COTSWOLD CLUSTER-FLUSH Bedienungsanleitung
CLUSTER-FLUSH
Milking Cluster Disinfection System
DOUBLE UP HI-LEVEL PARLOUR
Installation Instructions,
Sales & Service Information
Cotswold Dairy Equipment Co Ltd
Avenue 3 Station Lane Witney
Oxford OX28 4BP UK
Tel +44 (0)1993 774567
Fax +44 (0)1993 771776
e-mail sales@cotswold-dairy.couk
www.cotswold-dairy.com
MADE IN ENGLAND
AIR SUPPLY
CHEMICAL ENTRAINMENT
(option)
FLEXIBLE
PIPE
RUN
HEADER TANK
(Note: Level With Cylinders)
WATER INLET SYSTEM
CONNECTION TO MILK LINE (Y Piece)
COTSWOLD CLUSTER FLUSH
Milking Cluster Disinfection System
FOR SWING OVER PARLOURS
Model 220
PRODUCT MANUFACTURING, SERVICING & MAINTENANCE OVERVIEW
The Cotswold Cluster Flush is a system for the effective removal of infectious
material left in the milking cluster after a cow has been milked, so that the cluster
is disinfected before it is used to milk another cow.
The system mixes a small amount of recommended disinfectant with a pre-
determined amount of water, and automatically “flushes” each milking cluster with
this mixture. This process is repeated after every cow is milked.
Using the Cluster Flush System leads to a substantial reduction in the risk of
cross-infection between cows in the dairy.
SERVICES
The system is mains-powered (230v 50/60hz 1amp). At the point of use the
operating voltage is reduced to 24v dc.
The system requires a ready supply of fresh clean water and a clean compressed-
air supply (at 2 bar).
WIRING:
Connect the Power Supply Unit (PSU) to the mains via a double-pole isolation
switch, which should be visible and within easy reach of system operators.
Wiring from the power supply to each control box should be SELV, using a suitable
type of wire like H03VVF with a CSA of at least 0.75mm2.
All controllers and the power supply unit must be suitably earthed.
All connector tags and terminals will be zinc plated.
This equipment is rated for OV (over-voltage) Category 2 supplies.
PRESSURE VESSEL SPECIFICATION AND USAGE
The pressure cylinder is SEP-rated category-1 at its 2 bar mandatory operating
pressure. Its maximum safe pressure rating is 6 bar.
ENVIRONMENTAL CONDITIONS:
The system can be installed in milking parlours anywhere on the planet. Do not
use in the open, in direct sunlight or where pipework could be subject to freezing.
The protection offered by this product may be impaired or lost if installation and
maintenance is not carried out in line with the instructions in this manual.
LABELING
All labels used in this product comply with the CE Water and Hexane Rub Test. 3
CLUSTER FLUSH – PRODUCTION, SERVICING & MAINTENANCE
SAFETY INSTRUCTIONS –
(COMPLETE SYSTEM INCLUDING PRESSURE COMPONENTS)
(The Cotswold Cluster Flush – an SEP category 1 product)
These instructions relate primarily to factory manufacturing procedures, but since the
Cluster Flush needs regular onsite service and maintenance, we include them here too.
Component Preparation
All forming, bending drilling chamfering or any other working of
components must not cause changes in the mechanical characteristics of
those components and in no way reduce their efficiency.
Permanent joints in pressurised segments
For Cluster Flush pressure equipment (pressure cylinders), permanent
joining of components which contribute to their pressure resistance - and
components which are directly attached to them - must be carried out by
suitably trained personnel.
Permanent Joints and their adjacent zones must be free of any surface or
internal defects that could be detrimental to the safety of the equipment.
Permanent joints must always meet the minimum properties specified for
the materials to be joined.
Traceability
Inner pressure cylinders must be permanently labelled to show operating
pressure and year of manufacture.
Use label: (Pressure-Vessel (Sep-Category-1) , also label: (S Ayling materials
and date of moulding).
Final Testing
Pressure equipment must be subjected to final testing and inspection. A
test and inspection of the completed power supply unit and every control
panel/pressure cylinder assembly is essential.
IF IN DOUBT – ASK!
IEC 60417-5018)
CLUSTER FLUSH – PRODUCTION SAFETY INSTRUCTIONS.DOC
COTSWOLD CLUSTER FLUSH
Milking Cluster Disinfection System
4
COTSWOLD CLUSTER-FLUSH
Milking Cluster Disinfection System
FOR HIGH-LEVEL DOUBLE-UP PARLOURS:
DUAL
CONTROLLER
PSU
SOLENOIDS
SOLENOIDS
HEADER
OVERHEAD SCHEMATIC
(use in conjunction with attached
schematic side views)
WATER AIR
AIR
ANTI
SYPHON
VALVE
PERACETIC ACID CONCENTRATION
Set dosing at 0.5%
Usage @ Twice-A-Day Milking:-
0.7 Litres / 100 Cows / Day
INSTALLATION NOTES
(DOUBLE-UP PARLOUR HIGH LEVEL)
ORDER OF INSTALLATION
!For ease of installation, we recommend the following installation sequence:
! 1/ HEADER TANKS
2/ WATER / PLUMBING
3/ SET UP WATER CYLINDERS
4/ INSTALL AIRLINES
5/ CONTROLLERS and ELECTRICAL
WATER / CHEMICAL
Site the Header Tank at the same level as the cylinders. Ensure that the water level in the cylinders is
set 50mm (2 inches) below the top of the stainless tube, (see schematic drawings attached).
Run 2 inch (50mm) water tube from each header tank along the centre of the parlour, connecting to
each cylinder using tees, taps and 110x16mm i/d tube. At the lowest point fit a reversed (upside-
down) tee/tap so that it can be used as a drain point if required.
Chemical Dosing
We can supply Dosatron high accuracy dosing units if required. When dealing with chemicals, do
take all recommended precautions. Before commissioning the system, ensure all unions are tight
and the clusters hang correctly
AIR 2 - 3 bar, (pressure reducer may be required)
Connect the airline to the centre of the line of milking points, and Tee out to either side. Use 22mm
Flexible Tubing between the compressor (clean air filters should be fitted) and the centre
22x22x10mm tee.
Anti Syphon Valves, fit one valve either side of Tee connection of air line, at the mid point of each half
(see schematics)
Pressure Reducer
We can supply suitable pressure reducing valves if required.
ELECTRICAL
Locate Power Supply Unit (PSU) in a safe dry location, run 24v supply to the dual-solenoid control box.
If your system is Manually Triggered (by green Thumb-Switches in a grey boxes) locate convenient
positions for these and install them.
Also Arrange a convenient switch to turn off the system when it is not in use.
Always switch off system when washing parlour.
CONNECTION TO MILK LINE
Cut into the milk line and and fit the “Y” piece moulding using 13mm pvc tubing connecting to upper
horizontal outlet of stainless steel cylinder.
SHUT-OFF VALVE
(for Cluster Flush)
Controls maximum of two (2) cluster
points on either side of valve
(see schematic drawings for detail)
Flow
TO CYLINDER
To
MILK
LINE
To CLUSTER
Flow
Unit MUST be installed vertically (as above)
Flow
TO CYLINDER
To
MILK
LINE
To CLUSTER
WATER LEVEL
MILK LINE MILK LINE
AIR
HEADER TANK
CHEMICAL
STORE
(DOSATRON WILL
DRAW CHEMICAL
UP TO 7 METRES
HORIZONTALLY)
AIR
AIR AIR AIR AIR
Compressor
7 - 8 Bar
> 100 litres
IMPORTANT
Set Cylinder Levels To Header Tank.
Level Should Be 50mm Below Top
of Stainless Steel Cylinder
50mm
To see and set
water level
accurately,
detach push-on
water tube and
hold level with
stainless steel
cylinder
60°
END
VIEW
TAPS MUST BE
VERTICAL OR
SLOPING UP, TO
AVOID AIR-LOCKS
WATER
SUPPLY
DOSATRON
Chemical Induction
Unit (option)
STOP
TAP
AIR-SOLENOID BOX
(ALWAYS SWITCH OFF EITHER THE POWER SUPPLY
OR THE CONTROLLER(s) WHEN NOT IN USE)
AIR TO CENTRE
POINT OF RUN
ANTI-
SYPHON
VALVE
ANTI-
SYPHON
VALVE
INPUT
AIR-PLUMBING-SCHEMATIC-DOUBLEUP-July2013
SCHEMATIC
Double-Up Parlour Cluster Flush
Typical Layout for Cotswold Cluster
Flush for Double-Up Parlour
ON - OFF
COMPUTERISED
CONTROL PANEL
(controls sides A and B)
+ -
I1
(LEFT
A B ESC - + OK
I1
IB
IB
(RIGHT
GATE SWITCH (B) VACUUM
ELECTRICAL GATE SWITCHING SIGNAL (option)
ELECTRICAL GATE SWITCHING SIGNAL (option)
TO GATE SWITCH (A) VACUUM
POWER IN 230/240v
GATE SWITCH (OPTION)
GATE VAC CONTROLLER
GATE SWITCH (OPTION)
GATE VAC CONTROLLER
POWER
SUPPLY UNIT
24v FOR ELECTRICAL WIRING
SEE ELECTRICAL SCHEMATIC
MASTER
SWITCH
EURO / MCL
DOUBLE UP
Pressure Reducing
Valve 2 - 3 Bar
and food grade air filters
CF21 PERACETIC ACID CONCENTRATION
Set dosing at 0.5%
Usage @ Twice-A-Day Milking:-
0.7 Litres / 100 Cows / Day
WATER LEVEL
WATER LEVEL
WATER LEVEL
WATER LEVEL
SCHEMATIC
DoubleUp Parlour Cluster Flush
(30/30 or bigger)
Typical Layout for Cotswold Cluster Flush
for Double-Up Parlour, Hi/Lo, showing
how to split the air supply
(this is one side only)
SCHEMATIC
DoubleUp Parlour Cluster Flush
(30/30 or bigger)
Typical Layout for Cotswold Cluster Flush
for Double-Up Parlour, Hi/Lo, showing
how to split the air supply
(this is one side only)
COTSWOLD DAIRY EQUIPMENT
COTSWOLD DAIRY EQUIPMENT
MILK LINE MILK LINE MILK LINE MILK LINE MILK LINE
AIR
WATER LEVEL
AIR AIR AIR AIR AIR
AIR-SOLENOID BOX
AIR TO CENTRE
POINT OF RUN
(22mm)
ANTI-
SYPHON
VALVE
ANTI-
SYPHON
VALVE
INPUT
MILK LINE MILK LINE MILK LINE MILK LINE MILK LINE
AIR
WATER LEVEL
AIR AIR AIR AIR AIR
AIR-SOLENOID BOX
AIR TO CENTRE
POINT OF RUN
(22mm)
ANTI-
SYPHON
VALVE
ANTI-
SYPHON
VALVE
INPUT
2
1
3B
DOUBLE-UP
Split Flush
MasterSetSchematic/SplitFlush-July2013
ON - OFF
CONTROL PANEL
(controls sides A and B)
SCHEMATIC
FOR DOUBLE-UP PARLOUR
CONTROL PANEL
(controls sides A and B)
SCHEMATIC
FOR DOUBLE-UP PARLOUR
24V
+ -
IB
(LEFT
A)
ID
(RIGHT
B)
A B ESC - + OK
CHANNEL 1
CONTROLLED
CHANNEL 2
CONTROLLED
24v Input from
PSU or previous
controller
Outgoing 24v
Signals to Gates
Returning 24 volt
Switch Signals
from Gates
I1
IB
TRIGGER INPUTS
24v DC
Fuse
20mm
3 Amp
XD10
ALWAYS SWITCH OFF EITHER THE POWER SUPPLY
OR THE CONTRLLER(S) WHEN NOT IN USE
MCL
MCL
DOUBLE UP
DOUBLE UP
Standard 7
Inhaltsverzeichnis
Andere COTSWOLD Landwirtschaftliche Geräte Handbücher
