Nedap SmartFlow Instruction Manual
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Nedap SmartFlow Instruction Manual

Nedap SmartFlow Instruction Manual

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Instruction Manual
Nedap SmartFlow
Installation manual
Version 01.001 / 2021 / EN
Original instructions
Dairy Farming

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Summary of Contents for Nedap SmartFlow

  • Page 1   Instruction Manual Nedap SmartFlow Installation manual Version 01.001 / 2021 / EN Original instructions Dairy Farming...
  • Page 2 Copyright © Nedap N.V. All rights reserved. The information in this document is subject to change without notice, it is not to be reproduced in any way, in whole or in part, without the written consent of Nedap N.V. All trademarks referenced belong to their respective owners.
  • Page 3   Nedap SmartFlow Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...

  • Page 4: Table Of Contents

    Content Safety ....................4 SmartFlow overview ................6 SmartFlow introduction ....................6 Components ........................7 SmartFlow and MPCU in the milking parlor ..............9 Installation ..................10 Requirements for installation ..................10 3.1.1 Electrical requirements ....................10 3.1.2 Network requirements ....................11 3.1.3...
  • Page 5 Maintenance ..................41 Maintenance scheme ....................41 Replace the SmartFlow Float ..................41 Troubleshooting .................. 45 Malfunctions ......................... 45 Handling instructions ................46 Glossary ..................... 47 Technical specifications ..............48 Compliance ..................49 Nedap SmartFlow / Installation manual Dairy Farming...

  • Page 6: Safety

    Caution Install the system according to the local rules and regulations. Caution We advice to install and maintain the Nedap SmartFlow with at least 2 persons. Working environment Caution The installation area must be free from any obstacles, including animals.
  • Page 7 Make sure all cables are properly concealed, and form no danger for stumbling. Animal welfare and safety The automated actions of the Nedap Livestock Management systems do never discharge the installer and the user of the system from his/her responsibility to assure and to take care of the well-being of the animals.

  • Page 8: Smartflow Overview

    2 SmartFlow overview 2.1 SmartFlow introduction The Nedap SmartFlow milk meter measures and registers the milk yield and flow rate of individual cows during each milking. The mechanical geometry and electronic recording principle of the Nedap SmartFlow are designed for a continuous and optimally free milk and air flow. No flow obstruction or interruption occurs that could cause a vacuum drop, vacuum fluctuation or rough treatment of the milk.

  • Page 9: Components

    3. The Float measures the milk yield and milking process. 4. The main volume collects the milk and ensures a free air flow during milking. 5. The valve module makes sure the milk or cleaning fluid flows through the SmartFlow. The SmartFlow cleaning valve has 2 positions:...
  • Page 10 SmartFlow. b. Cleaning mode. When the SmartFlow cleaning valve is in the cleaning position, only a bit of the liquid can flow through the flow column. This will completely fill the rest of the SmartFlow with cleaning liquid, which ensures proper cleaning of the SmartFlow.

  • Page 11: Smartflow And Mpcu In The Milking Parlor

    2.3 SmartFlow and MPCU in the milking parlor The Nedap SmartFlow milkmeters and Nedap Milking Point Control Units (MPCU) are mounted in milking parlors to measure the milk flow and control the milking process. The location of the SmartFlows and MPCUs in the milking parlor are indicated in the following illustration.

  • Page 12: Installation

    Caution Nedap power supplies must be connected to a power socket with protective earth (PE). Always use a 3-pole connector with a PE contact. If there is no PE available, create a PE next to the power socket to be used for each power supply. The properties of a correct PE depend on local circumstances and legislation.

  • Page 13: Network Requirements

    Minimum upload speed: 1 MB/s Wi-Fi requirements To experience all the benefits of the Nedap system, a full covering Wi-Fi installation is crucial in the area where the system is applied. A functional Wi-Fi connection offers easy access to the mobile interface, allowing operation by smartphone or tablet.

  • Page 14: Additional Documentation

    (long) wave radio stations, which may cause interference with Nedap Animal Identification. No claims, representations or warranties, whether expressed or implied, are made by Nedap as to the performance, reliability, durability and safety of Nedap Animal Identification used in conjunction with abovementioned or other devices.

  • Page 15: Unpack The Smartflow Components

    The SmartFlow can be mounted in two configurations: The milk outlet is positioned either on the right side or the left side of the Smartflow. The mounting procedure only shows illustrations of the right side configuration, but is applicable for the left side configuration as well.

  • Page 16: Mount The Vp8002 Vpu And Vp2001 Power Supply

    1. Mount the bracket on a flat surface, for example a wall or a plate. Use appropriate mounting material. Make sure there is at least 10 cm free space above the bracket. Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...
  • Page 17 Use the drilling template that is delivered with the SmartFlow to mark 3 drilling holes on the wall or panel. b. Drill the holes. c. Mount the bracket using 3 hex bold screws or hex head lag wood screws (M6, at least 20 mm length) with washers.
  • Page 18 Use the two lower screws of the bracket to level the bracket in the sidewards direction (left or right). e. Tighten the 2 lower screws to lock the bracket. 2. Place the SmartFlow in the bracket as follows: Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...
  • Page 19 Press the push button at the bottom of he bracket backwards to open the hinges. b. Slide the lower part of the SmartFlow in the hinges and release the push button. Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...
  • Page 20 The hinges are closed and the lower part of the SmartFlow is now fixed in the bracket. d. Press the lever at the top of the bracket and slide the ridge of the SmartFlow under the lever. Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...
  • Page 21 Release the lever to snap the upper part the SmartFlow. The SmartFlow is now mounted firmly in the bracket. 3. Level the bracket in forward-backward direction: Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...
  • Page 22 Loosen the cover brackets of the SmartFlow. b. Remove the cover and spreader plate. Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...

  • Page 23: Prepare The Float

    4. Use the screw on top of SmartFlow to level the bracket in the forward-backward direction. 3.6.4 Prepare the Float When the SmartFlow has been mounted, the next step is to prepare the float and attach the milk and vacuum tubes to the SmartFlow: 1. Unpack the Float.
  • Page 24 2. Write down the number that is on the Float, and the number of the milking point where the float will be used. 3. Put the Float in the SmartFlow as is shown in the pictures. This is the only correct way to place the Float.
  • Page 25 4. Place the spreader plate as is shown in the pictures. There is only one correct way to place the spreader plate. 5. Place the cover of the SmartFlow: Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...
  • Page 26 6. Fasten the cover brackets. 7. Attach the milk tube for the inlet to the cover of the SmartFlow. The milk tube on the cover must be pointing to the left, as shown in the picture Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...

  • Page 27: Mount The Cleaning Installation

    3.7 Mount the cleaning installation The cleaning installation of the milking parlor, which is not sold by Nedap, must be connected with the SmartFlow milk meters. A vacuum line is used to operate the valves of the SmartFlow milk meters for cleaning purposes.
  • Page 28 55 kPa. Central cleaning valve The central valve in the vacuum line for cleaning operates the cleaning cyclus of all SmartFlow milk meters connected to the vacuum line: 1. The central cleaning valve must allow vacuum in the central vacuum line during cleaning.

  • Page 29: Configuration

    Routine checks (page 34)). Caution When a component of the SmartFlow is repaired or replaced, for instance the Float, the SmartFlow needs to be calibrated and validated again by executing step 2, 3 and 4. 4.1 Configure the VP8002 VPU and VP4102 reader Configure the VP8002 VPU(s) and VP4102 reader(s) before the SmartFlow milk meters are configured.

  • Page 30: Configure The Velos Software

    The Zero Point test is a static measurement that measures the raw sensor height of a Float in a known setting. The Zero Point test is carried out at installation of the SmartFlow or after changing the Float. Furthermore, the Zero Point test can be done at the annual validation check.
  • Page 31 4. At first installation the Zero Point Test must be run for all SmartFlow milkmeters. After the initial Zero Point test all or only a selection of SmartFlow milk meters can be tested: a. All SmartFlow milk meters: Click on the Start all Zero Point Tests button.

  • Page 32: Calibrate The Smartflow

    The Auto calibration procedure analyses milk yield and bulk tank data over an extended period to calculate a correction factor for each milk meter and a bulk tank correction factor. After the installation of the SmartFlow milk meters and the execution of the Zero Point Test, Velos must collect stable milk yield data for at least 21 days before the Auto calibration can be run.

  • Page 33: Milk Test

    Milk test Conditions • The milk that must be collected must flow through the SmartFlow before it is collected by a milking bucket. • Weigh the collected milk with a calibrated ICAR approved weighing scale. See the ICAR documentation for more information.
  • Page 34 3. Weigh each empty milking bucket and fill in the weight of the buckets in the cell of row A Empty bucket (kg) of the calibration sheet. 4. Place the milking buckets on the milking places. Make sure the milk first flows through the SmartFlow before it is collected in the bucket.

  • Page 35: Commissioning

    Make sure the end user knows how to find all information in order to be able to work with the system: 1. Instruct the end user about the use and maintenance of the SmartFlow. 2. Instruct the end user about the use of the Velos system: Help option in Velos, by clicking on the Help icon in the right upper corner of the screen.

  • Page 36: Routine Checks

    6 Routine checks All SmartFlow milk meters must be validated annually to ensure the accuracy of the milk yield data. The validation can be done by checking the auto calibration (recommended method) or by checking the Zero Point test: •...

  • Page 37: Check The Zero Point Test

    7. Send the SmartFlow report to the certifying organization. 6.2 Check the Zero Point test The Zero Point test can be used for the annual validation check of the SmartFlow milk meters. Start the zero-point test: 1. In Velos, go to Settings > Milking > Smartflow settings.
  • Page 38 2. PASSED: Zero Point test result is in range: No further action is needed, the result is stored and can be checked in the report. 3. FAILED: Zero Point test result is not in range: Check the SmartFlow in the milking parlor for technical issues.
  • Page 39 Store the new Zero Point test result by selecting the option to overwrite the existing value and recalibrate (see Calibrate the SmartFlow (page 30)). b. The SmartFlow is technically not fine: Follow the following procedure: 1. Fix the SmartFlow. 2. Perform a new Zero Point test. 3. Recalibrate (see Calibrate the SmartFlow (page 30)).

  • Page 40: Cleaning

    External surfaces of the SmartFlow The environment of the equipment can have a major effect on its service life. The plastics used in the SmartFlow have good resistance to hot water with acidic and alkaline milking machine cleaning agents and disinfectants.

  • Page 41: Cleaning Agents

    Although the SmartFlow and all its components can resist temperatures up to and above 100 ºC (212 ºF), it is not recommended to apply hot boiling water washing. The maximum allowed temperature is 75 ºC (167 ºF).

  • Page 42: Cleaning Cycle

    1. The central valve in the vacuum line must control the SmartFlow cleaning valve. 2. The SmartFlow milk meter must be completely filled with water for more than 50% of the time during each of the three phases of the cleaning cycle (see Cleaning cycle (page 40).

  • Page 43: Maintenance

    Replace the SmartFlow Float: Replace the SmartFlow   Float (page 41) 8.2 Replace the SmartFlow Float When the SmartFlow Float needs to be replaced, proceed as follows: Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...
  • Page 44 1. Loosen the cover brackets of the SmartFlow milk meter. 2. Remove the cover and spreader plate. Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...
  • Page 45 4. Rotate the SmartFlow to remove the Float. Caution Prevent the Float from falling on the ground. 5. Place the SmartFlow back in the mounting bracket and lock the lower and upper part of the SmartFlow. Nedap SmartFlow / Installation manual Dairy Farming...
  • Page 46 6. Use the screw on top of SmartFlow to level the bracket in the forward-backward direction. 7. Place the new Float following the procedure described in Prepare the Float (page 21). 8. Place the spreader plate and cover. 9. Fasten the cover brackets.

  • Page 47: Troubleshooting

    9.1 Malfunctions Malfunction Cause Solution No milk yield measurement. • SmartFlow milk meter is • Clean the inside of the SmartFlow. clogged. • Replace the Float. • Float broken/ Float does not • Replace the seal of the SmartFlow send data.

  • Page 48: Handling Instructions

    In so doing, you will help to conserve natural resources and improve standards of environmental protection in treatment and disposal of electrical waste (Waste Electrical and Electronic Equipment Directive WEEE 2012/19/EU). Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...

  • Page 49: Glossary

    VP8002 Velos Processing Unit (VPU) Velos Processing Unit (VP8002) VPU-online An online address for the herd manager that makes the Nedap system worldwide accessible by the Internet. Velos software Nedap software to control the system Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...

  • Page 50: Technical Specifications

    Parts in contact with milk: PPE (FDA approved) Operating temperature range 0 to 40 °C (32 to 104 °F) Operational relative humidity < 93% @ 45 °C (113 °F) Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...

  • Page 51: Compliance

    This Class B digital apparatus complies with the Canadian standard ICES-003. Cet appareil numérique de Classe B est conforme à la norme Canadienne ICES-003. Nedap SmartFlow / Installation manual Dairy Farming Version 01.001 / 2021 / EN...
  • Page 52 Hereby NEDAP N.V. declares that the subject equipment is in compliance with the directives 2014/53/ EU (Radio Equipment Directive) and 2011/65/EU (Restriction of the use of certain hazardous substances). The full text of the EU declaration of conformity is available at our Business Portal: http://www.nedap.com/...
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