Boumatic Xpedia 360IX User manual

Xpedia™ 360IX
Feeding System
BouMatic Global Headquarters PO Box 8050 Madison, WI 53708-8050 USA Tel: [phone] Fax: [phone]
BouMatic Europe Rue Jules Melotte 31 4350 Remicourt Belgium Tel: [phone] Fax: [phone]
www.boumatic.com
Installation Instructions

9e997 Xpedia 360IX Feeding System Installation Instructions
3/21/13
Instructional Content and Purpose
These instructions aim to aid those responsible (outlined under “Re-
sponsibilities”) for installing, operating, maintaining, troubleshooting,
and servicing this product.
Responsibilities
Procedures in these instructions are to be performed according toap-
plicable codes (state, local, and other) by the person(s) qualied (li-
censed, if applicable) to do so—that is:
• Welding must be done by a qualied welder;
• AC power wiring for voltages over 40V (50V in Europe) must be
done by a qualied (licensed) elecrician in compliance with the
latest edition of the ANSI/NFPA Standard 70, National Electrical
Code, (USA) or either LVD 2006/95/EC or EMC 2004/108/EC (Eu-
rope) and in compliance with the local wiring codes as applicable;
• Other installation, major maintenance, and service work must
be done by an authorized BouMatic dealer;
• Product/system checkout and troubleshooting steps are to be
performed by an authorized BouMatic dealer;
• Deviation from these instructions could affect product perfor-
mance or create a hazardous situation. Under no circumstances
will BouMatic be responsible for any problems caused in whole
or in part by and 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 prop-
erly operating, maintaining, and monitoring the product/system
to ensure that it works properly.
Close compliance with the procedures herein is essential for the owner
to get maximum benet from the product/system.
Disclaimers
No warranties are contained in these instructions. The division of re-
sponsibilities, 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.

Table of Contents
9e997 Xpedia 360IX Feeding System Installation Instructions
3/21/13
Introduction................................................................................................................................. 4
1. Preparation .............................................................................................................................. 4
1.1 Verifying Part and Tool Requirements ............................................................................... 4
1.2 Reviewing Installation Specications................................................................................ 4
1.3 Reviewing Personal Safety Messages................................................................................ 4
2. Installation .............................................................................................................................. 5
2.1 Feed Manger Assemble .................................................................................................. 6
2.2 Brisket Rails ................................................................................................................. 7
2.3 Cow Entrance Pinch Gate ............................................................................................... 8
2.4 Middle Swing Gate......................................................................................................... 9
2.5 Exit Pinch Gate ........................................................................................................... 10
2.6 Man Access Gate......................................................................................................... 11
2.6.1 External Man Access Gate................................................................................ 11
2.6.2 Internal Man Access Gate ................................................................................ 11
2.7 Installation of External Rails ......................................................................................... 12
2.7.1 Positioning at Man Passage(s) .......................................................................... 12
2.7.2 Positioning Around Perimeter ........................................................................... 12
2.7.3 Positioning at Cow Entrance/Exit....................................................................... 13
2.7.4 Installation of Bottom Rails .............................................................................. 13
2.8 Installation of Feed Hopper........................................................................................... 14
2.9 Finger Switches .......................................................................................................... 15
2.10 Electrical Installation.................................................................................................. 16
2.10.1 Feed Dispenser Control.................................................................................. 16
2.10.2 Main Control Panel Safety Switches ................................................................. 16
2.10.3 Brake Resistor.............................................................................................. 19

9e997 4 Xpedia 360IX Feeding System Installation Instructions
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Introduction
It is important that in preparation of the installation
of the Feeding System that this manual is read and
understood in conjunction with Xpedia™ 360IX In-
stallation Manual, literature number 9E-879.
1. Preparation
1.1 Verifying Part and Tool
Requirements
Dealer-Supplied Parts Quantity
Zinc Spray
Junction boxes
Cable Ties
Trunking and Conduit
When installing parts, the dealer should have standard in-
stallation tools. Nonstandard tools are noted where used.
Tools required:
Drill
Grinder
General Hand tools (Spanners, Hammer, Sockets)
Concrete hammer drill
Electrical crimpers
Electrical cable cutters
Welder
Additional Literature Referenced Section (§)
Xpedia™ 360IX Installation Instructions 9E- 879
1.2 Reviewing Installation
Specications
Plan the installation according to these guidelines:
• Review the instruction on page 1 under the
heading “Responsibilities” and perform only
those steps in this section for which you are
responsible.
• Read this entire instruction booklet (paying
close attention to personal safety messages
and installation specications in Section 1)
before starting procedures in this section.
• Bolt or tack weld parts in place, as required,
until the entire installation is complete.
Then, after all adjustments have been made,
fully weld the joints.
1.3 Reviewing Personal Safety
Messages
To prevent possible bodily injury, follow the safety
messages below and throughout this booklet. Safety
should be everyone’s primary concern. Note that the
owner is responsible for replacing safety labels should
they become illegible.
Provide positive, lockable disconnects to prevent un-
intended application of electrical, hydraulic or pneu-
matic power to the equipment. Refer to national reg-
ulations for proper lockout procedures for equipment
service or repair.
CAUTION
To avoid injury, do not operate the stall with person-
nel on the cow platform. (Label P/N 8507120)
CAUTION
The gates may move quickly when air is rst applied
to the system, which could result in injury if proper
precautions are not taken.
WARNING
Welding of galvanized steel parts may produce fumes
and gases hazardous to health. Avoid breathing these
fumes and gases. Use adequate ventilation.
WARNING
Use proper lifting equipment rated to handle heavy ob-
jects. Placement of the stalls requires a minimum of ten
people or a sturdy mechanical means for lifting the stalls.
Failure to meet these requirements could result in injury.

9e997 5 Xpedia 360IX Feeding System Installation Instructions
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2. Installation
Reference Figure 1 with the following concrete lay-
out for rail support posts instructions:
1. Mark the position of the entry/exit posts
and x them to the ground using the FBN
M10x160 anchor bolts, at a height of 70mm
(2.76 in.) from the ground, and observe di-
mension 920mm from the outside diameter
of the platform deck.
2. Mark out radius R15 on the ground and
observe dimension 850mm from the outside
diameter of the platform deck.
3. Starting from the middle entry/exit post,
mark out sections CC8.
4. Using the FBN M10x160 anchor bolts, secure
the rail support post plates at a height of
70mm (2.76 in.).
Concrete layout and installation of posts L997_1
1.
16/4 20/4 24/4 28/4 32/4 36/4
R15 mm 5640 6300 6964 7626 8287 8949
in. 222.0 248.0 274.2 300.2 326.3 352.3
CC8 mm 2726 2474 2418 2273 2163 2157
in. 107.3 97.4 95.2 89.5 85.2 84.9

9e997 6 Xpedia 360IX Feeding System Installation Instructions
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Feed manger mounting L997_3
3.
Upright
Post
Grind off
excess and
smooth
Assemble feed manger L997_4
4.
Alignment of feed manger L997_2
2.
2.1 Feed Manger Assemble
1. Align the back of the feeder shoot with the cir-
cumference of the rotary. It should be tangent
at its point of attachment. (See Figure 2.)
2. Attach the Feed Manger Support Arm to the
arch upright post on the platform using the
M10 U – bolts. Observer Standard height
recommendation for support arm (Figure
2). The height can be adjusted based on the
average cow size of the herd. After the Feed
Manger Support Arm is secured to the arch
upright post on the platform grind off excess
U-Bolt length and smooth. (See Figure 3.)
3. Assemble the Feed Manger to the Feed Man-
ger Support Arm using M12 Bolts. The bolt
head should be installed on the inside of the
Feed Manger and the threads to the outside.
The Feed Manger and Support Arm have
several mounting hole locations to allow for
adjustment depending on the average cow
length of the herd. (See Figure 4.)

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2.2 Brisket Rails
1. Attach the upper and lower entry and exit
guide rail supports (Figure 5a) for the front
rail using M12x90 Bolts at the angle speci-
ed in Figure 5b.
2. Assemble the front rails to the rail support
posts. (Figure 6.)
L997_5A
5a.
Entry
Guide
Rail
Supports
L997_5B
5b.
Cow Exit Cow Entrance
10° 8°
Installation of rails and support posts L997_6
6.

9e997 8 Xpedia 360IX Feeding System Installation Instructions
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Pinch gate clearance L997_6A
6a.
Pinch gate assembly L997_6B
6b.
Cow
Entrance
Upright
Post
Weld
2.3 Cow Entrance Pinch Gate
1. Position the Entrance Pinch gate to have
clearance of the Feed Manger as it passes
by. The Top Finger (Fig. 6a) should clear
above the feed shoot on the back of the
Feed Manger.
2. Weld the hinge brackets to the cow entrance
upright post. (See Figures 6a and 6b.)
3. Secure the sensor mechanism. (See Figure 7.)

9e997 9 Xpedia 360IX Feeding System Installation Instructions
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Pinch gate sensor L997_7
7.
Middle swing gate installation L997_8
8.
Manager Support Arm
Centered in Gap Weld
Hinge
Brackets
2.4 Middle Swing Gate
1. Position the Middle Swing gate to have clear-
ance of the Feed Manger as it passes through.
The Manger Support Arm should be centered in
height in the Gap of the Middle Swing Gate.
2. Weld the Hinge Brackets to the cow entrance
side of the wall plate post. (See Figure 8.)

9e997 10 Xpedia 360IX Feeding System Installation Instructions
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2.5 Exit Pinch Gate
1. Position the Exit Pinch gate to have clearance
of the Feed Manger as it passes by. The Top
Finger should clear above the feed shoot on the
back of the Feed Manger.
2. Weld the Hinge Brackets to the cow entrance
side of the wall plate post. (See Figure 9.)
3. Secure the sensor mechanism. (See
Figure 10.)
Exit pinch gate installation L997_9
9.
Weld
Hinge
Brackets
Exit pinch gate sensor L997_10
10.

9e997 11 Xpedia 360IX Feeding System Installation Instructions
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2.6 Man Access Gate
2.6.1 External Man Access Gate
1. The position of the rotary when stopped for
CIP wash must also be in the optimal Man
Access position for day to day operation of
milking. Also, the CIP wash position should
not have a Man passage aligned with the
cow entrance/exit area. (See Figure 11.)
2. Once the optimal positioning of the Man ac-
cess is determined the bottom Front Rail will
need a section removed 590mm to install
the Man Access Gate. (See Figure 12.)
Man passage L997_11
11.
Man passage installation L997_12
12.
Internal gate installation L997_24
13.
Internal gate installation L997_25
14.
2.6.2 Internal Man Pass Gate
Install the internal man pass gate(s) as shown in
Figures 13 and 14.

9e997 12 Xpedia 360IX Feeding System Installation Instructions
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External rail installation at support posts L997_14
16.
2.7.2 Positioning Around Perimeter
Install the external rails around the perimeter of the
rotary, securing them to the rail support posts with
the clamps as shown. (See Figures 16 and 17.)
2.7 Installation of External Rails
2.7.1 Positioning at Man Passage(s)
Install the rail brackets onto the man access gate by
bolting into place. Attach the bent sections of the ex-
ternal rails to the brackets as shown. (See Figure 15.)
External rail brackets at man passage L997_13
15.

9e997 13 Xpedia 360IX Feeding System Installation Instructions
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2.7.3 Positioning at Cow Entrance/Exit
Using bent sections, complete installation of the ex-
ternal rails by tying into the posts at the cow entrance
and exit using brackets as shown. (See Figure 15.)
2.7.4 Installation of Bottom Rails
Installation of the bottom rails will begin at the en-
trance/exit gate. Secure the ends in place using U-
bolts as shown in Figure 17. Maintain spacing around
the circumference of the rotary, securing with band
clamps at the support posts (Figure 16). At the man
passes, secure the ends of the two outer rails with
U-bolts and the inner rail by welding (Figure 18).
Installation of Bottom Rails L997_26
18.
External rail installation at entrance/exit L997_16
17.
Weld
U-bolts

9e997 14 Xpedia 360IX Feeding System Installation Instructions
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Feed dispenser location L997_17
19.
Second Stall Position
Third Stall Position
2.8 Installation of Feed Hopper
The feed dispenser must be located at one of two
positions depending on where the cow’s ID is read.
If the ID is read at the Texas gate, the dispenser
must be installed at the 2nd stall position. If the ID
is read once the cow is in position on the platform,
the dispenser must be installed at the 3rd stall posi-
tion. (See Figure 19.) Position the dispenser at an
appropriate spacing with respect to the platform so
that feed is dispensed into the passing hoppers. Se-
cure to concrete using (12 __ bolts)

9e997 15 Xpedia 360IX Feeding System Installation Instructions
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2.9 Finger Switches
There are two nger switches located on the dis-
penser which must be triggered simultaneously for
feed to be dispensed. One contacts the body of the
passing feeder while the other contacts a bolt ex-
tending off the back of the hopper. These must be
mounted as shown in Figures 20 and 21.
Feed dispenser sensors L997_18
20.
Sensor trigger bolt on feed manger L997_19
21.

9e997 16 Xpedia 360IX Feeding System Installation Instructions
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2.10 Electrical Installation
2.10.1 Feed Dispenser Control
Feed dispenser control box comes assembled and
programmed. Connect the nger switches to their ap-
propriate junctions inside the panel. See Figure 22.
2.10.2 Main Control Panel Safety
Switches
Follow instructions presented in the Xpedia IX Elec-
trical Manual (9e-879). For installations having a
pinch sensor installed at the exit gate, the following
modication will have to be made by piggybacking
the new sensor (DE4) onto DE2 or DE3 (consult g-
ure 37 in 9e-879, page 86). See Figure 23.
Feed dispenser control L997_20
22.
Exit pinch gate sensor wiring L997_21
23.

9e997 17 Xpedia 360IX Feeding System Installation Instructions
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Man passage sensor wiring L997_22
24.
The man-passage stop switches will be integrated
with the External Emergency Stop circuit according
to the following schematic. Refer to pages 86 and 97
of Manual 9e-879. See Figure 24.
The man pass and pull-cord electrical cable should be
run through the outside perimeter rail. (See Figure
25 on the following page.)

9e997 18 Xpedia 360IX Feeding System Installation Instructions
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Cable running for safety sensors L997_23
25.

9e997 19 Xpedia 360IX Feeding System Installation Instructions
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2.10.3 Brake Resistor
The brake resistor should be wired to the VSD by
connecting the terminals labeled PA+ and PB on the
resistor with the matching terminals on the VSD.
See Figure 26 for an example of how to mount the
brake resistor.
Mounting the Break Resistor L997_27
26.