GEA AutoSelect 3000 User manual

Automatic animal segregation
AutoSelect 3000 / AutoSelect 3000 SA (Ethernet)
Operation Manual / Installation Instructions / Parts List
(Original instructions)
7159-9001-108
01. February 2020
gea.com

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Contents
1 General 4.................................................................
1.1 Information on the document 4...............................................................
1.2 Manufacturer's address 6....................................................................
1.3 Customer services 6........................................................................
1.4 EC - Declaration of conformity for machines
in accordance with EC Machinery Directive 2006/42 /EC, Annex II 1. A 7...........................
2 Safety 8...................................................................
2.1 Use for the intended purpose 8...............................................................
2.2 Owner's obligation of care 8..................................................................
2.3 Subsequent modifications 9..................................................................
2.4 Explanation of the safety symbols warnings used 9..............................................
2.5 General safety instructions and dangers 10......................................................
2.6 Personnel qualifications 11....................................................................
2.7 Safety guards and devices 12.................................................................
3 Description 14..............................................................
3.1 Structure and functions 14....................................................................
3.1.1 Functional sequence (AutoSelect 3000 / AutoSelect 3000 HD) 19..................................
3.1.2 Segregation certainty 21......................................................................
3.2 Design guidelines 22.........................................................................
3.3 Technical Data 25...........................................................................
3.4 Default setting 25............................................................................
4 Transport and storage 26...................................................
4.1 Particular hazards 26.........................................................................
4.2 Storage conditions 26........................................................................
4.3 Transport equipment 26......................................................................
4.4 Transport 26................................................................................
4.5 Disposing of packaging material 26.............................................................
5 Mounting 27................................................................
5.1 Special Personnel Qualifications 27............................................................
5.2 Safety Instructions 27........................................................................
5.3 Particular hazards 28.........................................................................
5.4 Requirements 28............................................................................
5.5 Preparations before installation 29.............................................................
5.6 Installation of the frame 30....................................................................
5.6.1 Preassembling the entrance gate (AutoSelect 3000 / AutoSelect 5000) 30...........................
5.6.2 Preassemble gate frame (AutoSelect 3000) 34...................................................
5.6.3 Assembling the segregation gate 36............................................................
5.7 Assembling the gate lock (option) 40...........................................................
5.8 Setting up animal segregation 42..............................................................
5.8.1 Installing the driving passage 45...............................................................
5.8.2 Installing the control valve 46..................................................................
5.8.3 Photo eye sensors installation 48..............................................................
5.9 Installing the operating unit 52.................................................................
5.10 Installing animal identification 53...............................................................
5.11 Installation of non-return gate (option) 53........................................................
5.12 Screen for the segregation area (optional) 54....................................................
5.13 Connecting animal segregation 55.............................................................
5.14 Information on disposing of installation material after installation is finished. 56........................

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6 commissioning 57..........................................................
6.1 Special Personnel Qualifications 57............................................................
6.2 Safety Instructions 57........................................................................
6.3 Particular hazards 57.........................................................................
6.4 Requirements for commissioning 58............................................................
6.5 Align light scanners 59.......................................................................
6.6 Antenna transformer settings 60...............................................................
6.7 Settings in DairyPlan 61......................................................................
6.7.1 Settings with DairyPlan (DPSetup) 61...........................................................
6.7.2 Setting selections flags (DPSingle) 64..........................................................
6.7.3 Settings with DairyPlan (DPService 1.xx) 65.....................................................
6.7.4 Responder settings 67.......................................................................
6.8 Settings on the transceiver 67.................................................................
6.9 Setting the segregation gate opening and closing speed 67........................................
6.10 Checks before initial commissioning 68.........................................................
6.11 First Start 68................................................................................
6.12 Checks after first start 68.....................................................................
6.13 Handing over to the owner 70.................................................................
7 Operation and control 71....................................................
7.1 Special Personnel Qualifications 71............................................................
7.2 Safety Instructions 71........................................................................
7.3 Particular hazards 72.........................................................................
7.4 Description of the control elements 72..........................................................
7.5 Operation / Control 72........................................................................
7.6 Attaching the leg responders in ”stand-alone” operating mode (AutoSelect 3000) 76...................
8 maintenance 77............................................................
8.1 Special Personnel Qualifications 77............................................................
8.2 Safety Instructions 77........................................................................
8.3 Particular hazards 78.........................................................................
8.4 Inspections and preventive maintenance 78.....................................................
9 Operation Faults 80.........................................................
9.1 Special Personnel Qualifications 80............................................................
9.2 Safety Instructions 80........................................................................
9.3 Particular hazards 80.........................................................................
9.4 Transceiver faults 80.........................................................................
9.5 Faults and troubleshooting help 81.............................................................
10 Decommissioning 82.......................................................
10.1 Special Personnel Qualifications 82............................................................
10.2 Safety Instructions 82........................................................................
10.3 Particular hazards 82.........................................................................
10.4 Temporary decommissioning 82...............................................................
10.5 Final Decommissioning / Disposal 82...........................................................
11 Spare Parts 83.............................................................
11.1 Animal segregation 83........................................................................
11.1.1 control panel 87.............................................................................
11.1.2 Gate locking system 88.......................................................................
11.2 animal identification 89.......................................................................
11.3 Accessories for animal identification - AutoSelect 3000 SA 89......................................
12 Appendix 90...............................................................
12.1 Directories 90...............................................................................

General
Information on the document
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1 General
1.1 Information on the document
The manufacturer reserves the right to make changes due to technical
developments in the data and images given in this manual.
Reproductions, translations and copies of any kind, even of extracts, require written
authorisation from the manufacturer.
The abbreviations, units, technical terms, special names or industry-specific
terminology used in this manual are explained in greater detail in the Appendix.
This manual is 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 subject to an amendment service. The most recent version
at any time can be obtained through the technical dealer or directly from the
manufacturer.
This applies to the safety instructions in particular.
Target group
This manual contains information for the following target groups:
Information
(see Chapter)
Target group
Carrier Installation
mechanic
Maintenance
personnel Operator
Transport and storage x
assembly and
installation
x
commissioning x x x
Operation and control x x
maintenance x x
troubleshooting x x x
Repairs x x
Decommissioning x
For information on appropriate personnel qualification, please see Chapter:
on:
Safety / Personnel qualification
Scope of product documentation
● This manual is only part of the product documentation.
The complete documentation consists of the following manuals:
7159-90 . . -108 Animal segregation AutoSelect 3000 (Ethernet)
Automatic animal identification
7160-90 . . -422 Identification frame Ear identification
7160-90 . . -423 Neck/leg identification
7160-90 . . -427 Transmitter/receiver VP1801
7160-90 . . -533 Responder/Rescounter
In this manual the word ”product” is synonymous with:
Animal segregation AutoSelect 3000
- consisting of entrance gate and segregation gate
- without animal identification

General
Information on the document
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Necessary documents
All the manuals for other installed subsystems.
Structure of the manual
This manual has a modular structure and is intended exclusively for the named
product.
For more information on the product and its components refer to the corresponding
documents and manuals.
This applies to the safety instructions in particular.
Layout elements
Pictograms used
Note:
The signal word indicates information that is important for the product and
environment.
This pictogram refers to an information source.
(section, manual, Internet, …).
70 . . -90 . . -000 If a manual number is given, the middle 4 figures
indicate the language, as follows:
Language Language Language
-9000- German -9013- Dutch -9032- Serbian
-9001- English (United
Kingdom)
-9015- English (North
American)
-9034- Slovak
-9002- French (France) -9016- Polish -9035- Chinese
-9003- Italian -9018- Japanese -9036- Lithuanian
-9004- Romanian -9021- Danish -9038- Portuguese (Brazil)
-9005- Spanish (Spain) -9022- Hungarian -9039- French (Canada)
-9007- Swedish -9023- Czech -9040- Latvian
-9008- Norwegian -9024- Finnish -9041- Estonian
-9009- Russian -9025- Croatian -9043- Spanish (Central
America)
-9010- Greek -9027- Bulgarian -9046- Vietnamese
-9012- Turkish -9029- Slovene
All of the above languages may not be available.
!A correction bar in the margin indicates changes to the previous edition.
Header
The top line on each page provides information on the
main subject of that page. Main heading
Subheading
Main heading
Subheading
User aids
The character string ”!!” in the search field of the PDF document jumps to
correction bars. !

General
Customer services
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1.2 Manufacturer's address
GEA Farm Technologies GmbH
Siemensstraße 25-27
D-59199 Bönen
+49 (0) 2383 / 93-70
+49 (0) 2383 / 93-80
[email protected]
www.gea.com
1.3 Customer services
Authorized Technical Dealer
If necessary, please contact your nearest dealer.
There is a comprehensive dealer Internet search function on our web site at the
following address:
www.gea.com
European Contact Information:
GEA Farm Technologies GmbH
Siemensstraße 25-27
D-59199 Bönen
+49 (0) 2383 / 93-70
+49 (0) 2383 / 93-80
[email protected]
www.gea.com
US Contact Information:
GEA Farm Technologies, Inc.
1880 Country Farm Dr.
Naperville, IL 60563
+1 630 369 - 8100
+1 630 369 - 9875
[email protected]
www.gea.com

General
EC - Declaration of conformity for machines
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1.4 EC - Declaration of conformity for machines
in accordance with EC Machinery Directive 2006/42 /EC, Annex II 1. A
Manufacturer: GEA Farm Technologies GmbH
Siemensstraße 25-27
D-59199 Bönen
We, as manufacturer, declare in sole responsibility that the machinery
Name: Animal segregation
Model: 3000 / 3000 SA
Type: AutoSelect
complies to all relevant provisions of this and the following directives and regulations:
Relevant EC-Directives: 2006/42/EC EC Machinery Directive
2014/30/EU EMC Directive
Applied harmonized
standards, in particular:
EN 12100:2011 Safety of machinery - General design principles - Risk
assessment and risk reduction
EN 349:2009 Minimum distances to prevent pinching parts of the
body
EN 953:2009 Safety of machinery - Guards -
General requirements for the design and construction
of fixed and movable guards
DIN EN ISO
13857:2008-06
Safety of machinery - Safety distances to prevent
hazard zones being reached by upper and lower limbs
DIN EN
61000-6-2:2011-06
Electromagnetic compatibility (EMC) - Part 6-2:
Generic standards - Immunity for industrial
environments
DIN EN
61000-6-3:2011-09
Electromagnetic compatibility (EMC) - Part 6-3:
Generic standards - Emission standard for residential,
commercial and light-industrial environments
Remarks: We also declare that the special technical documentation for this machine has been
created in accordance with Annex VII, Part A and we obligate to provide these upon
reasoned request from the individual national authorities by data transfer.
Authorized person for compiling and handing over
technical documentation:
Josef Schröer
GEA Farm Technologies GmbH
Siemensstraße 25-27
D-59199 Bönen
'+49 (0) 2383 / 93-70
Boenen,
20. June2017 Jörg Krämer
(Managing Director)
Holger Siegwarth
(Head of Product Development -
DairyFarming)

Safety
Owner's obligation of care
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2 Safety
2.1 Use for the intended purpose
The product described has been designed for use in agricultural (mainly milk
producing) environments.
AutoSelect animal segregation automatically segregates individual animals
according to certain criteria.
Animal segregation must always be used in an environment that is protected from
frost and weather.
Applications which are not listed here are not part of the intended use and are
therefore considered as improper use.
The manufacturer/supplier is not liable for any resulting damage. The user alone
bears the risk.
Use for the intended purpose also includes reading the instructions and observing
the inspection and maintenance conditions.
● We would specifically like to point out that parts or accessories not supplied by
ourselves and setting instructions not provided by GEA Houle are not checked
or released by us either.
● The installation or use of products from other manufacturers may affect the
specified properties of the original parts and lead to injury to people and
animals.
● The manufacturer does not accept any liability for injury to persons or animals,
or damage to the product, caused by the use of products from other
manufacturers.
2.2 Owner's obligation of care
The product has been designed and constructed taking account of a potential risk
analysis and after careful selection of the compliant harmonized standards and
other technical specifications. It therefore ensures a maximum level of safety.
This safety can only be achieved in practice on the farm, however, if all the
necessary measures have been taken. It is part of the owner's duty of care to plan
these measures and check that they are carried out.
(producing appropriate operating instructions for example)
The owner must ensure the following:
● A complete, legible copy of the manual must always be available at the place
where the product is installed.
● All persons who work with the product must be able to consult the manual at all
times.
● The instructions in the section ”General safety instructions and dangers” must
be followed.
● The legal requirements are observed.
● The product may only be used for its intended purpose.
● The product may only be used if it is in perfect working condition. The safety
equipment, in particular, must be checked regularly to ensure it is working
properly.
● Work should only be carried out by suitably qualified persons.

Safety
Explanation of the safety symbols warnings used
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● The personnel is regularly instructed in all relevant matters of safety at work and
protection of the environment and is familiar with the manual, particularly the
safety instructions it contains.
● Operating personnel in training may only work with the product under the
supervision of an experienced operator. Their successful completion of training
is to be confirmed in writing.
● Safety signs, plates and decals affixed to the product must be replaced
immediately if they become illegible or lost.
● Escape routes must be indicated by signs in accordance with national
regulations.
● Any personal safety equipment required for the operating, maintenance or
repair personnel must be provided and used.
2.3 Subsequent modifications
Unauthorized changes of the product can have a negative impact on the safety, life
span or functionality of the product.
Any modifications not described in the product documentation are deemed to be
prohibited.
For safety reasons, do not carry out any unauthorized modifications!
Scheduled modifications must be approved in writing by the manufacturer.
Any unauthorized modifications to the product will invalidate the warranty and may
invalidate the conformity or installation declaration provided.
2.4 Explanation of the safety symbols warnings used
Safety symbols draw attention to the importance of the adjacent text.
The warning signs are designed in accordance with ISO 3864-2 and ANSI535.6.
Safety symbols and signalling word
Warning!
The signal word indicates an immediate danger that could lead to loss of life
or serious physical injury.
Attention!
A signal word indicates hazardous situations that could cause damage to
property or malfunction.

Safety
General safety instructions and dangers
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2.5 General safety instructions and dangers
Note:
There are warnings about specific residual hazards in the corresponding
chapters.
● Work or activities connected with the product might involve risks.
The safety and operating instructions in this manual must always be observed
to ensure that the product is used safely.
● The chapter on ”Technical data” gives the permissible working conditions
(pressure ranges, temperature ranges, airflow quantities etc.) and these must
be observed!
● Do not open or dismantle devices (risk of injury).
● Do not remove any protective devices (risk of injury)!
● Welding work constitutes a fire hazard.
Before starting welding work, remove all easily inflammable materials from the
work area and obtain a hot work permit from the operator.
● Electronic components (e.g. control cards) may be destroyed by welding work.
- Always disconnect these components from the mains before carrying out
any welding work.
- Disconnect components within a radius of 2 metres.
● Always observe the warnings given in the product safety data sheets and
operating instructions when using products from other manufacturers.
● Always keep the switchgear cabinet / all electricity supply units / 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. Do not use water
or high-pressure cleaners on these electrical products!
● Warning mains voltage.
The supply voltage should be disconnected if any work is to be performed on
the power supply!
Warning!
Crushing hazard!
Because the segregation gates move automatically in automatic mode, there
is a danger to life from crushing!
► It is strictly forbidden to go into these danger areas.
Attention!
Objects fastened to segregation gates may interfere with or prevent the ani
mal segregation function.
► Do not fasten anything to the gates.

Safety
Personnel qualifications
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2.6 Personnel qualifications
Everyone who performs work or activities in connection with the product must
carefully read and understand the manual and then act accordingly.
● All work on electrical equipment and electrical connection work should only be
performed by trained electricians.
● All work on pneumatic equipment should only be performed by technicians
trained for this purpose.
● All welding work must only be performed by qualified welders.
In addition, special qualifications are required for the following activities:
● Operation
● commissioning
● Operating faults
● maintenance
Note:
Work that requires special qualifications is described in the relevant
chapters!

Safety
Safety guards and devices
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2.7 Safety guards and devices
Safety signs
Replace any safety markings, signs, labels on the product if they become illegible
or lost.
Item Part No. Description
0010 0024-6063-000 Warning sign Injury to hands (50 x 43)
0020 0024-6060-000 Warning sign Automatic start! (50 x 43)
0030 0024-6061-000 Warning sign Automatischer Anlauf! (100 x 86)
Entrance gate
30
10

Safety
Safety guards and devices
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Animal segregation
10 20
Gate locking system
10
20

Description
Structure and functions
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3 Description
3.1 Structure and functions
Automatic animal segregation may consist of the following main components:
● Entrance gate (EG)
● Segregation gate (SG)
Frame structure to steer the animals into the segregation areas
All of the gates are operated by cylinders.
- Vacuum Cylinder
- Connection to the existing vacuum generator
● Automatic animal identification (ID)
Identifies the animals and controls the segregation gate
- The segregation process is controlled automatically by a control unit.
For further information, please refer to the instructions:
7160-90 . . -427 Transmitter/receiver VP1801
- The control unit receives the necessary information from the herd
management program.
For more information on this subject, please refer to the section on
commissioning / Settings in DairyPlan
- The flow of animals is monitored by several scanner in the entrance and
exits.
Versions
Animal segregation differs according to the task and surroundings.
● Number of segregation paths
(depending on the number of segregation gates)
Number Direction
Segregation gates Segregation
passageways left straight on (Z) right
1 2 1x 1x -
-1x 1x
2 3 1x 1x 1x
● Connection to a herd management program
● Identification frame
- neck
- Leg
- ear
Variant (AutoSelect 3000)
● This segregation system is connected to the DairyPlan herd management
system and receives the segregation criteria via the central process control PC.
● All animals are fitted with a responder/Rescounter.
● The animals which are marked with a corresponding segregation flag in
DairyPlan will be segregated.
- Rescounter on the front foot (in conjunction with DairyPlan)
- Responder/Rescounter round the neck (in conjunction with DairyPlan)

Description
Structure and functions
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Variant (AutoSelect 3000 SA - StandAlone)
Note:
The term AutoSelect 3000 is always used in this manual; the term SA is only
used for special functions which relate to the SA.
● This segregation system operates without being linked to a PC.
● The system is designed for herds without responders.
● The animals which are fitted with a responder for the back foot during the milking
process will be segregated. After selection, the responder is removed again.
- If only one segregation gate is connected to the transceiver, every animal
fitted with a responder will be segregated.
- If 2 segregation gates are connected to the transceiver, the animals are
segregated in the following way:
Animals with even responder numbers by segregation gate 1 (A)
Animals with odd responder numbers by segregation gate 2 (B)
● Animals not fitted with a responder can pass through the segregation system
unhindered.
Operating modes
Manual mode
Manual operation from the control panel
Automatic mode
The segregation process is controlled automatically by a control unit.
●Stand-alone mode
AutoSelect 3000 operates in DairyPlan or stand-alone mode (where it is not
linked to a herd management program).
The responders will be attached to the back leg of the animals to be segregated
in the milking parlour during milking.
Once the animal has been segregated, the responder must be taken off again
so that the animal will not be segregated again during the next milking session.

Description
Structure and functions
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Components
Example: AutoSelect 3000
● 3-way
● Neck identification
EG BID B3 B2 B2 AB1 SG
Z
A
B
IDEG
CU T/R
(VP1801)
M
VPU
(VP8001)

Description
Structure and functions
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Automatic animal segregation Segregation passageways 2 3
Item Description Qty.
Animal segregation (AutoSelect 3000)
EG Entrance gate 1 1
● Vacuum Cylinder 2 2
SG Segregation gate 1 1
● Gate frame 1 2
● Sort gate 1 1
● Light scanner B1,B2,B3
● Vacuum Cylinder 1 2
Light scanner 1 1
B1-B3 ● Light scanner (B1)
closes the entrance gate
● Light scanner (B2)
While a light scanner is recording an animal none of the segregation gates can move.
An acknowledgement is given as soon as all the light scanners are free.
● Light scanner (B3)
If there are 2 animals in the segregation area, the segregation gate moves when the light
scanner becomes free.
CU control panel 1 1
The entrance gate and segregation gates can be operated manually via a manual control
unit.
-Change-over box Controller compl. (7159-2680-080)
Processes signals from the control panel and the light scanners.
For installation see manual: 7159-90 .. - 427)
animal identification
ID ● Identification frame Neck/leg/ear identification 1 1
VPU ● Control unit VP8001 1 1
- Controls animal segregation
- connected to the herd management PC
T/R ● Transmitter/receiver VP1801 1 1
- Animal identification in the identification frame
- Processing signals from the operating unit
- Controlling connected components

Description
Structure and functions
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options
-Automatic gate locking system
The segregation gate is locked depending on the operating status of the vacuum pump.
In this way, segregated animals are prevented from pushing open the segregation gate and proceeding to
the milking parlour during the time between milkings.
Gate locked
(vacuum pump switched off)
Gate open
(vacuum pump switched on)
-Non-return gate
Non-return gates prevent the animals from coming out of the segregation bay back towards the milking
parlour.

Description
Structure and functions
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3.1.1 Functional sequence (AutoSelect 3000 / AutoSelect 3000 HD)
Notes
● All animals which are to be segregated will be fitted with a
responder/Rescounter according to the design in each case and will be
identified by the identification frame.
● AutoSelect 3000 SA:
Only the animals to be segregated are given a label.
Animal segregation initial position
● No animal in identification
EG SGID
31 22
EG Entrance gate
SG Segregation gate
ID Identification frame Example:
Leg identification
1-3 Light scanner B1-B3
- Entrance gate open
- Segregation gate(s) closed
- B1-B3: Light scanner free
- Identification is constantly active
Setting: DPService 010/000/009
Animal enters animal segregation
● Animal goes through the entrance gate
● animal identification (ID)
EG SGID
31 22
ID-A: Animal is not identified (no label)
- Segregation path unchanged
ID-B: Animal is identified
- Responder code is sent to DairyPlan
- DairyPlan sends the segregation path corresponding to the animal
● B1: Light scanner identifies the animal in the identification area
● Entrance gate closes if segregation path A or B is specified
EG SGID
31 22
● The light scanners are checked (B1, B2, B3)
A distinction is made between the following cases:
- 1 animal in the segregation area
- 2 animals in the segregation area

Description
Structure and functions
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1 animal in the segregation area
● B2 (2x): Light scanner free
● Segregation gate moves
EG SGID
31 22
2 animals in the segregation area
● B2 (2x): If the light scanners identify another animal, the segregation gate
remains in the initial position
EG SGID
31 22
● Segregation gate moves if:
A: The animals go to the segregation gate together
EG SGID
31 22
- B2 (2x): Light scanner not free
- B3: Light scanner free
The segregation gate moves and separates the animals
EG SGID
31 22
or
B: The animal to be segregated stays back
- B2 (2x): The light scanners are free
EG SGID
31 22
Animal leaves animal segregation
EG SGID
31 22
● B1 - B3: Light scanners confirm that the segregation area is free
● Animal segregation moves to the initial position
EG SGID
31 22