Fullwood M2erlin Quick guide

Fullwood M²erlin
Operating Instructions for Safe Use
User Manual 294130
Revision C
ORIGINAL MANUAL
Fullwood Limited
Grange Road
Ellesmere
Shropshire
SY12 9DF
England

Ref / Pt.No
: 294130 Operating Instructions for Safe Use
Fullwood M²erlin
Revision: C
Date
: 24-Mar-17
294130 Page 2 of 81
Contents
Fullwood M²erlin....................................................................................... 1
Operating Instructions for Safe Use....................................................... 1
Contents ................................................................................................... 2
Icons ......................................................................................................... 6
1. Health and Safety Statement........................................................ 6
1.1 Risk Assessment................................................................................................7
1.2 General...............................................................................................................7
2. Safety and Responsibility Instructions ....................................... 8
2.1 Basic Instructions...............................................................................................8
2.2 Intended Use......................................................................................................8
2.3 Improper Use......................................................................................................8
2.4 General Safety ...................................................................................................8
2.5 Safety dealing with sources of danger................................................................9
2.5.1 Electrical Safety........................................................................................................9
2.5.2 Operating fluids/materials.........................................................................................9
2.5.3 Unsuitable spare parts..............................................................................................9
2.5.4 Conversion or modification of the machine ...............................................................9
2.6 Users Responsibility.........................................................................................10
2.7 Assembly..........................................................................................................10
2.8 Positioning........................................................................................................10
2.9 Commissioning, operation and maintenance....................................................10
2.10 De-commissioning, storage and disposal.........................................................11
2.11 Danger Areas...................................................................................................11
2.12 Safety devices..................................................................................................12
2.13 Power Cut.........................................................................................................12
2.14 Technical Specifications...................................................................................13
2.15 Size of Machine................................................................................................13
2.16 Transport size...................................................................................................13
2.17 Weight..............................................................................................................13
2.18 Spatial Requirements / Size of machine...........................................................14
2.19 Power Supply Specifications............................................................................15
2.20 Ambient Temperature.......................................................................................15
2.21 Compressed Air Requirements ........................................................................15

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2.22 Air Drying..........................................................................................................15
2.23 Air Filtration......................................................................................................16
2.24 Noise................................................................................................................16
2.25 Vacuum............................................................................................................16
2.26 Water................................................................................................................16
2.26.1 Cold Water..........................................................................................................17
2.26.2 Hot Water............................................................................................................17
2.26.3 Drainage .............................................................................................................17
2.27 Luminance........................................................................................................17
2.28 Consumption Figures .......................................................................................17
2.28.1 Services..............................................................................................................17
2.28.2 Chemicals...........................................................................................................17
2.29 Herd Management System...............................................................................18
3. Safety Signs and Location ......................................................... 19
3.1 Understanding safety signs..............................................................................19
3.2 Position of safety sign.......................................................................................19
3.3 Hazard Areas ...................................................................................................20
4. Site Positioning, Fixing Levelling and Assembly..................... 21
5. Handling and Transporting ........................................................ 21
5.1 The Crate .........................................................................................................21
5.2 Process Cabinet...............................................................................................23
6. Cow Compatibility with Robotic Milking ................................... 24
6.1 Udder Shape Requirements.............................................................................24
6.2 High and Low Reach........................................................................................25
7. Starting the machine for the first time....................................... 25
7.1 Preparation.......................................................................................................25
7.2 Switching off in an emergency and switching on again....................................26
7.3 Pre-Milking Start Up .........................................................................................27
7.4 Wash times and chemical usage......................................................................27
7.4.1 Setting Hot Wash Cleaning Times..........................................................................27
7.4.2 Backflush................................................................................................................28
7.4.3 Cleaning Chemicals................................................................................................28
7.4.4 Chemicals used on M²erlin (Technical Data)...........................................................29
7.4.5 Chemical ................................................................................................................29
7.4.6 Changing Chemicals...............................................................................................30
7.5 Calibrate Feeders.............................................................................................31
8. Animal Identification................................................................... 33
8.1 Ear Transponder...............................................................................................33

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8.1.1 Best Cattle Tagging Practice ..................................................................................33
8.2 Pedometers......................................................................................................34
8.2.1 Removal of the Pedometer.....................................................................................34
8.2.2 Storage of Pedometers...........................................................................................34
8.3 Neck tags .........................................................................................................35
9. Introducing Animals to the New Milking System...................... 35
9.1 Preparation.......................................................................................................35
9.2 Introduction.......................................................................................................36
10. The Human Machine Interface (HMI).......................................... 36
10.1 HMI – Overview of Icons ..................................................................................36
Note; Not all the icons are visible by the user, some are for engineers
use only. ................................................................................................. 39
10.2 Milking the Cows ..............................................................................................40
10.3 Introducing new cows:......................................................................................40
10.4 Using the HMI...................................................................................................42
10.5 Milk Separation.................................................................................................48
10.5.1 Withheld and Undesirable Milk............................................................................48
10.5.2 Abnormal Milk .....................................................................................................48
10.6 Milk Cooling and storage..................................................................................48
11. Routine Daily Maintenance......................................................... 53
11.1 Changing the Liners.........................................................................................54
12. Cleaning the machine................................................................. 55
13. Service Schedule........................................................................ 56
14. Consumables / Spares................................................................ 59
14.1 Liners, Shells, Vacuum Chambers, Rope End Covers, Liner Gauge and ‘O’
Rings (Compatibility Chart).........................................................................................59
14.2 Chemicals.........................................................................................................60
14.3 Other ................................................................................................................60
15. Fault Recognition and Rectification.......................................... 61
15.1 General.............................................................................................................61
15.2 Alarm Messages...............................................................................................61
15.3 Alarm Message Codes.....................................................................................62
16. Milk Sampling.............................................................................. 77
16.1 Setting Cows for Sampling in Crystal ...............................................................77
16.2 Connecting the Multi Sampler ..........................................................................79

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Revision: C
Date
: 24-Mar-17
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17. Disclaimers.................................................................................. 81
Copyright © 2016, Fullwood Limited reserves the right to change the contents of this manual if
necessary, without warning. Fullwood Limited has taken every precaution to avoid errors and
omissions on the manual and equipment but does not accept any responsibility or liability for
damage of any kind arising from the use of this manual or Fullwood equipment; whether this
damage is direct or indirect. If you discover any inaccuracies please inform Fullwood Limited or
one of its agents and we will make corrections for the next release.

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: 294130 Operating Instructions for Safe Use
Fullwood M²erlin
Revision: C
Date
: 24-Mar-17
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Revision Control
Version
Date
Pages
Writer
Checked by
A
03/12/2014
73
G Williams
B
Nov 2016
81
G Williams
C
March 2017
81
G Williams
Icons
Icons are used in this manual to draw the reader’s attention to specific information. These icons
have the following meaning:
Failure to follow the instructions can result in severe injury to engineers, users,
bystanders or livestock
Indicates special precautions that must be taken to avoid damage to equipment.
Gives important information to prevent potential problems
Gives advice or suggestions to make procedures easier or clearer
Important information - read this first
1. Health and Safety Statement
Fullwood Limited specialises in the design, procurement, manufacture, installation and
commissioning of dairy and associated equipment comprising of pneumatic, electro-pneumatic
and electrical industrial control equipment. The nature of the company’s business activity places
emphasis on experience, capability, performance of design, manufacture and reliability. Whilst
Fullwood equipment will comply with all relevant directives, customers are reminded that all
equipment into which Fullwood equipment is to be incorporated must comply with all applicable
European directives.
The attention of the purchaser is drawn to the provision of Section 6 of the Health and Safety at
Work Act 1974. Section 6 of the Act provides that manufacturers, designers, importers or
suppliers of equipment for use at work have a duty to ensure, so far as reasonably practical,
that the equipment will be safe and without risk to health when properly used. The equipment is
not regarded as being ‘properly used’ if it is used without regard to any relevant information or
advice relating to its use made available by the manufacturer, designer, importer or supplier. It
is the responsibility of the purchaser to take such steps as are necessary to ensure that
appropriate information relevant to the equipment is made available to their employees and any
person to whom the purchaser supplies them.
It is important that the equipment be installed, commissioned, maintained and used by
competent trained/skilled persons in accordance with good engineering practice. International

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and national Wiring Regulations, Codes of Practice and all current relevant legislation
requirements and accepted rules or art for the industry concerned.
All installations and maintenance should be carried out within the provisions of ’The Electricity at
Work Regulations, 1989’ and by persons so qualified as defined in that act.
Fullwood Limited supplies document packs with all equipment. These documents are supplied
for information and should be disseminated to the relevant persons.
1.1 Risk Assessment
Risk Assessments are a legal obligation and an important step in protecting your personnel,
visitors as well as your business. It helps you focus on the risks that really matter in your
workplace, the ones with the potential to cause real harm. In many instances, straightforward
measures can readily reduce risks. These measures should be reviewed annually or when the
process changes, whichever comes first. The law does not expect you to eliminate all risk but
measures must be taken to reduce the risk as far as ‘reasonably practicable’.
For most, that means simple, cheap and effective measures to ensure your most valuable asset
– your workforce – is protected.
1.2 General
M²erlin is manufactured to the latest engineering standards and acknowledged safety
regulations. Nevertheless, dangers can arise through its operation;
•Danger to life and limb of the operator or third parties.
•Damages to the machine and other material assets.
Following instructions within this manual will prevent / minimise risk

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Fullwood M²erlin
Revision: C
Date
: 24-Mar-17
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2. Safety and Responsibility Instructions
2.1 Basic Instructions
•Before installing or operating the M²erlin, this manual and the appropriate operating
instructions must be read and understood.
•Only use the M²erlin if it is in a technically perfect condition and only for the purpose
it is intended; observe all safety measures and instructions.
•Immediately rectify / report any faults maintaining an efficient and safe machine.
•Wear the correct protective clothing and equipment.
2.2 Intended Use
•M²erlin is ONLY for use in dairy farming to facilitate the milking of cows; any other
use is considered incorrect. (e.g. Medical treatment of cows, milking of any other
animals).
•Operate the M²erlin only within its performance limits and under the conditions
specified in this manual.
2.3 Improper Use
•Never use the M²erlin for any other use (e.g. medical treatment of cows).
•Improper use can cause damage to property, severe injuries or even death.
•The manufacturer is not liable for any damages that may result from incorrect
use. The user alone is liable for any risks incurred.
2.4 General Safety
•All covers and guards shall be in place before operating M²erlin.
•Keep hands, feet, hair and clothing away from all moving parts.
•Keep unauthorized or untrained persons, including children away from the
hazardous area of the milking robot at all times.
•Do not enter the animal / milking area of the machine during operation.
•Do not block/obstruct the moving parts of the machine.
•Do not look directly into the laser light of the teat detection system.
•Do not weld on M²erlin unless instructed to do so by Fullwood Limited, follow
instructions e.g. remove all connections to PCB’s.
•If welding in an area within 5m of M²erlin, turn M²erlin off and remove the main
Harting connection.
•Keep the working area as clean and as dry as possible.
•Ensure first aid kits and firefighting equipment are available, are clearly visible and
easily accessible.
•Never use the equipment if you are not adequately trained or authorised to do so.
•Never attempt to service the equipment if you are not adequately trained or
authorised to do so.
•Wear PPE (Personal Protective Equipment)
e.g.:- oSafety overalls
oProtective gloves
oSafety boots
oEye protection
oEar protection

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2.5 Safety dealing with sources of danger
2.5.1 Electrical Safety
•SWITCH OFF the machine and isolate the electrical power supply, release
pneumatic pressure and wait for all moving parts to stop before you perform any
maintenance on the machine.
•Contact with electrical components can result in electric shocks, burns or death.
•Only a qualified and authorized electrician or trained personnel under the supervision
of a qualified and authorised electrician shall install the electrical power supply to the
machine according to local electrical regulations.
•All power supplies shall be fitted with lockable isolating devices.
•Ensure all electrical switches are in the OFF position before the electrical power
supply is switched on.
•Replace any damaged electrical lines, conduits, switches and components
immediately.
•Only use protective devices corresponding to the machine power.
•Isolate the electrical power supply at the wall mounted isolator and lock it off before
you open the electrical panel to work on the electrical system.
2.5.2 Operating fluids/materials
The used operating fluids and material can cause adverse health effects. Suitable
measures must be taken in order to prevent injuries.
•Only Fullwood recommended chemicals shall be used, any other product may result
in damage.
•Material Safety Data Sheets (MSDS) shall be reviewed prior to use together with a
risk assessment performed in accordance with COSHH regulations.
•Read safety instructions on the containers.
•Always wear protective gloves and safety goggles when handling chemicals, or when
working on parts of the robot where you may come into contact with chemicals.
•Strictly forbid fire, open flame and smoking.
•Avoid contact with skin and eyes.
•Do not inhale oil mist or vapour.
•Do not eat or drink when handling chemicals.
•Suitable fire extinguishing materials must be to hand.
2.5.3 Unsuitable spare parts
•Unsuitable spare parts compromise the safety of the machine and could invalidate
the manufacturer’s warranty:
•Use only spare parts approved by the manufacturer for use in this machine.
2.5.4 Conversion or modification of the machine
Modifications, additions to and conversions of the machine or the controller can result
in unpredictable dangers.
•Obtain written approval by the manufacturer prior to any technical modification or
expansion of the machine, the controller, or the control programs.

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Revision: C
Date
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2.6 Users Responsibility
•Check suitability of animals (e.g. low udders, misplaced teats, temperament)
•Check services are adequate (Power, Vacuum, Compressed Air, Water)
•Check calibration of Milk Meters and feed dispensers
•Check for hazards such as sharp objects that could cause injury to the animals.
•Check the performance of the animals during milking
•Follow manufacturers guidelines for cleaning and maintenance
•Servicing of M²erlin shall be carried out by approved dealers
•Never allow persons under the influence of drugs or alcohol operate M²erlin
•Following these instructions along with others within this and other supporting
manuals will help maintain an efficient operating milking machine.
•The manufacturers guarantee does not cover direct or consequential damage
caused by incorrect installation, incorrect usage, improper treatment, inadequate
cleaning or servicing, or incorrect software parameter inputs or hardware settings.
2.7 Assembly
•Do not climb onto the machine to gain access to upper areas.
•When working at height assess the risk and use appropriate equipment.
•Only use electrical cables that are suitable and approved for the surroundings and
electrical loads applied.
•Never dismantle compressed air pipes until they are fully vented.
•Only use pressure lines that are suitable and approved for the maximum working
pressure and intended medium.
•Do not allow connection pipes to be placed under mechanical stress.
•Do not induce any forces into the machine via the connections, so that the
compressive forces must be balanced by bracing.
2.8 Positioning
A suitable installation location for the machine prevents malfunction and accidents.
•Install the machine in accordance with Fullwood plans.
•Ensure sufficient lighting such that the display can be read and work can be carried
out comfortably and safely.
•Ensure accessibility so that all work can be carried out without danger.
2.9 Commissioning, operation and maintenance
During commission, operation and maintenance you may be exposed to dangers
resulting from; electricity, pressure and temperature. Careless actions can cause
accidents with severe adverse effects for your health.
•Allow maintenance work to be carried out only by authorised personnel.
•Switch off and lock out the power supply isolating device and verify the absence of
voltage.
•Close shut-off valves or otherwise isolate the machine from the compressed air
network to ensure that no compressed air can flow back into the machine.
•Do not open the electrical cabinet while the machine is turned on.
•Carry out regular inspections;
•for visible damages.
•of safety installations, guards etc.