LELY CRS M3 User manual

LELY CRS M3
Operator manual
PDF of the English original HTML, 5.1004.8514.0 -
EN - English

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ii

Contents
1. Introduction.........................................................................................................................................1-1
1.1 The CRS M3............................................................................................................................ 1-1
1.2 Trademarks, Copyright and Disclaimer....................................................................................1-1
1.3 Warranty Restriction.................................................................................................................1-2
1.4 List of Included Amendments...................................................................................................1-3
1.5 Applicability.............................................................................................................................. 1-3
1.6 Registration.............................................................................................................................. 1-3
1.7 Maintenance Authorization.......................................................................................................1-4
1.8 How to Use this E-Manual........................................................................................................1-5
1.8.1 The Page Layout......................................................................................................................1-5
1.8.2 Give Feedback!........................................................................................................................1-6
2. Safety...................................................................................................................................................2-1
2.1 Signal Icons..............................................................................................................................2-1
2.2 Safety Instructions....................................................................................................................2-1
2.3 General Safety......................................................................................................................... 2-2
2.4 Electrical Safety....................................................................................................................... 2-2
3. Specifications..................................................................................................................................... 3-1
3.1 Dimensions CRS M3/Extension Cabinet..................................................................................3-1
3.2 Power Supply........................................................................................................................... 3-1
3.3 Pressurized Air Supply.............................................................................................................3-2
3.4 Connected Devices.................................................................................................................. 3-2
3.5 Network Connections............................................................................................................... 3-2
3.5.1 T4C Network............................................................................................................................ 3-2
3.5.2 Telephone Connections........................................................................................................... 3-3
4. Description..........................................................................................................................................4-1
4.1 General Description................................................................................................................. 4-1
4.2 Control Panels CRS M3 and Extension Cabinet......................................................................4-2
4.2.1 CRS M3 Cabinet...................................................................................................................... 4-2
4.2.2 Extension Cabinet....................................................................................................................4-3
4.3 CRS M3 Web Interface............................................................................................................ 4-4
4.4 CRS M3 Functions................................................................................................................... 4-5
4.4.1 Tank Driver Procedure.............................................................................................................4-5
4.4.2 Partial Milk Collection Procedure............................................................................................. 4-6
4.4.3 Cleanings................................................................................................................................. 4-7
Contents iii
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4.4.4 Twin Filter (optional)................................................................................................................ 4-8
4.4.5 Precooler (optional)..................................................................................................................4-8
4.4.6 Valve Guard (optional)............................................................................................................. 4-9
4.4.7 Block and Bleed System (USA)............................................................................................. 4-10
4.5 Alarm System.........................................................................................................................4-10
4.5.1 Modalarm............................................................................................................................... 4-12
4.5.2 Modalarm Web Interface........................................................................................................4-12
5. Operating Instructions.......................................................................................................................5-1
5.1 CRS M3 Cabinet...................................................................................................................... 5-1
5.1.1 Replace a used Filter Element of the Twin filter...................................................................... 5-1
5.1.2 Start the Tank Driver Procedure.............................................................................................. 5-3
5.1.3 Start the Partial Milk Collection Procedure.............................................................................. 5-5
5.1.4 Mute the Buzzer.......................................................................................................................5-7
5.1.5 Clear the List of Active Alarms.................................................................................................5-8
5.2 CRS M3 Web Interface............................................................................................................ 5-9
5.2.1 Open the CRS M3 Web Interface............................................................................................ 5-9
5.2.2 Adjust Cluster Cleaning Times.................................................................................................5-9
5.2.3 Put a Cluster in or out of Operation......................................................................................... 5-9
5.2.4 Clear the List of Active Alarms...............................................................................................5-10
5.2.5 Test the Telephone Connection.............................................................................................5-10
5.3 ModAlarm...............................................................................................................................5-10
5.3.1 Open the Modalarm Web Interface........................................................................................5-10
5.3.2 Tab 'Dashboard'.....................................................................................................................5-10
5.3.3 Tab 'Devices'..........................................................................................................................5-11
5.3.4 Tab 'Phonebook'.................................................................................................................... 5-12
5.3.5 Tab 'Profile'............................................................................................................................ 5-13
5.3.6 Tab 'Settings'......................................................................................................................... 5-13
5.4 View the List of Active Alarms in T4C.................................................................................... 5-14
6. Troubleshooting................................................................................................................................. 6-1
6.1 Status LED on CRS M3 Cabinet flashes..................................................................................6-1
6.2 Cluster Indicator LED on CRS M3 Cabinet flashes..................................................................6-1
6.3 T4C Computer fails.................................................................................................................. 6-3
6.4 Modalarm Errors...................................................................................................................... 6-3
iv Contents
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1. INTRODUCTION
Welcome to the Lely E-Manual, the place where you can find technical
information, operating instructions, maintenance procedures and
troubleshooting information of the CRS M3.
Study and understand this information thoroughly before you operate the
CRS M3. Failure to do so could result in personal injury or damage to
equipment. Please consult your local Lely service provider if you do not
understand the information in this manual, or if you need additional
information.
All information in this manual has been compiled with care. Lely shall not be
liable for errors or faults in this manual. The recommendations are meant to
serve as guidelines. All instructions, pictures and specifications in this
manual are based on the latest information that was available at the time of
publication. Your CRS M3 may comprise improvements, features or options
that are not covered in this manual.
A team of writers continuously adds and updates new and existing
information based on what users like you tell us. So please keep sending
your feedback (page 1‑6) to us.
What's new
See the list of included amendments (page 1‑3) for the latest changes
and updates of this manual.
1.1 The CRS M3
The CRS M3 is part of the automated milking system that milks, feeds, and
monitors the health of cows. The milking system has four primary parts:
• The Astronaut milking robot (one or more)
•The milk storage tank
• The control system (CRS M3)
• T4C management system
The CRS M3 enables the emptying of the milk tank and controls and
monitors the cleaning and (alarm) reporting system of all connected milking
robots. The CRS M3 is connected to the T4C network and communicates
with other devices in the T4C network.
1.2 Trademarks, Copyright and Disclaimer
Lely, Astronaut, Astri, Atlantis, Attis, AWS, C4C, Calm, Caltive, Commodus,
Compedes, Cosmix, Discovery, F4C, Fertiliner, Gravitor, Grazeway,
Hibiscus, Hubble, InHerd, Juno, L4C, Lely Center, Lelywash, Lotus, Luna,
Nautilus, Orbiter, Quaress, Qwes, SAE, Shuttle, Splendimo, Storm, T4C,
Tigo, Vector, Viseo, Voyager, Walkway and Welger are registered
trademarks of the Lely Group. The right of exclusive use belongs to the
companies of the Lely Group. All rights reserved.
Introduction 1-1
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The information given in this publication is provided for informational
purposes only and does not constitute an offer for sale. Certain products
may not be available in individual countries and products supplied may differ
from those illustrated. No part of this publication may be copied, replicated or
published by means of printing, photocopying, microfilm or any other
process whatsoever without prior permission in writing by Lely Holding S.à
r.l.. Although the contents of this publication have been compiled with the
greatest possible care, Lely cannot accept liability for any damage that might
arise from errors or omissions in this publication.
The English language manual is the original manual. Translations into other
languages use the English language manual as the source document. Lely
accepts no liability for discrepancies between the original English language
manual and versions in other languages. If there is a conflict over the
content and accuracy of any translated manual, the English language
manual is the authority document.
Copyright © 2016 Lely Industries N.V.
All rights reserved
Lely Industries N.V.
Cornelis van der Lelylaan 1
3147 PB Maassluis
The Netherlands
Phone: [phone]
Fax: [phone]
Website: www.lely.com
1.3 Warranty Restriction
Excluded from this warranty are any cost or expenses due to:
• Abnormal use of the equipment which is not according to the
specifications stated in the Operator Manual or handled during the
Operators Service and Maintenance Certification program.
•The result of any intervention by technicians other than Lely service
technicians or technicians who have Lely’s approval to perform certain
duties.
• Incidents such as freezing, ice, fire, flood, inundation or any other form of
excessive water, lightning.
• Defect of the electrical system or grounding.
• The use of chlorinated chemicals used for rinse, sanitation or washing of
the robot may cause damage to the robot. All parts damaged as a result
of the use of chlorinated chemicals will be excluded from warranty, nor
will they be covered under the Total Responsibility Contract.
1-2 Introduction
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• Use of compressed air that does not meet the quality standards set by
Lely Industries.
• Hacking activities, viruses or the like.
•Damage to the electrical system as a result of vermin or the like.
• For USERS that have followed the Operators Maintenance and Service
Certification: any damage resulting from abnormal use of the equipment
which is not according to the specifications stated in the Operator
Technical Training Manual and are also not covered by the warranty
scheme.
Before start up of the installation the handover declaration (together with the
LAM form) has to be signed off by the customer and technician. By means of
the handover declaration the installation will be registered at Lely. Warranty
does apply only for correct registered machines.
Warranty does not apply to consequential damage which does not involve
the machine itself.
All systems are tested. However in the event of a malfunction Lely cannot be
held responsible for consequential damage.
1.4 List of Included Amendments
01/03/2016
• Initial release
1.5 Applicability
The table below shows the type numbers of CRS M3 for which this manual is
applicable.
Model designation
Model Type number
CRS M3 5.1004.6866.0
1.6 Registration
The type and serial number plate is attached to:
• The horizontal frame of the robot unit next to the robot control room
•The vertical frame behind the door of the central unit, next to the air
supply unit
Always include the type and serial numbers of your milking robot when you
contact your local Lely service provider or order spare parts.
Introduction 1-3
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Figure 1. Type and serial number plate
1.7 Maintenance Authorization
Only technicians certified by Lely Industries are authorized to do
preventive and/or corrective maintenance on the CRS M3, except for
the maintenance done by the operator as indicated in the Operator
Manual.
If people, who are not certified by Lely Industries, do maintenance on
the CRS M3, the warranty on the CRS M3 becomes invalid.
At the end of each visit, all work done on the CRS M3 must be written in the
logbook and the logbook must be signed by the certified technician. The
logbook must always be kept near the CRS M3 for the entire life of the
product. The information in the logbook must include:
• The maintenance done (includes also the parts exchanged)
•The date of the maintenance
• The name of the technician
• The certification level and ID of the technician
Technician Training
All the technicians certified by Lely Industries have completed an approved
training program, and passed written and practical examinations during and
at the end of the training program. The training is given by a product
specialist. The examinations are done under supervision of a master product
specialist and include troubleshooting and corrective maintenance of the
CRS M3.
There are four certification levels:
• Installation Technician (certification valid for two years)
• Service Engineer (certification valid for two years)
• Senior Service Engineer (certification valid for two years)
• Product Specialist (certification valid for one year)
During training, a trainee is permitted to work for up to a maximum of six
months under close supervision of a certified technician. A trainee can only
do work on the CRS M3 in the presence of a certified technician.
1-4 Introduction
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1.8 How to Use this E-Manual
1.8.1 The Page Layout
To help explain the various components of the web pages, a table is
provided. The images in the table below identify the primary components of
the pages.
Symbol Explanation
Home
To go to the 'Welcome' page of this manual.
Up
To go up one page.
Down
To go down one page.
Print
To print the current page.
Remark: to show all figures on the print page, all figure links must be expanded.
Search
• Single term searching
To search topics that include individual terms. Two or more words can be combined with
boolean operators. If boolean operators are not included, the terms are treated in the same
way as an OR search (which is the default search option).
Example: the search result of the term 'tool box' includes all topics with the word 'tool'
and/or the word 'box'.
•Phrase searching
To search topics that include specific phrases. Use quotation marks around two or more
words. The search result first shows all topics with the complete phrase, then it will show all
topics with the individual words.
Example: the search result of the term "tool box" (in quotation marks) includes all topics
with the complete term.
• Match partial words
To create more flexibility in the search term and to search not only exact matches, but also
partial matches. The search engine looks for words with the search term contained within
that word.
Example: the search result of the term 'book' includes all topics with the word 'book',
'books', 'booklet', 'logbook', etc.
Content Table of contents
This is the table of contents of the manual. It is a list of the parts of the manual organized in
the order in which the parts appear.
The contents includes the titles or descriptions of the first-level headers, such as
chapter(book) titles. By clicking on the arrow in front of the chapters the tree structure
collapse and the second level headers shows as well.
To hide the contents panel.
Introduction 1-5
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Symbol Explanation
To show the contents panel.
Temporarily show the contents panel. When the mouse pointer is outside the
contents panel, it is automatically hided.
Main page
The main page shows the page content.
Underlined text is a hyperlink to another page.
Underlined text with an arrow[ ] in front collapses an illustration below that paragraph or
procedure step. Select the underlined text or arrow[ ] again to hide the illustration.
1.8.2 Give Feedback!
Thank you for using the Lely E-Manual. We hope you found the information
you were looking for and found that information useful.
To further improve and expand the present information, we would like to
hear your opinion of the content: Is information missing? Did you find a
mistake? Do you have a suggestion?
Let us know, please give feedback!
How to give feedback on a page of the E-Manual?
1. Select the 'Give feedback' link on the bottom of the page.
2. A new email message window opens where you can enter your
comment.
3. Select 'Send'.
4. A confirmation mail is sent to you when we receive your email.
Thank you for your participation.
1-6 Introduction
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2. SAFETY
This chapter contains safety instructions, an explanation of the used signal
words in this manual, information about safety decals on the CRS M3.
2.1 Signal Icons
Note the use of the signal words DANGER, WARNING and CAUTION with
the safety messages. The signal word for each message uses the following
guidelines:
Danger: indicates an imminently hazardous situation that,
if not avoided, will result in death or serious injury.
Warning: indicates a potentially hazardous situation that, if not
avoided, could result in death or serious injury, and includes hazards
that are exposed when guards are removed.
Caution: indicates a potentially hazardous situation that, if not avoided, may
result in minor or moderate injury or product or property damage.
Note: this shows extra information that may help the reader.
2.2 Safety Instructions
YOU are responsible for the SAFE operation and maintenance of your CRS
M3. Make sure that you and anyone else who is going to operate, maintain
or work in the vicinity of the CRS M3 knows all the related SAFETY
information in this manual.
YOU are the key to safety. Good safety practices protect you and the people
around you. Make these practices a working part of your safety program.
Make sure that EVERYONE who operates or maintains the CRS M3 obeys
the safety precautions. Do not risk injury or death by ignoring good safety
practices.
•CRS M3 owners must train operators before they operate the CRS M3.
This training must be repeated at least annually.
•The operator must read, understand and obey all safety and operating
instructions in the manual.
• A person who has not read and understood all safety and operating
instructions is not permitted to operate the CRS M3.
• Do not modify the equipment in any way. Unauthorized modification may
impair the function and/or safety and could affect the life of the
equipment, and persons.
• Only use approved spare parts, and make sure that they are only
installed by authorized technicians.
Safety 2-1
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2.3 General Safety
• Read and understand the manual and all safety signs before you operate
the CRS M3.
• Only trained personnel is permitted to operate the CRS M3.
•Make sure that the doors of the CRS M3 and the extension cabinet are
closed before you operate the CRS M3. Only technicians certified by Lely
Industries N.V. are permitted to open the doors.
• Before the pneumatic pressure is supplied to the CRS M3, make sure
that all parts are tightened and that all tubes and fittings are in good
condition.
• Wear the correct protective clothing and equipment.
• Know the emergency medical center number for your area.
• Contact the nearest Lely service provider if you have any questions.
• Review safety related items with all operators frequently (annually).
2.4 Electrical Safety
• An authorized electrician must install the electrical main power supply
connection for the Lely CRS M3.
• Damaged electrical lines, conduits, switches and components must be
replaced immediately.
•Make sure that the electrical grounding of the electrical system and all
parts of the Lely CRS M3 meet the local rules and regulations.
• Each CRS M3/extension cabinet must be connected to either:
• A maintenance switch. The maintenance switch must be purchased
locally and must meet the local rules and regulations.
• A wall socket. The electrical power supply cable and plug must be
purchased locally and must meet the local rules and regulations.
• The electrical connection must be fused according to the local rules and
regulations.
• Make sure that the Lely CRS M3 is disconnected from the main power
supply (maintenance switch in OFF position or power plug disconnected)
and (if applicable) that the battery is disconnected, before doing
maintenance, adjustment or repair.
• Prevent damage by vermin.
2-2 Safety
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3. SPECIFICATIONS
3.1 Dimensions CRS M3/Extension Cabinet
• IP65 certified (dust-tight and splashproof)
Dimensions
• A: 400 mm (15.7 in)
• B: 400 mm (15.7 in)
•C: 76 mm (3.0 in)
• D: 210 mm (8.2 in) (door closed)
• D: 600 mm (23.6 in) (door open)
3.2 Power Supply
• The electrical power supply cable and plug must be purchased locally
and must meet the local rules and regulations.
• Power consumption: < 160 W
•Operating voltage: 100 to 240 VAC
• Frequency: 50 to 60 Hz
CRS M3
• Each CRS M3/extension cabinet must be connected to the main power
supply through a maintenance switch. The maintenance switch must be
purchased locally and must meet the local rules and regulations.
• The electrical group must be fused.
• An authorized electrician must do the installation.
• The CRS M3/extension cabinet must be connected to a ground
connection point.
Specifications 3-1
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General
• To do maintenance at least one and preferably two wall outlets must be
installed in:
•The control room
• The room where the central unit is installed
• The tank room (close to the CRS M3)
• The compressor room (close to the compressor)
• If continuous power supply from the grid is not guaranteed, a generator is
an option. For example a tractor driven generator (PTO) or a motor driven
generator:
• The generator must be electronically controlled (brushless).
• The connection power of the generator must be the sum of all
connected equipment (central unit with robot unit(s), compressor, milk
tank, and other (optional) equipment).
• An authorized electrician must approve the final electrical installation
(including grounding) and supply an official report that is given to the Lely
service provider before the first milking is started.
3.3 Pressurized Air Supply
• Pressure input: 6.5 to 7.75 bar (94 to 112 PSI)
• Input air quality: oil free and complied to ISO 8573-1:2001 part 1, class 0
(based on the Atlas Copco classification)
•Diameter air supply tube: 10 mm (0.39 in)
3.4 Connected Devices
• Maximum no. of robot units: 20
• Maximum no. of clusters: 4
•Maximum no. of main tanks: 4
• Maximum no. of buffer tanks: 2
• Maximum no. of buffer vessels: 2
3.5 Network Connections
3.5.1 T4C Network
• Data transfer speed: 10/100 Mbit/s
Network cable
• S-FTP 200 MHz Cat5e with shielded connections
•Number of wires: 8 (4 twisted pairs)
• Max. length of a single cable: 100 m (328 ft)
3-2 Specifications
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Network connectors
• Type 1 network connector
•Connection standard: T-568A or T-568B
• Shielded
• Type 2 network connector
• Connection standard: T-568A
• Shielded
Router/modem
The router/modem is not part of the T4C network, but enables the service
provider to remotely control the T4C computer through an internet
connection for technical support.
The specifications of the router or modem are not influenced by the T4C
network. Contact your local Internet Service Provider (ISP) for more
information about the specifications of the router/modem.
3.5.2 Telephone Connections
• Mobile phone SIM card:
•SIM card of a local provider (standard size)
•Postpaid contract with minutes and texts (data is not necessary)
• PSTN telephone line:
• 45 to 50 VDC on two phone wires
• Not connected to other phones or other devices
Only one of the two options is necessary, but it is recommended to use both
connections.
Specifications 3-3
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3-4 Specifications
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4. DESCRIPTION
4.1 General Description
The CRS M3 is usually installed in the tank room and is connected to the
T4C network. The CRS M3:
Figure 2. CRS M3 cabinet (1) and extension cabinet (2)
• Communicates with other devices in the T4C network
•Coordinates scheduled (main) cleanings for all milking robots in the
cluster(s) (a cluster is of a group of milking robots that are connected to
one milk line)
• Enables emptying of the main tank
• Offers cluster process data
• Controls the valves of the buffer tank (optional) or buffer vessel (optional)
• Controls the valves of the precooler (optional)
• Controls the valves of the twin filter (optional)
• Supports a 'main tank console'
• Guards the valve positions (optional)
• Shows active alarms and generates alarm phone calls (speech) through
the Modalarm
The CRS M3 has two operator interfaces to control and monitor the cleaning
and (alarm) reporting system of all connected milking robots:
• Interface on the cabinet itself for the daily operation
• Web interface for more advanced operations
Description 4-1
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The CRS M3 is a modular system, so it can be fitted to specific needs. The
standard configuration can be expanded with optional modules:
• Standard configuration:
•1x CRS M3 cabinet
• 1x Air valves block
• 1x Filter/pressure reducer
• Optional modules:
• Air valves block(s)
• Extension cabinet
4.2 Control Panels CRS M3 and Extension Cabinet
4.2.1 CRS M3 Cabinet
The control panel on the CRS M3 cabinet has these buttons and indicator
LEDs:
Figure 3. CRS M3 control panel
KEY:
1. Milk tank selection button - 2. Tank driver procedure button - 3. Partial milk collection
button - 4. Main tank valve button - 5. Cluster selection button - 6. Twin filter reset button -
7. Alarm buzzer mute button - 8. CRS M3 status LED
Buttons/LEDs Explanation
Main tank selection button (1) Push the button to select a main tank. The green LED shows the selected
milk tank.
Tank driver procedure button
(2)
Push and hold the button for 2 seconds to start or stop the tank driver
procedure for the selected main tank:
• Green LED flashes: start/stop tank driver procedure requested
•Green LED is on: system is ready to empty the main tank
4-2 Description
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Partial milk collection button
(3)
Push and hold the button for 2 seconds to start or stop the partial milk
collection procedure for the selected main tank:
• Green LED flashes: start/stop tank driver procedure requested
•Green LED is on: system is ready to partially empty the main tank
Main tank valve button (4) Push the button to open or close the valve of the selected main tank:
• Open the valve when the tank can be (partially) emptied. The green LED
is on when the valve is open.
• Close the valve when the tank is (partially) empty. The green LED goes
off when the valve is closed.
Cluster selection button (5) The LEDs show the status of the cluster(s):
• Green LED is on: the cluster is in operation
• Green LED flashes: the cluster is not in operation
Push the button to select a cluster (A, B, C or D) to see the twin filter status
(6):
• Green LED is on: the cluster is selected
• After 10 seconds the LEDs return to the cluster status indication
Twin filter reset button (6) Push the button after a filter element has been replaced to identify that the
filter is clean:
• Green LED is on: the related filter is in use
• Red LED is on: the related filter is dirty and not in use
Alarm buzzer mute button (7) Push the button to mute the buzzer sound for 10 minutes, when an alarm
with buzzer sounds is generated:
• Red LED is on: there is/are active alarm(s)
Push and hold the button until the LED goes off to clear the list of active
alarms.
Status LED (8) • Green LED is on: the CRS M3 is in operation and operates correctly
• Green LED flashes: the CRS M3 is in error state
4.2.2 Extension Cabinet
The control panel on the extension cabinet has one indicator LED:
Description 4-3
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Figure 4. Extension cabinet interface
LED Explanation
Status LED • Green LED is on: system is in operation and operates correctly
•Green LED flashes: there is no communication with the CRS M3 cabinet
(e.g. system starts up)
4.3 CRS M3 Web Interface
The CRS M3 web interface can be opened through T4C ('Configuration' >
'Devices' > tab 'T4C Network' > CRS M3 URL). The CRS M3 web interface
has three tabs (3) with information fields (4):
4-4 Description
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