LELY ASTRONAUT A4 User manual

Lely ASTRONAUT A4
Milking Robot
Safety and Warranty Information
5.1004.8506.0 -
English Original

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Table of Contents
1. Warranty and Copyright Information................................................................................................1-1
1.1 List of Included Amendments...................................................................................................1-1
1.2 Trademarks, Copyright and Disclaimer....................................................................................1-1
1.3 Warranty Restrictions...............................................................................................................1-2
2. Safety Instructions............................................................................................................................. 2-1
2.1 Signal Icons..............................................................................................................................2-1
2.2 General Safety......................................................................................................................... 2-1
2.3 Electrical Safety....................................................................................................................... 2-2
2.4 Chemical Safety....................................................................................................................... 2-2
2.5 Operating Safety...................................................................................................................... 2-3
2.6 Installation Safety.....................................................................................................................2-3
2.7 Maintenance Safety................................................................................................................. 2-4
3. Location of the Safety Decals........................................................................................................... 3-1
4. Safety Decals...................................................................................................................................... 4-1
4.1 Chemical Hazards (Swallowing/Burning)................................................................................. 4-1
4.2 Chemical Replacement Instruction.......................................................................................... 4-1
4.3 Electrocution Hazard................................................................................................................4-2
4.4 Laser Light Hazard...................................................................................................................4-2
4.5 No Admittance for Unauthorized Persons................................................................................4-3
4.6 No Fluids in Vacuum Pump......................................................................................................4-3
4.7 Pinching Hazard.......................................................................................................................4-4
4.8 Rotating parts - Entanglement Hazard.....................................................................................4-4
4.9 Temperature Hazard................................................................................................................ 4-5
5. Safety Decal Maintenance................................................................................................................. 5-1
6. Emergency Stop Buttons...................................................................................................................6-1
7. Basic Operating Instructions............................................................................................................ 7-1
7.1 Switch ON/OFF the Robot Unit and the Central Unit............................................................... 7-1
7.1.1 Switch ON the Central Unit...................................................................................................... 7-1
7.1.2 Switch ON the Robot Unit........................................................................................................ 7-2
7.1.3 Switch OFF the Robot Unit...................................................................................................... 7-4
7.1.4 Switch OFF the Central Unit.................................................................................................... 7-6
7.2 Put the Central Unit in Operation............................................................................................. 7-9
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7.3 Take the Central Unit Out of Operation....................................................................................7-9
7.4 Put the Robot Unit in Operation............................................................................................... 7-9
7.4.1 Put the Robot Unit in Operation with the E-Link...................................................................... 7-9
7.4.2 Put All Robots in a Cluster in Operation with the CRS+.......................................................... 7-9
7.5 Take the Robot Unit Out of Operation....................................................................................7-10
7.5.1 Take One Robot Unit Out of Operation with the E-Link......................................................... 7-10
7.5.2 Take All Robots in a Cluster out of Operation with the CRS+................................................7-10
7.6 Reset the Robot Unit..............................................................................................................7-10
7.7 Calibrate the Robot Arm.........................................................................................................7-11
7.8 Move the Robot Arm to the Service Position......................................................................... 7-11
7.9 Move the Robot Arm to the Home Position............................................................................7-12
7.10 Interrupt a Visit....................................................................................................................... 7-12
7.11 Interrupt a Pretreatment......................................................................................................... 7-13
7.12 Postpone a Rinse...................................................................................................................7-13
7.13 Alarms on the E-Link..............................................................................................................7-13
7.13.1 Confirm Alarms...................................................................................................................... 7-13
7.13.2 Overview of Alarms on the E-Link..........................................................................................7-13
7.14 Alarms on the CRS+.............................................................................................................. 7-14
7.14.1 Show List of Active Alarms.................................................................................................... 7-14
7.14.2 Reset Alarms......................................................................................................................... 7-14
7.14.3 Display History of Alarms.......................................................................................................7-14
7.14.4 Clear the Alarm List............................................................................................................... 7-14
7.14.5 Ignore Alarms for next 60 Minutes......................................................................................... 7-15
7.14.6 Show Event History................................................................................................................7-15
iv Table of Contents
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1. WARRANTY AND COPYRIGHT
INFORMATION
1.1 List of Included Amendments
2010/11
• Initial release
2015/02
• Update
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, 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. 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 © 2015 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
Warranty and Copyright Information 1-1
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1.3 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 Total Responsibility 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.
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.
1-2 Warranty and Copyright Information
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2. SAFETY INSTRUCTIONS
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 General Safety
• Read and understand the manual and all safety signs before you connect
power supplies to operate, maintain or adjust the milking robot.
• Only trained persons are permitted to operate the milking robot.
• Only use the robot unit to milk cows. Do not use the robot unit for other
purposes, such as medical treatment.
• A first-aid kit must be available near the central unit and the robot unit(s).
Store in a highly visible place.
• A carbon dioxide or foam fire extinguisher must be available near the
central unit and robot unit(s). Store in a highly visible place.
• Install all protective covers and guards before you operate the milking
robot.
• Wear the correct protective clothing and equipment.
• SWITCH OFF the milking robot, disconnect and isolate the electrical
power supply, release pneumatic pressure and wait for all moving parts
to stop before you clean or do maintenance on the milking robot.
• 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).
• Industrial electronical equipment may cause interference with household
electronical equipment. In such an event the affected equipment should
be removed.
Safety Instructions 2-1
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2.3 Electrical Safety
• Only an authorized electrician must install the electrical power supply for
the milking robot
• Make sure the electrical grounding of the electrical system and all parts of
the milking robot meet the local rules and regulations
• Make sure all electrical switches are in the OFF position before you
switch on the electrical power supply
• Prevent damage by vermin
• Replace any damaged electrical lines, conduits, switches and
components immediately
• Isolate the electrical power supply at the master panel before you open
the electrical panel to work on the electrical system.
2.4 Chemical Safety
• The ASTRONAUT A4 uses chemicals for cleaning and disinfection
purposes. There is space in the central unit to store the jerry cans for the
chemicals (acids based liquid, alkaline based liquid and brush cleaner
liquid). The udder care drum must be stored away from the chemical jerry
cans, but within 5 m (16.4 ft) from the central unit.
• The stock of each chemical must be stored outside the robot control/
compressor room according to local rules and regulations. Contact your
local Lely service provider for more information.
• To prevent exchange of the chemicals , make sure the correct tube is
connected to the correct cleaning detergent can. Severe damage to the
live stock, human and parts of the robot can be done when chemical
products are exchanged.
• Each chemical has a color code. Each suck tube has a color
corresponding with the chemical. Each suck tube has a disk with the
name of the chemical.
• Read the safety instructions on the cans.
• Always wear protective gloves and safety goggles when you do work on
parts where a chemical product flow through.
• We always recommend to use the Lely Astri products for cleaning and
disinfection, as their use in the Lely system is proven and does not harm
or damage the Lely equipment.
• Do NOT use chlorine, or other acids than phosphor and citric acid
products in the cleaning system.
• Lely Industries N.V. is not liable for, and does not cover under warranty,
any damage or harm due to the use of other cleaning products not
meeting the Lely specifications.
• Do NOT mix up the chemical products when you replace the jerry cans.
• Use only the correct chemicals for a hot cleaning.
• The safety data sheets of the Lely products are available at
www.Lely.com
2-2 Safety Instructions
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For the link to the safety data sheets internet connection required.
2.5 Operating Safety
• Read and understand the applicable manual and all safety signs before
you connect power supplies to operate, maintain or adjust the milking
robot
• Only trained persons are permitted to operate the milking robot
• Do NOT use chlorine products in the cleaning system. Lely Industries
N.V. is not liable for, and does not cover under warranty, any damage or
harm due to the use of other cleaning products in the cleaning system
which do not meet the Chemicals Specifications.
• Do NOT mix up the chemicals when you replace the jerry cans.
• SWITCH OFF the milking robot, disconnect and isolate the electrical
power supply, release pneumatic pressure and wait for all moving parts
to stop before you clean or do maintenance on the milking robot
• Install all covers and guards before you operate the milking robot
• Keep hands, feet, hair and clothing away from all moving parts
• Keep unauthorized persons, especially small children away from the
milking robot at all times
• Before the pneumatic pressure is supplied to the milking robot, make
sure all parts are tight and that all hoses and fittings are in good condition
• Make sure the cow detection camera is free of dirt and debris
• Do not enter the operating area of the robot arm
• Do not block the robot arm. It can move with sufficient force to cause
injury to you and/or the cow
• Do not help the milking robot from the control area when it is attaching
the teat cups to the cow
• Always be alert for unexpected movement of the cow. Cows can transmit
large forces to parts of the machine
• Do not look directly into the laser light of the sTDS
• Keep the working area as clean and as dry as possible
• Contact your nearest Lely service provider if you have any questions
• Review safety related items with all operators frequently (annually).
2.6 Installation Safety
• Do not install the tubular fencing on the cow side of the robot unit before
the robot unit is in the correct position.
• The robot unit weighs approximately 650 kg (1433 lb) and the central unit
weighs approximately 320 kg (705 lb). Always use the correct lifting
equipment when you move the robot unit or central unit.
• Read and understand the instructions in the Building Specifications
Manual and Installation Manual.
• Use the special carrying frame when a fork lift truck is used to transport
the robot unit.
Safety Instructions 2-3
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• A special wheel kit can be used to move the robot unit on flat (including
slatted) floors.
• The robot is not stable until it is correctly installed, make sure it is
correctly supported at all times during movement and installation.
• Make sure the robot unit and central unit are correctly installed in the
barn.
• The robot unit must be installed in a horizontal position. If necessary,
install filler pieces to make sure the floor of the robot is horizontal.
• Make sure the electrical power supply is correct before you connect it to
the robot unit or central unit.
• Only an authorized electrician must install the electrical power supply for
the robot unit and central unit.
• Make sure the electrical grounding of the electrical system and all parts of
the robot unit and central unit meets the local rules and regulations.
• Do not climb the ASTRONAUT A4.
• Always use a proper scaffold or a double sided ladder during installation
of the ASTRONAUT A4.
2.7 Maintenance Safety
• Read and understand the applicable manual and all safety signs before
you connect power supplies to operate, maintain or adjust the milking
robot.
• Only trained persons are permitted to maintain the milking robot.
Technicians working on the milking robot must be certified by Lely
Industries N.V. The required level is at least Service Level 1.
• SWITCH OFF the milking robot, disconnect and isolate the electrical
power supply, release pneumatic pressure and wait for all moving parts
to stop before you do work on the milking robot.
• Take extreme care when you work near or with high-pressure pneumatic
systems. If possible, depressurize the system before you do work on it.
• Wear protective clothing and safety goggles when you do work on the
pneumatic system.
• Wear protective gloves and safety goggles when you do work on parts
where disinfective and cleaning fluids flow through.
• Make sure all covers and guards are installed when maintenance work is
complete.
• Some parts (vacuum pump, parts where cleaning fluid flows through) can
have a hot surface. Make sure they are cooled down before you do
maintenance.
• Do not climb the ASTRONAUT A4.
• Always use a proper scaffold or a double sided ladder when you do
maintenance on the ASTRONAUT A4.
• Block the cow traffic to the robot unit when you do maintenance on the
cow side of the robot unit.
2-4 Safety Instructions
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3. LOCATION OF THE SAFETY
DECALS
Central unit
Figure 1.
KEY:
1. Electrocution hazard (page 4‑2) - 2. Temperature hazard (page 4‑5) - 3. No fluids
in vacuum pump (page 4‑3) - 4. Chemical hazards (page 4‑1) - 5. Chemical
replacement instruction (page 4‑1)
Location of the Safety Decals 3-1
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Robot unit
Figure 2.
KEY:
1. Pinching hazard (page 4‑4) - 2. Electrocution hazard (page 4‑2) - 3. Rotating parts,
entanglement hazard (page 4‑4) - 4. Laser light hazard (page 4‑2) - 5. Chemical
hazards (page 4‑1) - 6. Temperature hazard (page 4‑5)
3-2 Location of the Safety Decals
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4. SAFETY DECALS
4.1 Chemical Hazards (Swallowing/Burning)
Figure 3. Chemical Hazards Symbol (except Canada and USA)
Figure 4. Chemical Hazards Symbol (Canada and USA)
May cause serious burns to fingers or hands.
Obey all applicable health and safety rules.
Avoid contact between the cleaning agent and your skin or eyes. Wear
gloves, safety goggles and protective clothing. If the cleaning agent
comes into contact with your eyes: rinse immediately with water and
get medical advice.
4.2 Chemical Replacement Instruction
Figure 5. Chemical replacement instruction decal
Safety Decals 4-1
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4.3 Electrocution Hazard
Figure 6. Electrocution Hazard Symbol (except Canada and USA)
Figure 7. Electrocution Hazard Symbol (Canada and USA)
Stop the milking robot, turn off electrical power at the master panel and
wait for all moving parts to stop before doing maintenance, adjustment
or repair.
Disconnect and switch off the main electrical power switch.
4.4 Laser Light Hazard
Figure 8. Type one Laser Light Hazard Symbol (except Canada and USA)
Figure 9. Type two Laser Light Hazard Symbol (except Canada and USA)
4-2 Safety Decals
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Figure 10. Laser Light Hazard Symbol (Canada and USA)
Class 2 laser product. Laser radiation. Do not look into the laser beam.
4.5 No Admittance for Unauthorized Persons
Figure 11. No admittance for unauthorized persons
Only persons who have read and understood all applicable safety
instructions are allowed to enter the area.
4.6 No Fluids in Vacuum Pump
Figure 12. Symbol: no fluids in vacuum pump
Fluids in the vacuum pump result in irreparable damage.
Safety Decals 4-3
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4.7 Pinching Hazard
Figure 13. Pinching Hazard Symbol (except Canada and USA)
Figure 14. Pinching Hazard Symbol (Canada and USA)
Danger of being pinched by moving parts.
Keep away from all moving parts during operation of the ASTRONAUT
A4.
4.8 Rotating parts - Entanglement Hazard
Figure 15. Rotating Parts - Entanglement Hazard Symbol
Danger of being entangled by rotating parts.
Keep hands, loose clothing and long hair away from moving parts
during operation of the ASTRONAUT A4.
4-4 Safety Decals
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4.9 Temperature Hazard
Figure 16. Type One Temperature Hazard Symbol (except Canada and
USA)
Figure 17. Type Two Temperature Hazard Symbol (except Canada and
USA)
Figure 18. Temperature Hazard Symbol (Canada and USA)
Do not touch the cleaning system components until they have cooled.
High Temperatures can cause injuries.
Make sure you wear protective gloves.
Safety Decals 4-5
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4-6 Safety Decals
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5. SAFETY DECAL
MAINTENANCE
Safety decals on the Astronaut milking robot display important and useful
information that will help you safely operate and maintain the milking robot.
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.
Safety Decal Maintenance 5-1
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5-2 Safety Decal Maintenance
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