COTSWOLD CLUSTER-FLUSH 220 User manual

Cotswold
CLUSTER-FLUSH
Milking Cluster Disinfection System
SWINGOVER PARLOUR
Installation Manual
MODEL 220
Cotswold Dairy Equipment Co Ltd
Avenue 3 Station Lane Witney
Oxford OX28 4BP UK
Tel [phone]
Fax [phone]
e-mail [e-mail]
www.cotswold-dairy.co.uk

AIR SUPPLY
Requires Food-
Grade Air Filters)
CHEMICAL ENTRAINMENT
SYSTEM (DOSATRON)
(option)
FLEXIBLE
TUBING
HEADER TANK
(Note: Installed Level With Cylinders)
WATER INLET SYSTEM
CONNECTION TO MILK LINE (Y Piece)
COTSWOLD CLUSTER FLUSH
Milking Cluster Disinfection System
2

COTSWOLD CLUSTER FLUSH
Milking Cluster Disinfection System
FOR SWING OVER PARLOURS
Model 220
PRODUCT MANUFACTURING, SERVICING & MAINTENANCE OVERVIEW
The Cotswold Cluster Flush is a system for the effective removal of infectious
material left in the milking cluster after a cow has been milked, so that the cluster
is disinfected before it is used to milk another cow.
The system mixes a small amount of recommended disinfectant with a pre-
determined amount of water, and automatically “flushes” each milking cluster with
this mixture. This process is repeated after every cow is milked.
Using the Cluster Flush System leads to a substantial reduction in the risk of
cross-infection between cows in the dairy.
SERVICES
The system is mains-powered (230v 50/60hz 1amp). At the point of use the
operating voltage is reduced to 24v dc.
The system requires a ready supply of fresh clean water and a clean compressed-
air supply (at 2 bar).
WIRING:
Connect the Power Supply Unit (PSU) to the mains via a double-pole isolation
switch, which should be visible and within easy reach of system operators.
Wiring from the power supply to each control box should be SELV, using a suitable
type of wire like H03VVF with a CSA of at least 0.75mm2.
All controllers and the power supply unit must be suitably earthed.
All connector tags and terminals will be zinc plated.
This equipment is rated for OV (over-voltage) Category 2 supplies.
PRESSURE VESSEL SPECIFICATION AND USAGE
The pressure cylinder is SEP-rated category-1 at its 2 bar mandatory operating
pressure. Its maximum safe pressure rating is 6 bar.
ENVIRONMENTAL CONDITIONS:
The system can be installed in milking parlours anywhere on the planet. Do not
use in the open, in direct sunlight or where pipework could be subject to freezing.
The protection offered by this product may be impaired or lost if installation and
maintenance is not carried out in line with the instructions in this manual.
LABELING
All labels used in this product comply with the CE Water and Hexane Rub Test. 3

CLUSTER FLUSH – PRODUCTION, SERVICING & MAINTENANCE
SAFETY INSTRUCTIONS –
(COMPLETE SYSTEM INCLUDING PRESSURE COMPONENTS)
(The Cotswold Cluster Flush – an SEP category 1 product)
These instructions relate primarily to factory manufacturing procedures, but since the
Cluster Flush needs regular onsite service and maintenance, we include them here too.
Component Preparation
All forming, bending drilling chamfering or any other working of
components must not cause changes in the mechanical characteristics of
those components and in no way reduce their efficiency.
Permanent joints in pressurised segments
For Cluster Flush pressure equipment (pressure cylinders), permanent
joining of components which contribute to their pressure resistance - and
components which are directly attached to them - must be carried out by
suitably trained personnel.
Permanent Joints and their adjacent zones must be free of any surface or
internal defects that could be detrimental to the safety of the equipment.
Permanent joints must always meet the minimum properties specified for
the materials to be joined.
Traceability
Inner pressure cylinders must be permanently labelled to show operating
pressure and year of manufacture.
Use label: (Pressure-Vessel (Sep-Category-1) , also label: (S Ayling materials
and date of moulding).
Final Testing
Pressure equipment must be subjected to final testing and inspection. A
test and inspection of the completed power supply unit and every control
panel/pressure cylinder assembly is essential.
IF IN DOUBT – ASK!
IEC 60417-5018)
CLUSTER FLUSH – PRODUCTION SAFETY INSTRUCTIONS.DOC
COTSWOLD CLUSTER FLUSH
Milking Cluster Disinfection System
4

PERACETIC ACID CONCENTRATION
Set dosing at 0.5%
Usage @ Twice-A-Day Milking:-
0.7 Litres / 100 Cows / Day
IMPORTANT
BEFORE installation of your new Cotswold Cluster Flush system:
ensure that all EXISTING milk shut-off valves are working
satisfactorily, (sealing fully and without leaks)
COTSWOLD CLUSTER FLUSH
Milking Cluster Disinfection System
AIR
2 - 3 bar
AIR 2 - 3 bar
WATER
HEADER TANK
BREATHER 22mm
Pressure Reducing
Valve 2 - 3 Bar
Compressor
7 - 8 Bar
IMPORTANT
Set Cylinder Levels To Header Tank.
Level Should Be 50mm Below Top
of Stainless Steel Cylinders
FOR SWINGOVER PARLOURS:
One controller per 2 milking clusters
Model 220
ON-OFF ON-OFF
POWER
SUPPLY
To Next
Milking
Points etc...
MAINS IN
230v 50/60hz
WATER LEVEL
SCHEMATIC
output
24v DC
Double Pole
Isolator
Water
Supply
1.5 amp
20mm
fuse
Drain Tap (at
lowest point)
22mm
(flexible)
Rigid
TO
CLAW
(clear PVC
11mm i/d)
ON - OFF
AIR
VAC SWITCH VAC SWITCH
AIR WATER
WATER
TO
MILK LINE
& CLAW A
(clear PVC
10mm I/D)
TO
MILK LINE
& CLAW B
(clear PVC
10mm I/D)
Clear PVC
13mm I/D
10mm
CONTROL PANEL
(one panel per two
milking points)
24V
+ -
Do Not
Install Directly
Above Electrical
Equipment
A B ESC - + OK
(ALWAYS SWITCH OFF EITHER THE POWER SUPPLY
OR THE CONTROLLER(s) WHEN NOT IN USE)
GATE 1
VACUUM
GATE 2
VACUUM
24v DC
FROM PSU
FOR WIRING
SEE
ACCOMPANYING
LARGE SCALE
DRAWING
PERACETIC ACID CONCENTRATION
Set dosing at 0.5%
Usage @ Twice-A-Day Milking:-
0.7 Litres / 100 Cows / Day
24V
+ -
24V
+ -
5

INSTALLATION NOTES
ORDER OF INSTALLATION
For ease of installation we recommend the
following installation sequence:-
1/ Header Tank(s)
2/ Water / Plumbing
3/ Set Up Water Cylinders
4/ Install Airlines
5/ Controllers and Electrical
WATER / CHEMICAL
Site the Header Tank at the same level as the
cylinders. Ensure that the water level in the
cylinders is set 50mm (2 inches) below the top
of the stainless tube, (see drawing opposite).
Run 2 inch (50mm) water tube from header tank
along the centre of the parlour, connecting to
every cylinder using tees, taps and 10x16mm
i/d tube. Terminate this tube with a reversed
(upside-down) tee/tap so that it can be used as
a drain point if required.
Chemical Dosing
We can supply Dosatron high accuracy dosing
units if required. When dealing with chemicals,
do take all recommended precautions. Before
commissioning the system, ensure all unions
are tight and the clusters hang correctly
Schematic Top View
disposition of system components for
swing-over parlour
HEADER
TANK
COMPRESSOR
MAINS ISOLATOR
SWITCH
PSU
AIR 24v DC WATER
CONTROLLERS
CONTROLLERS
CONTROLLERS
AIR 2 - 3 bar, (pressure reducer may be
required)
Use 22mm Flexible Tubing between the
compressor (clean air filters should be fitted)
and the first 22x22x10mm tee located adjacent
to the first controller. Continue to following
controllers using rigid tubing. Terminate the air
line in a blanking cap.
Anti-Syphon Valves
fit one valve either side of the Tee connection of air line, at the mid-point of each half (see schematics)
Pressure Reducer
Cotswold can supply a suitable pressure reducing valve if required.
ELECTRICAL
Install Power Supply Unit (PSU) in a safe dry location adjacent to the dairy, run 24v supply to first controller,
and then daisy-chain the supply from controller to controller.
Each controller controls two milking points simultaneously.
Arrange a conveniently located switch to turn off the system when not in use.
Always switch off system when washing-down the parlour
CONNECTION TO MILK LINE
Cut into the milk line and fit the “Y” piece moulding using 13mm pvc tubing connecting to upper
horizontal outlet of stainless steel pressure cylinder.
= Anti Syphon
Valve
AIR
WATER
24v
6

SHUT-OFF VALVE
(for CLUSTER FLUSH)
To Claw
Flow
Flow
Unit MUST be installed vertically (as above)
Controls maximum of two (2) cluster
points on either side of valve (see
schematics in this manual).
COTSWOLD CLUSTER FLUSH
Milking Cluster Disinfection System
7

ON - OFF
CONTROL PANEL WIRING
(controls sides A and B)
24V
+ -
IB
(LEFT
A)
A B ESC - + OK
24v Input from
PSU or previous
controller
I1
IB ID
Fuse 20mm 1.5 Amp
24v SIGNALS OUT TO GATES
24v GATE
SWITCH RETURNS (Option)
TRIGGER INPUTS
24v DC
(ALWAYS SWITCH OFF EITHER THE POWER SUPPLY
OR THE CONTROLLER(s) WHEN NOT IN USE)
ID
(RIGHT
B)
VACUUM SWITCH
VACUUM SWITCH
(FIT TO PRE-EXISTING
HOLES IN BOX).
Switch
AIR AIR
CONTROLLER -
SWINGOVER AND
ROTARY PARLOUR
EXHAUST VENT
XD10
GATE
VACUUM
CONNECTION
CONNECT RED LIVES TO PERMANENT LIVE SUPPLY, BLACKS TO CONTROLLER AS SHOWN
MAIN CONTROLLER
EARTH THROUGH TO
STAINLESS BACKPLATE
1 2 3
4 5
ELECTRICAL CONNECTIONS 1 EARTH
2 24v DC Live
3 24vdc Neutral
4 Outgoing 24v dc Live
5 Outgoing 24v dc Neutral
GATE
or ACR
VACUUM
CONNECTION
EXHAUST VENT
ISSUE 2 23 April 2019
COTSWOLD DAIRY EQUIPMENT
8

ACCESSING TIMING PARAMETERS
XD10 CONTROLLER
To open main screen, press the “- ” (minus) button twice.
To access any sub-menu
Press OK
Then A
then either “+” or “-” to move between sub-menus
2. Sub Menu 1 = Milk Sweep Setup
2a. When finished, press esc
3 Timer Setup - Maintenance
(Change Timings)
(a) Initial Delay
Milk Sweep
Flush Delay
First Flush
Fill Time
Second Flush
3. Maintenance Help
Shows “A” Solenoid Function
4. Help - Version (call dealer)
5. Software Version
No. eg: R5-4-M5
CLUSTER FLUSH
MAIN MENU
CLUSTER FLUSH MENU
(Milk Sweep Setup)
Timer Setup
Press OK
CLUSTER FLUSH MENU
(TIMER SETUP)
Maintenance
Press OK
CLUSTER FLUSH MENU
(MAINTENANCE)
Help
Press OK
CLUSTER FLUSH MENU
(HELP)
Version
Press OK
CLUSTER FLUSH MENU
(VERSION)
Press OK
Manuals/BackFlush/MASTERFILESControllerSetup-Crouzet-MCL.pdf
9

IMPORTANT
Set Cylinder Levels To Header Tank.
Level Should Be 50mm Below Top
of Stainless Steel Cylinder
50mm
(ALWAYS
SWITCH OFF
WHEN NOT IN USE)
AIR
2 - 3 bar
HEADER TANK
IMPORTANT
Set Cylinder Levels To Header Tank.
Level Should Be 50mm Below Top
of Stainless Steel Cylinders
24V
+ -
ON-OFF
24V
+ -
ON-OFF
POWER
SUPPLY
WATER LEVEL
SCHEMATIC
Not To Scale
Out
24vDC
Out
24vDC
1.5 amp 20mm fuse
LOCATE PSU IN
ADJACENT SERVICES ROOM
Drain Tap
(at lowest point)
22mm
(flexible)
Rigid
COTSWOLD CLUSTER FLUSH
SWINGOVER & ROTARY PARLOUR
Crouzet Controller
TEE OFF
ACR
VACUUM
SUPPLY
TEE OFF
ACR
VACUUM
SUPPLY
TEE OFF
ACR
VACUUM
SUPPLY
COTSWOLD DAIRY EQUIPMENT
CHEMICAL STORE
(UP TO 7 METRES HORIZONTALLY)
POWER SWITCH
Pressure Reducing
Valve 2 - 3 Bar
and food grade air filters
DOSATRON (Option) Chemical Induction Unit
STOP VALVE
PERACETIC ACID CONCENTRATION
Set dosing at 0.5%
Usage @ Twice-A-Day Milking:-
0.7 Litres / 100 Cows / Day
COTSWOLD CLUSTER FLUSH
SWINGOVER & ROTARY PARLOUR
Crouzet XD10 Controller
10

Cluster Flush Servicing page 1
Service interval: 22,000 flushes
At 1 year, the following service parts should be fitted
Dosatron Service Kit
Food Grade Air Filter (For Compressor)
Specify CF21 for Metalwork (orange) Unit
or CF21B for Camozzi (grey) unit
InlineTap /
Lever Valve
152-153
Bracket -
Pressure Vessel
CF38A
Bracket -
Swingover Control
Box
CF100
Dosatron Service Kit DOS/KIT
For Video on using this kit, go to
/ cotswold-daiiry.co.uk
Food Grade Air Filters - orange “Metalwork” system
- Service Kit CF21
Also available Service Kit for grey Camozzi Filter CF21B
(first supplied November 2017)
see overleaf for Major Service info...
Other parts you may find useful to have with you when servicing a cluster Flush system.
10 mm i/d x 16mm o/d hose (30m)………………….. 351-102
10mm i/d x 20mm o/d hose (30m) ........................... 351-127
13mm i/d Hose (30m)………………………………… 351-118
Herbi (plastic) Clips 16mm…………………………… 354-153B (no special tools required)
or 16mm Eazy Clip (if you have an Eazy Clip Tool)
Herbi Clips (plastic) 20mm ..................................... 354-154C (no special tools required)
10mm Jubilee clips………………………………….. 354-159A
or 20mm Eazy Clip (if you have an Eazy Clip Tool
Brackets for pressure vessels………………………… CF 38A
Brackets for swing over control box…………………... CF 100
Taps……………………………………………………… 352-153 11

Cluster Flush Servicing page 2
Service interval: 22,000 flushes
At 22,000 flushes, the following service parts should be fitted
(in addition to annual servicing)
Cylinder Mini-Service Kit: CF99B (here)
CF99B Replaces all wearing parts in and around the cylinder
Order one Service Part per Milking Point:
Cylinder Service Kit: Part No CF 99 (below)
CF 99 - Replaces all the internal parts of the pressure vessel.
Order one Service Part per Milking Point:
examples (erither kit): 10 x 20 parlour, order 10, or 20 x 20 parlour, order 20
Replacing the complete vessel assembly is:
Assured: Complete assembly factory-tested before dispatch.
Quick: Internal parts exchanged in-place without moving vessels.
Simple: No small parts to take apart. No leaky re-assembly.
Warranty: We will give 3 years warranty on serviced assembly.
** See a video of cylinder service procedure on our Website**
Additional Non-Return Valve: You will also need to replace the external non-return
valve, which is included in the service kit.
You may want to change flexible tubes during the service
30 Metres 10mm tube - 151-102B
30 Metres 13mm tube – 151-118
30 metres 20mm tube - 151-127
Thoroughly rinse out header tanks and pipe work with alkaline cleaner.
Check water levels: (See picture)
o Water level must be level with or just below top label on the vessels.
o Important - water levels above this level risk contamination of milk.
Best way to set water levels:
o Set the water in the header tanks level with the overflow
o Set the top label of the vessels level with the overflow
o This way if the water level rises it only overflows the header tank
Prevent dust and dirt getting into the header tank.
Non-Return Valve
CF91
NRV Kit comes
with 2 x Tube Clamps
Pressure Vessel
Service Kit
CF99
12

PRODUCT Qty CotsNum Supplier SupNum
Power Supply 200W 1 306-109 Farnell 165-7463
Box 1 310-104H Hawco
Plate 1 110-104P Cotswold
Screws 4 FOC with Box Hawco
Fuseholder 1 305-121R Rapid 26-0350
Fuse 1.5A 20mm 1 305-104C Rapid 26-1098
Boot - Fuseholder 1 105-126 RS 408-426
Cable Gland 2 109-201 Captop EPN250
Nut - Cable Gland 2 109-201b Captop
Cable 3-core 0.75 (m) 2 108-106 Farnell 133-3066
Chris
Fuse
1.5 amp 20mm
CLUSTER FLUSH
POWER SUPPLY
(Switched Mode)
outlets, 24v supply
to Cluster Flush
system
13

CF40
Header Tank Assembly CF35
Food Grade
Air Filter Set
CF28
Power
Supply
CF37
½” Tap
CF91
Milk Valve
CF29
Digital Controller
(programmed)
CF30
Swept Tee
CF21
Air Filter
Service Kit
CF99
Cylinder
Service Kit
CF110
Eazy Clip Tool
CF48
Cluster Hanger
CF27
Vac Switch
CF24
Solenoid
CF25
Solenoid
CF26
Solenoid
CF112
20mm Eazy Clip
COTSWOLD CLUSTER FLUSH - Major Parts
14

DECLARATION OF CONFORMITY
EC – Declaration of Conformity according to;
Low Voltage Directive 2014 / 35 / EU
Electromagnetic Compatibility Directive 2014 / 30 / EU
Restriction of Hazardous Substances Directive 2011 / 65 / EU
Pressure Equipment Directive 2014 / 68 / EU
We, Cotswold Dairy Equipment Co Ltd, located at Avenue 3, Station Lane, Witney, OX28
4BP, United Kingdom, declare in exclusive responsibility that the Cluster Flush meets the
essential health and safety requirements of the above mentioned directives.
To ensure presumption of conformity, the product has been assessed for compliance with
the following directives and standards either in part or in full.
Directive
Requirements and / or Standards applied
LVD 2014/35/EU
BS EN 61010-1: 2010+A1: 2019
BS EN 61010-2-201: 2018
RoHS 2011/65/EU
EN 50581: 2012
EMC 2014/30/EU
BS EN 61000-6-4: 2007+ A1: 2011
BS EN 61000-6-2: 2005 AC: 2005
BS EN 61000-3-2: 2014
BS EN 61000-3-3: 2013
PED 2014/68/EU
Annex I
TCF reference no. : CE_TCF_Cluster_Flush
Name:Stephen Gibson
Title:Director
Date:4th April 2023
Signature:
9