Merlin/3 Way Separation Gate Installation Technical 006798 Revision 01
Contents Contents... 2 Important information - read this first... 4 Icons... 4 1. Introduction... 5 2. Services... 5 3. BOM... 6 3.1 Stallwork...6 3.2 Components...8 3.3 Fasteners...9 4. Layout Drawing... 10 4.1 Installation Notes...10 4.1.1 Post Hole No.1;... 10 4.1.2 Post Hole No.2;... 10 4.1.3 Control Gate Notes;... 10 5. Installation Procedure... 11 5.1 Control Gate Post Installation...11 5.2 Diverting Gate Post Installation...12 6. Bracing Gates... 13 6.1 Brace Two Sets of Posts...13 6.2 Brace Structure...15 7. Control Gate Installation... 16 7.1 Control Gate Cylinder...17 8. Diverting Gate Installation... 19 8.1 Gate Assembly...19 8.2 Cylinder Mounting Bracket...21 8.3 Cylinder Assembly...23 8.4 Mounting Cylinder...25 8.4.1 Cylinder Rod Eye Installation... 25 8.4.2 Cylinder Installation... 27 9. Locating & Fitting Sensors... 29 9.1 Control Gate Sensor...29 10. Air Tube Connections... 30 006798 Page 2
10.1 Control Gate Cylinder...30 10.2 Diverting Gate Cylinder...31 11. Cylinder Set-up... 32 12. Walk Over Antenna Installation... 33 12.1 Antenna Cable...34 13. Assemble Valve Setup... 35 13.1 Components...35 13.2 Procedure...36 14. Air Regulation... 40 15. External References... 41 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. 006798 Page 3
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. 006798 Page 4
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 006798 Page 5
3. BOM 3.1 Stallwork 069727 069728 069726 069730 092776 006798 Page 6
092771 193363 006798 Page 7
3.2 Components 092783 092780 092790 092788 092789 007756 007757 007978 069776 069725 003529 060910 007829 069840 069729 004843 094628 004846 004847 004850 004818 005026 006798 Page 8
3.3 Fasteners 001523 M12 Plain Washer BZP 8 001291 M12 Nyloc Nut BZP 8 000401 M8x25 HT Capscrew 8 001143 M8 Nyloc Nut-BZP 8 001516 M8 Washer(Type A) BZP 8 000553 M10x40 Hex Hd Setscrew MS BZP 8 001522 M10 Plain Washer BZP 16 001271 M10 Nyloc Nut-BZP 16 000280 M10x55 SS Sckt Cap Screw 8 001099 M24 Nyloc Nut BZP 4 001528 M24x44 Flat Washer BZP 8 001097 M24 Nut BZP 4 000058 M16x100 Hex Hd Bolt-BZP 4 001524 M16 Plain Washer BZP 8 001098 M16 Nyloc Nut BZP 4 000099 M12x120 Hex Hd Bolt BZP 4 001291 M12 Nyloc Nut BZP 12 001523 M12 Plain Washer BZP 4 001099 M24 Nyloc Nut BZP 4 001097 M24 Nut BZP 4 001528 M24x44 Flat Washer BZP 4 001737 M24x40 Spring Washer BZP 4 000058 M16x100 Hex Hd Bolt-BZP 4 001524 M16 Plain Washer BZP 4 001098 M16 Nyloc Nut BZP 8 000062 M16x80 Hex Hd BZF Bolt 2 001527 M16x50 Flat Washer BZP 2 000920 M6x25mm Chs M/C Screw BZP 4 001521 M6 Plain Washer BZP 4 001282 M6 Nyloc Nut 4 000063 M10x70 Hex Hd Bolt BZP 2 001522 M10 Plain Washer BZP 2 001271 M10 Nyloc Nut-BZP 2 001219 M3 Nyloc Nut SS 2 001637 M3x7mm od x 0.5mm SS Washer 4 000996 M3x60mm Chs M/C Screw SS 2 000097 M12x100 Hex Hd Bolt BZP 8 000432 M6x30mm Lg SS Hex Hd S/Screw 6 001158 M6 SS Nyloc Nut 6 000937 No10x1.5"Round Hd WoodScrw SS 12 006798 Page 9
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 4.1.1 Post Hole No.1; Holes to be 350 x 350 x 450mm deep (2 places) for control gate posts. 4.1.2 Post Hole No.2; Holes to be 500 x 500 x 730mm deep (2 places) for diverting gate posts 4.1.3 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) 006798 Page 10
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. 069728 Using 069728, brace cow control posts together and stand in prepared holes Fasteners used for bracing control gate posts 000097 001291 001523 Check all levels and heights as per plans and concrete around posts. 006798 Page 11
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. 006798 Page 12
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 006798 Page 13
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. 006798 Page 14
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 006798 Page 15
7. Control Gate Installation 000058 001524 001099 001528 069725 001098 001524 001097 006798 Page 16
7.1 Control Gate Cylinder 069729 004850 004849 069840 069730 069728 160566 Insert 1/4 Flow Control Valves into control gate cylinder, see section 11 for cylinder setup C A B 006798 Page 17
004846 004847 A 000062 001524 Insert 069824 001524 001098 B 001524 001098 069824 C 006798 Page 18
8. Diverting Gate Installation 8.1 Gate Assembly 092776 001097 Insert 069776 into gate hinge assy 001099 001099 069725 092771 000058 001098 001524 006798 Page 19
092771 006798 Page 20
8.2 Cylinder Mounting Bracket 092783 092771 092789 M12 U Bolt 001523 M12 Washer 001291 M12 Nyloc Nut 006798 Page 21
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8.3 Cylinder Assembly 092780 007757 007756 000280 Use Fasteners; 000280 - M10x55 SS Sckt Cap Screw 001522 - M10 Plain Washer BZP 001271 - 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 006798 Page 23
060910 007978 006798 Page 24
8.4 Mounting Cylinder 8.4.1 Cylinder Rod Eye Installation 092788 007829 Use to attach 092788 to Diverting gates as shown in picture below 007829 & 092788 006798 Page 25
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8.4.2 Cylinder Installation There is one cylinder to be installed per diverting gate, procedure as follows; 092790 Use plate and fasteners to attach the cylinder assembly to Cylinder Mounting Arm Assembly (092783), as shown below. 006798 Page 27
Image shows the set up of the cylinder mounting and diverting gate, repeat for opposite side 006798 Page 28
9. Locating & Fitting Sensors 9.1 Control Gate Sensor 094628 Fabricate a bracket to take the sensor Bolt Bracket in place (bracket not supplied by Fullwood) 092790 006798 Page 29
10. Air Tube Connections 10.1 Control Gate Cylinder Mount trunking 005176-20mm Flex Conduit Grey 004846 004847 003529 - Blue Plastic Tube 8mm OD 006798 Page 30
10.2 Diverting Gate Cylinder 003529 - Blue Plastic Tube 8mm OD Bracing Tubes Run the 8mm blue plastic tube from the diverting gate cylinders through the bracing tubes 006798 Page 31
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). 006798 Page 32
12. Walk Over Antenna Installation Part No Description Qty 033573 Antennae(Low Freq)Blue 1 000432 M6x30mm Lg SS Hex Hd S/Screw 6 001158 M6 SS Nyloc Nut 6 000937 No10x1.5"Round Hd WoodScrw SS 12 002400 25mm 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 80-120 cm wide and 160-180 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. 006798 Page 33
12.1 Antenna Cable Route the antenna cable as shown Antenna cable 006798 Page 34
13. Assemble Valve Setup 099040-200 va 24vac PSU 099704 - Fus Activity Adpt UCC-FwAA 13.1 Components 007882 x 1 007317 x 3 007316 x 3 006798 Page 35
13.2 Procedure Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 006798 Page 36
Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 006798 Page 37
Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 006798 Page 38
Figure 20 004766-8mm x 1/8"BSP Swivel Elbow 005026-1/4"BSP Exhaust Muffler 500-2 004818-1/4"BSP- 10mm Straight Connector Mount valve assembly on Din rail and mount in enclosure 006798 Page 39
14. Air Regulation 003527 - Mnf 10/8 Blue Tube 10mm 004818 007980 - Regulator To Source To Gate 005067-8-1/4 Straight Male Connector Fit Regulator in place using 007981 - Angle Brkt+Plstc Nut AIR PRESSURE SHOULD BE SET TO 7 BAR 006798 Page 40
15. External References Please refer to manuals indicated below for pedometer and tiris setups; 006762 - Cow Sep Gates Instruct 006780 - FAA Technical 006781 - FSAC Tech V1.03 006798 Page 41