LELY SHUTTLE XY User manual

innovators in agriculture
www.lely.com
Lely Industries N.V.
Lely SHUTTLE XY
Sampling Device
Operator Manual
D-H021.1011EN
English Original

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TRADEMARKS, COPYRIGHT AND
DISCLAIMER
Lely, Astronaut, Astri, Astrodata, Atlantis, Attis, Calm, Commodus,
Compedes, Cosmix, Discovery, E-link, Fertiliner, Gravitor, Grazeway,
Hibiscus, Hubble, Juno, L4C, Lely Center, Lelywash, Lotus, Luna, Nautilus,
Orbiter, Shuttle, Splendimo, T4C, Tigo, 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. The information given in this publication is provided for
information 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 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 © 2010 Lely Industries N.V.
All rights reserved
Lely Industries N.V.
Weverskade 110
3147 PA Maassluis
the Netherlands
Phone: [phone]
Fax: [phone]
Website: www.lely.com

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WARRANTY RESTRICTIONS
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 Super contract.
•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.
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.

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LIST OF INCLUDED AMENDMENTS
No: Issue Date
(yy/mm)
Chapter(s) Remarks
2 10/11 All Illustrations updated
1 - 6, 8 Textual changes
6 Cleaning procedure added
7 Test and calibration procedures added
8 Alarm code and attention codes added
9 Diagram added
1 10/01 Initial Issue

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PREFACE
Manual Contents
This manual contains the information necessary to operate the SHUTTLE
XY Sampling Device. It also includes maintenance and troubleshooting
information that can be done by an operator.
Study and understand this information thoroughly before you operate
the SHUTTLE. 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 milking robot may
comprise improvements, features or options that are not covered in this
manual.
Applicability
The first table below shows the type number of the SHUTTLE for which
this manual is applicable. The second table below shows the type
numbers of the Lely milking robots for which the SHUTTLE can be used.
Model designation
Model Type number
SHUTTLE XY Sampling Device 5.1503.0001.0
Milking Robot Connectivity
Model Type number
Lely Astronaut A2 5.1001.0000
5.1002.0000
Lely Astronaut A3 5.1003.0000
5.1103.0000
Lely Astronaut A3 Next 5.1003.0010
5.1103.0010

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Registration
The Type and Serial Number Plate is attached to the back of the base of
the SHUTTLE. Always include the type and serial numbers of your
SHUTTLE when you contact your local Lely service provider or order
spare parts.
Type and Serial Number Plate
We suggest you complete the table below with the type and serial
numbers of your SHUTTLE. This makes sure you can easily find the
information.
Type number
Serial number
Maintenance Authorization
WARNING
Only technicians certified by Lely Industries are authorized to do
maintenance on the SHUTTLE, 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 SHUTTLE, the warranty on the SHUTTLE becomes invalid.
Before a technician does maintenance on an SHUTTLE, the owner must
examine the service pass of the technician and make sure the technician
is currently certified to do maintenance on the SHUTTLE.
At the end of each visit, all work done on the SHUTTLE must be written
in the logbook and the logbook must be signed by the certified
technician. The logbook must always be kept near the SHUTTLE for the
entire life of the product. The information in the logbook must include:
•The maintenance done
•The date of the maintenance
•The name of the technician
•The certification number of the technician.

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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 SHUTTLE.
There are five 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)
•Master 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 do work on the milking robot can only in the presence of a certified
technician.
When the training program is completed successfully, Lely issue a
certificate and a service pass to the technician. The service pass contains
the following information:
•The name of the technician
•A photograph of the technician
•The certification number of the technician
•The date of expiry of the certification.
Local Maintenance Contact Number
We suggest you write the telephone number and email address of your
local maintenance contact in the table below. This makes sure you can
easily find the information.
Telephone number
email address

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Table of Contents
1. Introduction 1-1
2. Safety 2-1
2.1 Safety Instructions 2-1
2.1.1 General Safety 2-1
2.1.2 Transport Safety 2-1
2.1.3 Operating Safety 2-2
2.1.4 Maintenance Safety 2-2
2.2 Safety Decals 2-3
2.2.1 Safety Decal Messages 2-3
2.2.2 Maintenance of Safety Decals 2-4
2.2.3 Installation of Safety Decals 2-4
2.3 Emergency Stop Procedure 2-4
3. Specifications 3-1
4. Description and Operation 4-1
4.1 Description 4-1
4.2 Operation 4-3
4.3 Operator Panel 4-4
5. Operating Instructions 5-1
5.1 Transport the SHUTTLE 5-1
5.2 Connect the Sampling Device 5-2
5.3 Replace the filled Bottles and Trays 5-9
5.4 Disconnect the Sampling Device 5-10
5.5 Print the List of Sample Details 5-11
5.5.1 Print the List in T4C 1 5-11
5.5.2 Print the List in T4C 3.0 5-11
5.6 Calculate the 24 h Milk Yield 5-12
6. Maintenance 6-1
6.1 Clean the SHUTTLE 6-1
7. Test and Adjustment 7-1
7.1 Preparation 7-1
7.2 Test the SHUTTLE 7-2
7.3 Calibrate the SHUTTLE 7-2
8. Troubleshooting 8-1
8.1 Attention Codes 8-1
8.2 Alarm Codes 8-2
8.3 Reset an Alarm 8-5
8.4 Reset the SHUTTLE 8-5

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9. Diagram 9-1
Glossary of Terms
Index

Introduction 1-1
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1. INTRODUCTION
The SHUTTLE is a removable and external sampling device for the Lely
Astronaut milking robots. Once connected, the SHUTTLE can
automatically collect up to a 100 milk samples.
The SHUTTLE uses a sample box with bottles of CRV Nederland. The
bottles are filled with approximately 30 ml of milk.
The SHUTTLE has the following parts:
•Base
•Sample box, with bottles
•Cover
•Fill unit
•Operator panel.
Figure 1. SHUTTLE overview
KEY:
1. Sample box with bottles - 2. Fill unit - 3. Operator panel - 4. Cover - 5. Base

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Safety 2-1
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2. SAFETY
2.1 Safety Instructions
YOU are responsible for the SAFE operation and maintenance of your
robotic milking system. YOU must make sure that you and anyone else
who is going to operate, maintain or work in the vicinity of the milking
robot 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 EVERYONE who operates, maintains or works near
the milking robot obeys the safety precautions. Do not risk injury or
death by ignoring good safety practices.
•SHUTTLE owners must train operators before they operate the
SHUTTLE and the milking robot. 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 milking robot
•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 they are only installed
by authorized technicians.
2.1.1 General Safety
•Read and understand this manual, the operator manual of the
milking robot and all safety signs before you connect the SHUTTLE to
the milking robot
•Only trained persons are permitted to operate the SHUTTLE and the
milking robot
•Wear the correct protective clothing and equipment
•Disconnect the CAN-bus cable before you clean or do maintenance
on the SHUTTLE
•Know the emergency medical center number for your area
•Contact your nearest Lely service provider if you have any questions
•Review safety related items with all operators frequently (annually)
2.1.2 Transport Safety
•Only use the transport handle or the handle on the cover when you
transport the SHUTTLE
•Close and lock the cover when you transport or store the SHUTTLE
•Do not transport the SHUTTLE with filled sample bottles installed.

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2.1.3 Operating Safety
•Read and understand this manual, the operator manual of the
milking robot and all safety signs before you connect the SHUTTLE to
the milking robot
•Only trained persons are permitted to operate the SHUTTLE and the
milking robot
•Disconnect the CAN-bus cable before you clean or do maintenance
on the SHUTTLE
•Make sure the cover of the SHUTTLE is closed and secured before you
start the sampling
•Make sure the transport handle is fully in
•Lock the cover with a lock when sampling bottles are in the SHUTTLE
•Keep the cover closed when the fill head moves or when the fill head
is in fill position
•Keep the working area as clean and as dry as possible
•Make sure the transport handle is fully in when the SHUTTLE is in
position
•Make sure the robot arm cannot hit you when you work on the
SHUTTLE
•Make sure the robot arm cannot hit the SHUTTLE
•Make sure the SHUTTLE, the sampling bottles and milk tube are
clean. Clean the SHUTTLE if it is not used for more than three days.
•Contact your nearest Lely service provider if you have any questions
2.1.4 Maintenance Safety
•Read and understand this manual, the operator manual of the
milking robot and all safety signs before you connect the SHUTTLE to
the milking robot
•Only trained persons are permitted to operate the SHUTTLE and the
milking robot
•Disconnect the CAN-bus cable before you clean or do maintenance
on the SHUTTLE
•Make sure all covers and guards are installed when maintenance
work is complete

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2.2 Safety Decals
2.2.1 Safety Decal Messages
General safety messages appear in this safety messages section. Specific
safety messages are in applicable parts of this manual when potential
hazards may occur if the instructions or procedures are not followed.
2.2.1.1 Poisonous Substance - Chemical Hazard
A chemical hazard decal is affixed to the cover.
Figure 2. Example of the chemical hazard decal
WARNING
The content of the sample box contains poisonous substances
necessary to preserve the milk samples. There is a danger of damage
to health when:
- large quantities of the preservative are inhaled
- the preservative comes in contact with the skin
- the preservative is swallowed.
Store the sample box locked and in a safe place out of the reach of
children.

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2.2.2 Maintenance of Safety Decals
Safety decals on the SHUTTLE XY Sampling Device display important and
useful information that will help you safely operate and maintain the
SHUTTLE.
Obey the instructions below to make sure all the decals stay in the
correct position and condition.
•Keep the safety decals clean and legible at all times. Clean the safety
decals with soap and water. Do not use mineral spirits, abrasive
cleaners or other similar agents that may damage the safety decals
•Replace safety decals that are missing or are illegible
•Safety decals can be purchased from your local Lely service provider.
2.2.3 Installation of Safety Decals
1. Make sure the installation surface is clean and dry.
2. Make sure the temperature of the mounting surface is not less than
5 °C (41 °F).
3. Identify the correct position for the decal before you remove the
backing paper.
4. Remove a small part of the backing paper.
5. Put the decal in the correct position on the mounting surface and
carefully press the small part of exposed adhesive surface of the
decal onto the mounting surface.
6. Slowly remove the backing paper and attach the rest of the decal
to the mounting surface.
7. Puncture small air pockets in the decal with a pin and use the
backing paper to smooth the decal.
2.3 Emergency Stop Procedure
Method 1
1. Disconnect the CAN-bus cable from the E-Link connector on the
bottom of the multiple function box.
2. Disconnect the milk tube from the SHUTTLE.
3. Pinch the milk tube to prevent unwanted drainage of milk.
Method 2
1. Push and hold button [Reset/Stop] for more than 5 s.