GEA DairyRobot R9500 User manual

DairyRobot R9500
Automatic milking system
Sampling device
Operation Manual / Installation Instructions / Parts List
(Original operating instructions)
7821-9001-005
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gea.com

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Contents
1 Preface 4.................................................................
1.1 About this manual 4.........................................................................
1.2 Manufacturer's address 7....................................................................
1.3 Customer services 7........................................................................
1.4 Declaration of incorporation for incomplete machinery
in accordance with EC Machinery Directive 2006/42/EC, Annex II 1. B 8............................
2 Safety 9...................................................................
2.1 The owner of this product must ensure compliance with the following requirements 9.................
2.2 Explanation of safety symbols 10..............................................................
2.3 Basic safety instructions 10...................................................................
2.4 Personnel qualification 11.....................................................................
2.5 Safety guard and devices 11..................................................................
3 Description 12..............................................................
3.1 Intended Use 12.............................................................................
3.2 Product Changes 12.........................................................................
3.3 Design of the equipment 13...................................................................
3.4 How the System Works 15....................................................................
3.5 Technical Data 20...........................................................................
4 Transport 21...............................................................
4.1 Safety instructions for transport 21.............................................................
4.2 Transport 22................................................................................
4.3 Delivery 24.................................................................................
4.4 Storage conditions 24........................................................................
4.5 Information on disposing of packing material 24..................................................
5 Sampling device 25.........................................................
5.1 Special personnel qualification required for sampling 25...........................................
5.2 Safety instructions for sampling 25.............................................................
5.3 Description of the operating elements 26........................................................
5.4 Overview of the steps involved in the sampling process 27.........................................
5.5 Prepare for sampling 27......................................................................
5.6 Take samples 41............................................................................
5.7 Interrupt sampling 41.........................................................................
5.8 End sampling 43............................................................................
5.9 Displaying information about the current sampling process 46......................................
5.10 Clean 48...................................................................................
6 Sample data export 49......................................................
6.1 To call up the program 50.....................................................................
6.2 Program execution 54........................................................................

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7 Operating faults 68.........................................................
7.1 Special personnel qualification required for troubleshooting 68.....................................
7.2 Safety Instructions for Troubleshooting 68.......................................................
7.3 Possible faults and troubleshooting help 69......................................................
8 Maintenance 71............................................................
8.1 Special personnel qualification required for maintenance work 71...................................
8.2 Safety instructions for maintenance 71..........................................................
8.3 Inspections and preventive maintenance 73.....................................................
9 Decommissioning 80.......................................................
9.1 Safety instructions for decommissioning 80......................................................
9.2 Temporary decommissioning 80...............................................................
9.3 Final decommissioning/disposal 80.............................................................
10 Spare Parts 81.............................................................
10.1 Milk sampling device 81......................................................................
10.2 Bottle racks 90..............................................................................
11 Appendix 92...............................................................
11.1 Order of the sample bottles in the rack 92.......................................................
11.2 Terminal diagram for the CUP electronic card 93.................................................
11.3 Pin assignment 93..........................................................................
11.4 Abbreviations 94............................................................................
11.5 Quick guide 95..............................................................................

Preface
About this manual
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1 Preface
1.1 About this manual
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, including 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.
These instructions are part of the supply.
● 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 manual has a modular structure and is intended exclusively for the
mentioned product.
For more information on the product and its components, please refer to the
corresponding documents and manuals.
This applies, in particular, to the safety instructions!

Preface
About this manual
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Necessary documents
● Instructions on components connected with the product:
(not a complete list):
Part no. Description
7821-90 . . -000 ”DairyRobot R9500” operating instructions
7160-90 . . -531 DairyManagementSystem ”DairyPlan C21”

Preface
About this manual
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Pictograms used
Note
The signalling word indicates information that is important for the product
and environment.
This pictogram indicates a special tool required for installation.
!A correction bar in the margin indicates changes to the previous edition.
The character string ”!!” in the search field of the PDF document locates
the correction bar.
This pictogram refers to another document or section.
If a manual number is given, the middle 4 digits 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
-9012- Turkish -9029- Slovene
All of the above languages may not be available.

Preface
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
Authorised Technical Dealer
If necessary, please contact your nearest authorized technical dealer.
There is a comprehensive dealer Internet search function on our website 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

Preface
Declaration of incorporation for incomplete machinery
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1.4 Declaration of incorporation for incomplete machinery
in accordance with EC Machinery Directive 2006/42/EC, Annex II 1. B
Manufacturer: GEA Farm Technologies GmbH
Siemensstraße 25-27
D-59199 Bönen
We, as manufacturer, declare in sole responsibility that the incomplete machinery
Name: Automatic milking system
Model: DairyRobot R9500
Type: International Sample unit
complies with the following provisions of the above-mentioned Directive:
According to Annex I, the following points are fulfilled. .
1.1.5, 1.3.1, 1.3.7, 1.3.8, 1.4.1, 1.4.2, 1.5.13, 1.6.1, 1.6.2, 1.7.1
Relevant EC
Regulations:
2006/42/EC EC Machinery Directive
2014/30/EU EMC Directive
Applied harmonized
standards, in particular:
DIN EN ISO 12100:2011-03 Safety of machinery - General principles for design
- Risk assessment and risk reduction
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
Bönen,
20. June 2017 Jörg Krämer
(Managing Director)
Holger Siegwarth
(Head of Product Development -
DairyFarming)

Safety
The owner of this product must ensure compliance with the following requirements
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2 Safety
2.1 The owner of this product must ensure compliance with the following requirements
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 when all of the
necessary measures have been taken. It is part of the farmer's obligation of care
to plan these measures and check that they are carried out.
The owner must ensure the following:
● Anyone performing work or activities relating to this product must carefully reads
the instructions (especially the safety instructions and warnings) and signs to
confirm that they have understood them and will act in accordingly!
● The manual must always be available, in a legible and complete condition, at
the place where the product is used.
● All persons who carry out work on the product must be able to consult the
manual at any time.
● The instructions given in the section on ”Basic Safety Instructions” must be
followed.
● The legal requirements are observed.
● Operating instructions must be developed for and specially adapted to the
conditions of the farm to take account of all aspects of safety.
● 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
devices especially must be checked regularly to ensure they are working.
● The computer and the software installed on it must be installed and operated
in accordance with the specifications.
● A working data backup system must be available.
Only use computers which are in perfect working condition.
● Work should only be carried out by suitably qualified persons.
● 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.
● To start with, operating personnel who require training may only operate the
equipment under the supervision of an experienced person. Their successful
completion of training is to be confirmed in writing.
● Safety signs, plates and decals, which are attached to the product, must be
replaced immediately if they become illegible or lost!
● Unauthorized persons (e.g. children) are not allowed in hazardous areas and
should not have access to cleaning agents or disinfectants.

Safety
Basic safety instructions
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2.2 Explanation of safety symbols
The safety symbols draw attention to the importance of the adjacent text.
The design of the warnings is based on ISO 3864-2 and ANSI535.6.
Safety symbols and signalling words
Warning!
The signalling word indicates an immediate danger that could lead to loss of
life or serious physical injury.
Attention!
The signalling word indicates hazardous situations that could lead to
damage to property.
2.3 Basic safety instructions
Note
There are warnings about specific residual dangers in the corresponding
chapters.
● There are risks involved in the operation and maintenance of equipment for
dairy farms. For your own safety, read and follow the operating manual carefully
(especially the section entitled ”Safety information”)!
● 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)!
● When working with cleaning and disinfecting agents observe the notes on
dangers and protective measures (risk of caustic burns)!
● Also observe the safety and warning instructions given in the operating manuals
for the milking system.
● Always keep the control 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!

Safety
Safety guard and devices
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2.4 Personnel qualification
Everyone who performs work or activities in connection with the product must
carefully read and understand the manual and then act accordingly.
● Only use trained or briefed personnel!
In addition, special qualifications are required for the following activities:
● Installation
● Commissioning
● Operation
● Troubleshooting
● repairs
Note
Work that requires special qualifications is described in the relevant
chapters!
2.5 Safety guard and devices
● Cover plate, protective cover
● Safety symbols, warnings, warning signs and labels

Description
Product Changes
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3 Description
3.1 Intended Use
The product described has been designed for use in agricultural (mainly milk
producing) environments.
The international sampling device is to be used exclusively for automatic milk
sampling in MIone and DairyRobot R9500 automatic milking systems with Metatron
milk meters.
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.
Correct use 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 the manufacturer/supplier
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 people or animals,
or damage to the product, caused by the use of products from other
manufacturers.
3.2 Product Changes
Unauthorised product changes may have a negative impact on the service life or
function 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 changes!
Scheduled modifications must be approved in writing by the manufacturer.
Unauthorised modifications of the product will void the warranty and may invalidate
the Manufacturer's Declaration or Declaration of Incorporation.

Description
Design of the equipment
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3.3 Design of the equipment
Milk sampling device
Sampling equipment in the lid
This area contains all of the sampling electronics, the
motors, the electromagnetic crimp valve and hose
pump, the chain, chain holder, etc. (see next page)
Bottle rack positioning device
This device can be used to position the bottle rack
correctly.
Bottle rack
80 x 15 ml to 35 ml sample bottles can be
placed in different racks.
Sampling case
This case contains all of the accessories for the
sampling device.
Sample tank unit
The sample tank is connected to the milk meter.
Once the milk sample has been collected, air is let
into the tank to mix the milk. A sample is then taken
from the tank through the sampling tube.
The tank is then ventilated and the milk is drawn into
the milk line.
Sampling case
This case contains all of the accessories for the
sampling device.
Air intake valve

Description
Design of the equipment
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Sampling equipment in the lid
Chain with nozzle
The nozzle is positioned over the
sample bottle with the chain.
Chain tensioners
Used to maintain the correct chain
tension.
Chain link nozzle
The chain link nozzle closes the
chain and fills the sample bottles.
Limit switch
The limit switch stops the
chain motor when the filling
nozzle reaches the start
position.
Electromagnetic
crimp valve (mixing
valve)
When this valve is actuated,
the sample in the sample tank
is mixed by atmospheric air.
Hose pump
The pump pumps a small
amount of milk into the drain
channel to rinse the hose
before the sample is placed in
the sample bottle.
Chain motor
Brings the nozzle contained in
the chain to the correct
position.
Sampling device electronics
The whole sampling process is
controlled by its own CPU.

Description
How the System Works
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3.4 How the System Works
Milking system
Sampling device
1
2
3
4 5
6
78
Legend:
1Sample tank 5Hose pump
2Stop balls 6Filling nozzle
3Air intake valve 7Drain channel
4Mixing valve 8Sample bottle
The following diagrams show how the sampling device works:

Description
How the System Works
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3.4.1 Mix sample
● During the milking process the sample tank is filled with about 2.5% of the actual
milk produced.
● After milking, atmospheric air flows through the open mixing valve and mixes
the sample in the sample tank.
3.4.2 Draw sample
● The hose pump (turning 100%) draws the sample out of the sample tank.

Description
How the System Works
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3.4.3 Rinse lines with milk
● The hose pump (turning 60%) pumps the first part of the sample into the drain
channel.
3.4.4 Position filling nozzle
● The filling nozzle is positioned over the next sample bottle.

Description
How the System Works
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3.4.5 Fill sample bottle
● The hose pump (turning 60%) fills the sample bottle with the sample.
3.4.6 Drain lines
● atmospheric air flows in through the open mixing valve and drains the intake
line.
● The hose pump (turning 60-100%) also drains the pressure line.

Description
How the System Works
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3.4.7 Return
● The filling nozzle is moved to the next drain position through one of the two drain
channels.
3.4.8 Drain sample tank
● Air flows into the sample tank through the open air inlet valve releases the stop
balls and drains the sample tank.

Description
Technical Data
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3.5 Technical Data
Geometric data
Dimensions
(width x height x depth) 650 x 530 x 240
Weight of the case
(without bottle rack) 24,5 kg
Electrical data
Electrical Connection 24 V DC
Manufacturer's plate
The rating plate is placed on the side of the
sampling device.