Merlin/3 Way Separation Gate Installation Manual. Technical Manual Revision 01

Transcription

1 Merlin/3 Way Separation Gate Installation Technical Revision 01

2 Contents Contents... 2 Important information - read this first... 4 Icons Introduction Services BOM Stallwork Components Fasteners Layout Drawing Installation Notes Post Hole No.1; Post Hole No.2; Control Gate Notes; Installation Procedure Control Gate Post Installation Diverting Gate Post Installation Bracing Gates Brace Two Sets of Posts Brace Structure Control Gate Installation Control Gate Cylinder Diverting Gate Installation Gate Assembly Cylinder Mounting Bracket Cylinder Assembly Mounting Cylinder Cylinder Rod Eye Installation Cylinder Installation Locating & Fitting Sensors Control Gate Sensor Air Tube Connections Page 2

3 10.1 Control Gate Cylinder Diverting Gate Cylinder Cylinder Set-up Walk Over Antenna Installation Antenna Cable Assemble Valve Setup Components Procedure Air Regulation External References Copyright 2007, Fullwood Limited reserves the right to change the contents of this manual if necessary, without warning. Fullwood Limited has taken every precaution to avoid errors and omissions on the manual and equipment but does not accept any responsibility or liability for damage of any kind arising from the use of this manual or Fullwood equipment; whether this damage is direct or indirect. If you discover any inaccuracies please inform Fullwood Limited or one of its agents and we will make corrections for the next release Page 3

4 Important information - read this first Before installing or operating the equipment, this manual and the appropriate operating instructions must be read carefully. The equipment must be used only for the application described. Installation of the equipment must be carried out by skilled and authorized technicians only. Proper handling of the equipment is the basis for correct functioning. Never remove any covers or parts off the system before the electrical power is disconnected and isolated. Do not wash the electronic equipment with volume washers or high pressure hoses. It is the responsibility of the farmer to check his animals and the performance of the equipment. If, for any reason, the system is not operational or individual animals refuse to use the system, it is the responsibility of the farmer to make alternative arrangements to feed and milk the animals. To avoid injury to animals and equipment, check there are no projections (pipes or anything similar) protruding in the parlour on which transponder neck bands or leg bands can get caught. Calibration of milk meters/monitors and feed dispensers are of utmost importance in obtaining accurate milking and feeding results. If calibration is incorrect, or the wrong values have been programmed, milking results and feed distribution will remain adversely affected until calibration has been corrected. The manufacturers guarantee does not cover direct or subsequent damage caused by incorrect installation, incorrect usage, improper treatment, inadequate cleaning or servicing, or incorrect software parameter inputs or hardware settings. Incorrect operation of the milking or management system may seriously affect the animals in an adverse way. It is therefore necessary to double check all inputs and outputs of the system. Icons Icons are used in this manual to draw the reader s attention to specific information. These icons have the following meaning: Failure to follow the instructions can result in severe injury to engineers, users, bystanders or livestock. Indicates special precautions that must be taken to avoid damage to equipment. Gives important information to prevent potential problems. Gives advice or suggestions to make procedures easier or clearer Page 4

5 1. Introduction This manual is a guide to the installation of a 3-way separation gate, contained within is step by step instructions; ensure that the work is carried out in the same sequence as shown. This manual deals with the set up of the gate structure but also gives details of manuals to reference for connection to services. In order to ensure that the Fullwood separation gates are installed to give optimum operational performance on all site locations, the following must be adhered to; All workmanship shall be carried out in accordance with national codes of practice. Industrial best practice shall be adopted when no codes are available. All current EU directives and national regulations shall be adhered to. An animal can only pass this separation system after identification just before the Texas gate. In other words an animal without an ear tag/pedometer will not pass the separation unit. 2. Services The following are not supplied as part of the assembly but will be required for the installation; Power Supply o Regulated and smoothed o 24VDC ± 3VDC Compressed Air Supply o Filtered o 7 bar minimum pressure Page 5

6 3. BOM 3.1 Stallwork Page 6

7 Page 7

8 3.2 Components Page 8

9 3.3 Fasteners M12 Plain Washer BZP M12 Nyloc Nut BZP M8x25 HT Capscrew M8 Nyloc Nut-BZP M8 Washer(Type A) BZP M10x40 Hex Hd Setscrew MS BZP M10 Plain Washer BZP M10 Nyloc Nut-BZP M10x55 SS Sckt Cap Screw M24 Nyloc Nut BZP M24x44 Flat Washer BZP M24 Nut BZP M16x100 Hex Hd Bolt-BZP M16 Plain Washer BZP M16 Nyloc Nut BZP M12x120 Hex Hd Bolt BZP M12 Nyloc Nut BZP M12 Plain Washer BZP M24 Nyloc Nut BZP M24 Nut BZP M24x44 Flat Washer BZP M24x40 Spring Washer BZP M16x100 Hex Hd Bolt-BZP M16 Plain Washer BZP M16 Nyloc Nut BZP M16x80 Hex Hd BZF Bolt M16x50 Flat Washer BZP M6x25mm Chs M/C Screw BZP M6 Plain Washer BZP M6 Nyloc Nut M10x70 Hex Hd Bolt BZP M10 Plain Washer BZP M10 Nyloc Nut-BZP M3 Nyloc Nut SS M3x7mm od x 0.5mm SS Washer M3x60mm Chs M/C Screw SS M12x100 Hex Hd Bolt BZP M6x30mm Lg SS Hex Hd S/Screw M6 SS Nyloc Nut No10x1.5"Round Hd WoodScrw SS Page 9

10 4. Layout Drawing Consult parlour plans to determine correct position of the separation gates 4.1 Installation Notes Diverting Gate Hinge Post; Height from floor to top of hinge post is 2500mm Height to top of gate is 2200mm Post Hole No.1; Holes to be 350 x 350 x 450mm deep (2 places) for control gate posts Post Hole No.2; Holes to be 500 x 500 x 730mm deep (2 places) for diverting gate posts Control Gate Notes; Height from floor to top of hinge post is 2350mm. This should ensure that the framework is installed high enough so that the cylinder carrier beam clears the top of the walkthrough antenna. (Antenna height is approximately 2100mm) Page 10

11 5. Installation Procedure 5.1 Control Gate Post Installation Prepare holes as described in installation notes 4.1 for cow control post in the positions specified on plans at 930mm centres Using , brace cow control posts together and stand in prepared holes Fasteners used for bracing control gate posts Check all levels and heights as per plans and concrete around posts Page 11

12 5.2 Diverting Gate Post Installation Prepare holes as described in installation notes for diverting post in the positions specified on plans at 1100mm centres Page 12

13 6. Bracing Gates 6.1 Brace Two Sets of Posts Fullwood gate posts are to be braced together as shown in this section When bracing two sets of gates together, use galvanised box section supplied. Brace control and diverting gates CONTROL GATE POSTS DIVERTING GATE POSTS To Diverting gate post Brace control posts together, Fully weld brace to both posts To Diverting gate post Control Gates posts Page 13

14 Brace diverting posts together, Fully weld brace to both posts Long tubes to brace control gate posts to diverting gate posts The long brace tubes from the control gates to the diverting gates are also used to run the 8mm air tubes from the gate cylinders back to the control Page 14

15 6.2 Brace Structure It may be necessary to brace the complete separation gate structure to a wall or I beam (RSJ), this not only adds to the rigidity of the assembly but also gives a neat finish for running electric cables and air tubes to source. Gate setup braced to RSJ. Neat routing for cables Control Gate Post Ensure that the control gate post are welded or braced to the cow race rails Cow Race Rail Page 15

16 7. Control Gate Installation Page 16

17 7.1 Control Gate Cylinder Insert 1/4 Flow Control Valves into control gate cylinder, see section 11 for cylinder setup C A B Page 17

18 A Insert B C Page 18

19 8. Diverting Gate Installation 8.1 Gate Assembly Insert into gate hinge assy Page 19

20 Page 20

21 8.2 Cylinder Mounting Bracket M12 U Bolt M12 Washer M12 Nyloc Nut Page 21

22 Page 22

23 8.3 Cylinder Assembly Use Fasteners; M10x55 SS Sckt Cap Screw M10 Plain Washer BZP M10 Nyloc Nut-BZP Locate cap head bolts as shown and secure behind bracket using 4 x washers and nyloc nuts Tighten securely using allen key and spanner Page 23

24 Page 24

25 8.4 Mounting Cylinder Cylinder Rod Eye Installation Use to attach to Diverting gates as shown in picture below & Page 25

26 Page 26

27 8.4.2 Cylinder Installation There is one cylinder to be installed per diverting gate, procedure as follows; Use plate and fasteners to attach the cylinder assembly to Cylinder Mounting Arm Assembly (092783), as shown below Page 27

28 Image shows the set up of the cylinder mounting and diverting gate, repeat for opposite side Page 28

29 9. Locating & Fitting Sensors 9.1 Control Gate Sensor Fabricate a bracket to take the sensor Bolt Bracket in place (bracket not supplied by Fullwood) Page 29

30 10. Air Tube Connections 10.1 Control Gate Cylinder Mount trunking mm Flex Conduit Grey Blue Plastic Tube 8mm OD Page 30

31 10.2 Diverting Gate Cylinder Blue Plastic Tube 8mm OD Bracing Tubes Run the 8mm blue plastic tube from the diverting gate cylinders through the bracing tubes Page 31

32 11. Cylinder Set-up Adjust the speed of the cylinder to suit the animal traffic Adjust the speed of the cylinder cushions and check the cushioning at each end stroke (start by closing the cushioning completely and open ¼ to ½ a turn). With the Gates in the open / separation position (cylinder extended), put slight pressure on the gate, as if to try and open further (to take out any slack in hinges / fixings) and slide rubber buffers to leave a 10mm 20mm gap between the rubber buffers and the wheels in the track, bolt the rubber buffers in this position (this is so the cylinder dose not use the rubber buffers as a stop) Page 32

33 12. Walk Over Antenna Installation Part No Description Qty Antennae(Low Freq)Blue M6x30mm Lg SS Hex Hd S/Screw M6 SS Nyloc Nut No10x1.5"Round Hd WoodScrw SS mm x 3mm SS Flat 6 The pedometer antennas are installed in the separation gate at the same height as the pedometer, which is about 20cm above the floor. The maximum identification range can be approximately 80cm. If the antenna is used for walk over identification, a stainless steel strip is used to increase the identification range of the antenna. The same figure shows in detail how the stainless steel strip should be connected to the antenna. Be sure that the stainless steel loop is closed with a "bridge" at the back of the antenna. Construct using 25x3mm SS flat steel THE CABLE OUTLET OF THE ANTENNA SHOULD ALWAYS POINT DOWNWARDS TO PREVENT MOISTURE PROBLEMS OTHERWISE WATER MAY PENETRATE INTO THECABLE INLET. The maximum size of the walk over antenna can be 1.3 meter wide and 2 meter long. Usually the size of the antenna is about cm wide and cm long. The pedometer will be identified when it comes into the antenna. The antenna may not be longer then the length of a cow, because otherwise two pedometers can be in the antenna at the same time and then both pedometers will not be identified Page 33

34 12.1 Antenna Cable Route the antenna cable as shown Antenna cable Page 34

35 13. Assemble Valve Setup va 24vac PSU Fus Activity Adpt UCC-FwAA 13.1 Components x x x Page 35

36 13.2 Procedure Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure Page 36

37 Figure 9 Figure 10 Figure 11 Figure 12 Figure Page 37

38 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure Page 38

39 Figure mm x 1/8"BSP Swivel Elbow /4"BSP Exhaust Muffler /4"BSP- 10mm Straight Connector Mount valve assembly on Din rail and mount in enclosure Page 39

40 14. Air Regulation Mnf 10/8 Blue Tube 10mm Regulator To Source To Gate /4 Straight Male Connector Fit Regulator in place using Angle Brkt+Plstc Nut AIR PRESSURE SHOULD BE SET TO 7 BAR Page 40

41 15. External References Please refer to manuals indicated below for pedometer and tiris setups; Cow Sep Gates Instruct FAA Technical FSAC Tech V Page 41