
They should be kept close at hand and remain with the equipment even if the equipment is sold.
This manual is not covered by an amendment service. The current version can be obtained through your
technical dealer or directly from BouMatic.
We reserve the right to make changes of the data and illustrations in this manual due to technical
developments.
Reproduction, translation or copying in any form, including extracts, requires written authorization from
BouMatic.
1.1 MANUFACTURER’S ADDRESS
If necessary, please contact your nearest authorised dealer.
BouMatic Europe
EMC compliance has been tested and this equipment meets the requirements of the applicable European
and national guidelines.
Conformity has been proved and the manufacturer holds the relevant statements and documents.
To maintain this state and ensure safe operation, you, as a user, must observe this operator manual.
1. PREFACE
1.1 MANUFACTURER’S ADRESS
1.2 CUSTOMER SERVICE
1.3 GUIDELINES, LAWS, STANDARDS
BouMatic A/S
Jernvej 2
6900 Skjern
Denmark
Tel: [phone]
Fax: [phone]
BouMatic Gascoigne Melotte Sprl.
Rue Jules Melotte 31
4350 Remicourt
Belgium
Tel: [phone]
Fax: [phone]

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1.3.1 DECLARATION OF CONFORMITY
In process!

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1.4 SUCCESSFUL MILKING
Prerequisites for successful milking:
A milking installation designed in accordance with ISO 5707 or 3 A and set up correctly.
Stable vacuum conditions due to an appropriately sized vacuum pump, a balance tank and vacuum reserve as well
as properly sized vacuum lines.
Milking vacuum and automatic cluster removal must be set correctly to suit the animals.
Regular checks and adjustments to meet any herd changes will also ensure successful milking.
A milking cluster selected to suit the animals.
Correctly positioned cluster. Keep hoses as short as possible to avoid unnecessary sagging.
Scheduled maintenance and cleaning of the milking installation. Regular thorough cleaning and disinfection of
the milking installation will help improve animal health, milk quality and therefore milking results.
When replacing parts, only use genuine BouMatic spare parts!
Recommended settings are only valid in conjunction with genuine BouMatic products.
The conscientious implementation of milking routines will have a positive eect on milking results.
Rub to
remove any
residual
bedding.
Dip with
pre-dip.
Strip/wash
teat end
with
gloved hand.
Dry with
one circular
motion - flip
towel and
aggressively
squeeze
teat end.
Attach
unit.
Adjust unit
for proper
placement.
Post-dip -
cover
complete
teat!!
10 to 12 seconds of teat contact
time. (stripping, washing and
drying)
Attach unit
within 75-90
seconds after
steps 3 and 4.
After attachment, adjust unit to
hang squarely on the cow as soon
as the last teat cup is attached.
Gently,
Quickly and
Completely
Always Milk Your Cows...
7 Step Udder Prep
BouMatic.com
1 2 3 4 5 6 7
Attention!
Milking without milk ow (overmilking) must be avoided, as it will very quickly have an adverse
eect on teat condition and udder health

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Design and construction of this product were preceded by risk assessment and careful identication of applicable
harmonized standards and other technical specications. This product therefore represents the state-of-the-art
of technology and ensures a maximum level of safety. To achieve safety on farms, all necessary measures must be
taken. The owner is responsible for planning such measures and for verifying their implementation.
In particular, the owner has to ensure the following:
• Legal requirements must be met.
• Instructions on basic safety precautions must be followed.
• Safety signs, stickers and labels on the product must be replaced immediately if they are illegible or lost!
• All applied safety signs or warning instructions must stay in place and remain legible.
• Escape routes must be indicated by signs in accordance with national regulations!
• The required personal protection equipment must be available and used by operators, maintenance and
service personnel.
• A full set of legible instructions must always be kept near the product. Anyone having to work on the
product must have the possibility to look into the instructions at any time.
• The owner has to ensure that his sta receive adequate training adapted to suit the specic conditions of
his facility; emphasis should be placed on safety aspects.
• Unauthorised persons (e.g. children) are not permitted into hazardous areas and must not have access to
cleaning agents or disinfectants.
• Anyone involved in the operation, maintenance, inspection or handling of this product in any other way
must know and understand this manual (especially the safety information and warnings).
• This product
-should only be used for its intended purpose.
-should only be used if in perfect operating condition. The safety equipment, in particular, should be
regularly checked to make sure it is in perfect operating condition.
• Operating personnel who require training may only work on the product under the supervision of an
experienced person. The successful completion of training is to be conrmed in writing.
• Persons carrying out work on this product must be suciently qualied!
2. SAFETY
2.1 OWNER’S DUTY OF CARE

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• There are dangers involved in the operation and maintenance of dairy farm equipment. For your own safety,
please read and observe these instructions carefully (especially the section on “Safety instructions”).
• Permissible working conditions (pressure ranges, temperature ranges, airow quantities etc.) must be ob-
served!
• Do not open or dismantle any devices (risk of injury)!
Do not remove any protective devices (risk of injury)!
• When working with cleaning and disinfecting agents observe the notes on dangers and protective measures
(risk of caustic burns)!
• When working with products from other manufacturers always observe the warnings on the material safety
data sheets and the operating instructions of the manufacturer!
• Observe noise protection measures!
• Do not stand underneath suspended loads.
• Always keep control cabinets, all power supply units and electrical control units closed.
Access is only permitted to authorized personnel with a key or special tool.
• Protect live and high-voltage components against moisture.
Water jets and high-pressure cleaners must NOT under any dircumstances be directed at them!
Work to be performed by qualied personnel only:
-Transportation
-Handling
-Maintenance
-Cleaning
Work to be performed by authorized personnel only:
-Installation
-Start-up
-Service
-Troubleshooting
-Repairs
-Decommissioning
These personnel will be regularly instructed in all relevant matters of safety at work and protection of the environ-
ment and by familiar with this manual, particularly the safety instructions it contains.
Attention!
2.2 BASIC SAFETY INSTRUCTIONS

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Anyone carrying out work or activities in connection with the product must carefully read the manual and sign to
conrm that they have understood it and will act accordingly!
Responsibilities:
• AC power wiring for voltage over 40 V (in Europe 50 V) must be done by a qualied (licensed) electricain in
compliance with the latest edition of the ANSI/ NFPA-Standard 70, National Electrical Code (USA) or either LVD
2006/95/EC oder EMC 2014/30/EU (in Europe) and in complianced with the local wiring codes as applicable.
• Any work on the hydraulic and pneumatic equipment should only be performed by specialist personnel trained
for this purpose.
• Any welding should only be performed by specialist personnel with knowledge in welding.
• Other installation, major maintenance, and service work must be done by an authorized BouMatic dealer.
• Product / system checkout and troubleshooting must be done by an authorized BouMatic dealer.
In addition, special qualications are required for the following activities:
• Transportation
• Handling
• Maintenance
• Cleaning
• Installation
• Start-up
• Service
• Troubleshooting
• Repairs
Deviation from these instructions could aect product performance or create a hazardous situation. Under no
circumstances will BouMatic be responsible for any problems caused in whole or in part by a deviation from the
procedures specied in these instructions without prior written approval from BouMatic.
Operation steps may be performed by the owner/operator once the dealer or technician has successfully nished
the product/system checkout. The owner/operator is responsible for properly operating, maintaining, and moni-
toring the product/system to ensure that it works properly.
Disclaimer
No warranties are contained in these instructions. The division of responsibilities, stated above, is a general reminder
of those provisions in the applicable dealer contract and does not change any agreement between BouMatic and
the dealer. Information in these instructions is not all-inclusive and cannot cover all unique situations.
2.3 PERSONNEL QUALIFICATION

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Attention!
• Risk of death from electric shock!
Covers of electrical connection boxes must always be closed, otherwise there is danger of contact with
live parts.
• Risk of burns from acidic or alkaline detergents!
Risk of eye injuries or skin irritation.
• Risk of injury by putting your hand into the vacuum system!
Never reach into openings of the system when the machine is running. Extremities could be sucked in
by the vacuum prevailing in the system.
Safety signs, stickers and labels axed to the product must be replaced immediately when illegible or lost!
Packaging materials must be disposed of in accordance with applicable local regulations!
BouMatic equipment and components are designed exclusively for agricultural facilities (mostly dairy farms).
This product/component is designed exclusively for use during the milking process in parlors for cows or goats.
Any application not listed here is not part of the intended purpose and therefore considered as improper use!
The manufacturer / supplier is not liable for any resulting damage. The user alone bears the risk.
Correct use also includes reading the instructions and observing the inspection and maintenance conditions.
Genuine BouMatic parts and accessories are specially designed for Boumatic components; use only genuine spare
parts.
2.4 PROTECTIVE EQUIPMENT
2.5 SAFETY SIGNS, STICKERS AND LABELS
2.6 PACKAGING MATERIALS
2.7 CORRECT APPLICATION

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Attention!
• Please note that parts or accessories not supplied by us and instructions not provided by BouMatic
are not checked or released by us either.
• If such products are installed or used, this can have a negative eect on the specied properties of
BouMatic products and put people and animals at risk.
• The manufacturer cannot be held liable for injury to people and animals or for damage to BouMa-
tic products caused as a result of using non-genuine parts or accessories or by incorrect settings.
• During repair and service operations, always cut the power to the control unit by turning o the
switch.
• The control unit contains 230/400 V AC circuits and may only be opened by a BouMatic installer or
a qualied electrician.
• Installation, together with any repairs during the warranty period, may only be undertaken by an
authorised BouMatic dealer/installer, or in accordance with instructions from BouMatic, otherwise
the warranty will be invalid.

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DUH217111400
DUH217111400
Main work station
3. DESCRIPTION
3.1 INSTALLATION CONDITIONS
The HD2 milking parlour must be installed in a building (under a roof), protected against negative weather conditions.
The premises should have a minimum temperature of 5° Celsius and not have excessive humidity levels.
The installation conditions of the HD2 with regard to the external electrical and water connections, the structural building
conditions and other conditions on site do not fall within the sphere of responsibility of BouMatic.
Please follow the instructions in this manual.
Objects or other components that are added to the system or are located/assembled nearby must not interfere in any way
with its correct and safe operation.
To operate the Formule 1milking parlour, pneumatic energy must be available: compressed air between 4 and 8 bars, oil
free.
The system is operated by a control unit installed in the milking pit so that its operation can bemonitored from cow entry
to exit gate.
3.2 NOISE LEVEL
The noise level does not exceed 70 dB (A).

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Please check the scope of delivery of the delivered goods and conrm receipt.
Check the delivered goods against the order conrmation and delivery note for correctness and possible
transport damage.
Damages or apparent inconsistencies must be reported in writing within 48 hours of delivery.
Ensure that the machine used to unload the system from the lorry (forklift, tractor with front loader, etc.) has the
appropriate power.
The weight per pallet varies according to the milking parlour size. The weight does not exceed 3000 kg per
pallet/unit however.
Receipt of goods:
BouMatic cannot be held liable for damage caused by improper unloading!
Do not stay under suspended loads during unloading and later assembly!
The following rules must be observed when storing the delivered goods:
Do not store the product outdoors or in areas with chemical vapours, moisture, excessive temperature and/or
dirt.
Do not store the product on the bare oor/ground.
Ensure proper storage of electrical components and/or fragile objects.
Strong exposure by e.g. exposure to sunlight at high humidity inuences the appearance of metal parts and
can cause damage to electrical and pneumatic components.
Plastics can change in colour due to excessive UV radiation and, in extreme cases, can become brittle.
3.3 DELIVERY
3.4 STORAGE

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3.5 RECOMMENDATIONS
Any inappropriate use of the HD2 can have dangerous and serious consequences.
Before commissioning the complete installation, make sure that it complies with all the applicable legislative
directives.
At the rst start-up, problems caused by settings may arise. This is why it is necessary to carry out the rst milking
shifts in the presence of qualied personnel able to analyse and solve such problems. However, even when
settings are correct, a certain time lapse is necessary for adaptation of the operator and the herd.
The HD2 is destined for the milking of cows under best conditions: calmly and without stress for the animals.
Never use this installation in any other way than for the milking of cows and/or under conditions other than those
recommended.
For security reasons, the user must make sure that no other person is present on the cow deck before the arrival of
the animals as well as during the use of the installation.
Also, during operation, it is important to keep an eye on the installation from the control box.
Do not let any person that is unqualied or unaware of the risks involved intervene on the installation. Do not
leave the installation unattended during operation.
Security measures are installed for the protection of people, animals and equipment. It is important to
permanently maintain them. The non-observance of certain mounting conditions can result in risks of serious
injury.
Excessive vibration or suspect noises can be caused by a default that must be immediately communicated to the
maintenance personnel and removed.
3.6 SYMBOLS
: Grease : Galvanize :Grease the
screws

2
2
2
1
1
1
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4. CONTROL AND OPERATING UNIT
4.1 CONTROL UNIT
1 – gate opening: - pull on this button to open the gate.
2 – gate closing: - push on this button to close the gate
4.2 OPERATION OF THE HD2
The HD2 is operated by the control unit(s).
A control unit activates the opening and closing of a gate.
Cow trac is organised by the opening and closing of the entry and exit gates.

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5. CLEANING
To secure the longevity of the installation, it is important to regularly clean the exposed elements to protect them from
corrosive attacks.
However, some recommendations should be taken into account:
- do not clean the HD2 with a jet under too high pressure.
- do not use products that are too aggressive
- do not spray live components, pneumatic or bearing elements (bearing type)
- when cleaning, pay attention to spraying or inadvertent splashing of electrical equipment. Make sure the pneumatic
components are clean.
During cleaning requiring access out of the milking pit, rst make sure that the HD2 is stopped, switched o, with the
pneumatic circuit cut so that no third party can endanger intervening sta or aect ongoing operations.
Waste water and cleaning products must not be abandoned outdoors and must be disposed of in accordance with the
legal provisions in force
In all cases of maintenance (unless necessary), the operations must be carried out after ensuring that the HD2 is stopped,
with pneumatic circuit cut in such a way that no third party could endanger the intervening sta or aect the current
operations.
Where appropriate, the means of access to the points of intervention, mainly at height, must be stable and allow
operations to be carried out safely
General maintenance:
Periodic, monthly and semi-annual maintenance consisting of checks may be carried out by non-specialised personnel in
this eld.
However, they must have minimum technical knowledge to understand the purpose of the operations to be conducted
and be able to interpret them accordingly.
If unscheduled maintenance or maintenance requiring more than just a check are required, it must be performed by
qualied personnel who are familiar with the assembly rules for this type of installation and who are aware of the risks
involved.
Parts that are too worn must be replaced with original spare parts.
- It is recommended (unless contraindicated) to use the following lubricants:.
- Grease: Unil Opal Polyfood
Equipment will perform more eectively over time if it is well maintained. That is why it is important to respect the
maintenance intervals.
6. MAINTENANCE

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Ad hoc maintenance:
Periodically lubricate the joints. Use the recommended grease or product with equivalent characteristic Warning: a lack of
lubrication of the articulated elements can lead to premature wear, even to breakage.
Greasing frequency in the rst term depending on to the joints concerned
Joints concerned Greasing frequency (milking hours)
Entry gate joints 750 or 6 months
Exit gate joints 750 or 6 months
fz
When lubricating the joints, it is advisable to operate them to ensure proper operation and to properly dispense the
lubricant.
Respecting the greasing frequency guarantees good functioning to the extent that the greasing is not aected by the
surrounding operations (e.g. removal of the grease after the cleaning)
If the pneumatic circuit of the installation does not have an automatic purge, it must be purged regularly.

DUH217111401
DUH217111401
DUH217111402
DUH217111402
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Greasing points entrance gate:
Greasing points exit gate:

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- Monthly check:
Check the status of the following points of the installation monthly
- the gate cylinders must be supplied with compressed air at a maximum of 4 bars.
- Half-yearly check:
Check the status of the following points of the installation on a half-yearly basis:
- control the joints, they work normally with a minimum clearance. If there is too much clearance, make the necessary
adjustments. If necessary, replace the worn parts with original spare parts.
- all the data and information indicated on the various elements must always remain legible and in its original state.
(Nameplates, pictograms, ...)
Warning!
Lubricants, solvents and detergents are toxic / harmful to health:
- if they come into direct contact with the skin, they can cause irritation
- if they are inhaled, they can cause serious intoxications
- if they are ingested, they can lead to death
They should therefore be handled with care using the appropriate personal protection devices. They must not be
abandoned outdoors and must be disposed of in accordance with the legal provisions in force.
Warning: the pneumatic cylinders do not require any particular maintenance. Make sure they are clean and in good
working order. However, as soon as a cylinder is lubricated once, it becomes necessary to lubricate it permanently

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7. DECOMMISSIONING
7.1 SPECIAL PERSONNEL QUALIFICATION REQUIRED FOR
DECOMMISSIONING
Decommissioning may only be performed by specially qualied personnel in accordance with the safety instruc-
tions.
Attention!
Also see the section on “Personnel qualication“.
To prevent damage to property and/or life-threatening injury to people when decommissioning, the following
points must always be observed:
Attention!
Also read the chapter on“Safety“.
• All of the steps involved in the decommissioning work must be worked through in the order specied.
• First of all, make the operating area for decommissioning completely safe.
• Make sure that operating supplies are disposed of without harming the environment.
7.2 SAFETY INSTRUCTIONS FOR DECOMMISSIONING
• Components which have not been removed correctly may fall o or twist.
• There is a risk of injury from open components /tools/… with sharp edges.
• Suspended loads can fall and then there will be a risk of death – do not stand underneath suspended
loads!
After decommissioning, all of the components should be handled correctly and disposed of in accordance with
valid local requirements on the disposal or recycling of waste.
7.3 SPECIAL DANGERS INVOLVED IN DECOMMISSIONING
7.4 FINAL DECOMMISSIONING / DISPOSAL

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