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Summary of Contents for Boumatic HandyFloor 2015
- Page 1 HandyFloor Model 2015 9e1034 Installation and Maintenance Manual 03-2016 9e1037...
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Page 2: Table Of Contents
Contents: 1. PREFACE MANUFACTURER’S ADDRESS ................................... 4 CUSTOMER SERVICE ...................................... 4 GUIDELINES, LAWS, STANDARDS ................................4 1.3.1 DECLARATION OF CONFORMITY ................................5 SUCCESSFUL MILKING ....................................6 2. SAFETY OWNER’S DUTY OF CARE ................................... 7 BASIC SAFETY INSTRUCTIONS .................................. 8 PERSONNEL QUALIFICATION ..................................9 PROTECTIVE EQUIPMENT ..................................10 SAFETY SIGNS, STICKERS AND LABELS ............................10 PACKAGING MATERIALS ....................................10... - Page 3 9. SPARE PARTS DRAWINGS AND PARTS LISTS SPARE PARTS DIAGRAM HANDYFLOOR ........................45 LIFTING UNITS..................................47 CONTROL WITH 2 SPINDLE MOTORS ..........................49 CONTROL WITH 3 SPINDLE MOTORS ..........................50 CONTROL WITH 4 SPINDLE MOTORS ...........................51 ELECTRICAL PARTS ................................53 10. APPENDIX 10.1 SERVICE SCHEDULE FOR HANDYFLOOR MODELL 2015 ..................55 Page 3 9e1034...
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Page 4: Preface
This manual is not covered by an amendment service. The current version can be obtained through your technical dealer or directly from BouMatic. We reserve the right to make changes of the data and illustrations in this manual due to technical developments. -
Page 5: Declaration Of Conformity
Council Directives (EEC): • Low Voltage Directive 2006/95/EC • Machinery Directive 2006/42/EC • EMC Directive 2004/108/EC Authorized signatory 15/12/2015 Jørgen Frederiksen Date Manager, Technical Department/R&D, BouMatic A/S Page 5 9e1034... -
Page 6: Successful Milking
• When replacing parts, only use genuine BouMatic spare parts! • Recommended settings are only valid in conjunction with genuine BouMatic products. • The conscientious implementation of milking routines will have a positive effect on milking results. 7 Step Udder Prep... -
Page 7: Safety
2. SAFETY 2.1 OWNER’S DUTY OF CARE Design and construction of this product were preceded by risk assessment and careful identification of applicable harmonized standards and other technical specifications. This product therefore represents the state-of-the-art of technology and ensures a maximum level of safety. To achieve safety on farms, all necessary measures must be taken. -
Page 8: Basic Safety Instructions
Attention! Work to be performed by qualified personnel only: - Transportation - Handling - Maintenance - Cleaning Work to be performed by authorized personnel only: - Installation - Start-up - Service - Troubleshooting - Repairs - Decommissioning These personnel will be regularly instructed in all relevant matters of safety at work and protection of the environ- ment and by familiar with this manual, particularly the safety instructions it contains. -
Page 9: Personnel Qualification
Deviation from these instructions could affect product performance or create a hazardous situation. Under no circumstances will BouMatic be responsible for any problems caused in whole or in part by a deviation from the procedures specified in these instructions without prior written approval from BouMatic. -
Page 10: Protective Equipment
The manufacturer / supplier is not liable for any resulting damage. The user alone bears the risk. Correct use also includes reading the instructions and observing the inspection and maintenance conditions. Genuine BouMatic parts and accessories are specially designed for Boumatic components; use only genuine spare parts. -
Page 11: Noise
During repair and service operations, always cut the power to the control unit by turning off the switch. • The control unit contains 230 V AC circuits and may only be opened by a BouMatic installer or a qualified electrician. Installation, together with any repairs during the warranty period, may only be undertaken by an •... -
Page 12: Description
3. DESCRIPTION 3.1 FUNCTIONAL CHARACTERISTICS The BouMatic HandyFloor consists of a control panel, a control unit and a floor. The control panel has 2 pushbuttons for raising and lowering the floor. For safety reasons, the control unit has a built-in 230V/24V transformer and a printed circuit board so that the power to the spindle motors is low voltage. -
Page 13: Correct Use
4. CORRECT USE 4.1 OPERATION The BouMatic HandyFloor is constructed for use in milking parlours to ensure a good, ergonomically correct working position for the milker and relieve the stress on the milker’s legs thanks to its non-slip, flexible flooring. -
Page 14: Installation Instructions
Subsequent installation instructions are for HandyFloor in milking parlours. Should you have any questions in relation to these installation instructions, do not hesitate to contact your BouMatic dealer or BouMatic. The HandyFloor is installed in the following 8 steps. -
Page 15: Installation Equipment
5.1 INSTALLATION EQUIPMENT Metal saw for 100x100 mm square tubes Welder for welding 2 mm stainless steel 3 x 120 mm plate (stringer). Hand drill for drilling max Ø12 Saw for adjusting gratings Gen. hand tools: spanners, screwdrivers, unbrako spanners, tool for wire ferrules. Attention! Check the following before beginning the installation. -
Page 16: Iinstallation Of Guide For Lifting Unit
5.2 INSTALLATION OF GUIDE FOR LIFTING UNIT Min. Remark 4.0 m 16.0 m 4.0 – 6.0 = 2 lifting units 6.0 – 11.0 = 3 lifting units 11.0 – 16.0 = 4 lifting units 0.7 m 1.1 m Fixed measurement 0.7 m or 1.1 m (see section/table 7.2.2). -
Page 17: Placing Of Guides/Lifting Units
5.3 PLACING OF GUIDES / LIFTING UNITS 1 reinforcement 0, 8, 10.0 10.5 2 reinforcements 11.0 2 reinforcements 11.5 10.0 12.0 10.4 12.5 10.8 13.0 11.2 13.5 11.6 14.0 12.0 14.5 12.4 1 reinforcement 15.0 12.8 2 reinforcements 15.5 13.6 3 reinforcements 16.0 14.0... -
Page 18: Installation Of The Guide
5.4 INSTALLATION OF THE GUIDE � � Position the guide on the wall (see sec- Drill Ø10 mm for S10 plugs tion 5.2). The guide must be plumb (max. deviation is 5 mm from top to bottom). � Mark mounting holes. �... -
Page 19: Installation Of The Lifting Unit
5.5 INSTALLATION OF THE LIFTING UNIT The lifting units are supplied in standard sizes that can be adapted to the individual milking pit. Measure the distance between the internal Saw off lifting unit according to sketch. surfaces (Distance = B measurement) NB! Conical Handy Floors have lifting units of different lengths. - Page 20 Check distance C Install lifting unit between guides C= 120 mm Attention! Spindel in spindle motor must be fully retracted (see drawing). Attach lifting unit to guide Fine-tune lifting unit Bolt Important: The bolt must be screwed down at least 15 mm into the adjusting nut.
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Page 21: Installation Of The Floor Frame
5.6 INSTALLATION OF THE FLOOR FRAME Sawing off tube for frame DETAIL A DETAIL B DETAIL C SECTION D-D Longitudinal tubes for the main frame are sawn off so that there is a gap of 50 mm between the tubes and the wall/stairs (see detail B). At the end of the ramp there must be 700 mm to the wall (see detail A). - Page 22 Welding of longitudinal tubes Use approved welding wire for AISI 304 Weld seam: 6x50 mm on each side. Tubes fully welded with welding wire approved for AISI 304 Centre of lifting unit Reinforcement Centre of lifting unit Reinforcement Centre of lifting unit The reinforcement should only be welded if the centre distance between the lifting brackets is greater than 4.0 m.
- Page 23 Installation of longitudinal tubes and brackets Bracket Longitudinal tube Measurement/text 150 mm 487 mm 400 mm Max 487 mm 150 mm (Adjusted when last row has been fitted) Tighten longitudinal tube to lifting unit. Page 23 9e1034...
- Page 24 Drilling of holes for spindle motor cable Installation of corner joints 4 Ø8mm Ø24 Fit mounting assembly loosely to the corner joint and mark the holes on the transverse stringer. Drill 4 ø8 holes. Bolt assembly tightly to corner joint. Frame is installed Page 24 9e1034...
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Page 25: Installation Of Cables And Control
5.7 INSTALLATION OF CABLES AND CONTROL UNIT Positioning of cable ducts Cable duct 22 m Cable duct 18 m Cable duct 12 m Cable duct 8 m Cable outlet Installation of cable ducts Demount the cover. Pull the cover out and remove the stopper plugs. Loosen the screws of the spindle motor. - Page 26 Tie cables together. Mount the cover and tie the cables. Spiral hose Stuffing box Before the cable is fed through the tube, a TET 1 m of spiral hose is wound round the cables at 10-14 type rubber stuffing box must be fitted the cable outlet.
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Page 27: Installation Of Cables And Control
5.8 INSTALLATION OF RAMP Installation of ramp Remember to adjust the ramp so that the cables and tubes are not trapped when the floor moves up and down. Page 27 9e1034... -
Page 28: Iinstallation Of Stringer And Grating
5.9 INSTALLATION OF STRINGER AND GRATING Shorting the stringer for the grating Installation of stringer for grating Bracket Stringer for grating B=400 mm 400 mm B B B B 10 mm When installing the first stringer, 2 M10 nuts are installed as spacers between the transverse stringer and the bracket. - Page 29 Installation of grating General: The gratings must always be laid staggered (see above). For rectangular floors: The gratings are laid starting on one side and the last grating of the layer is adapted. If the grating that has to be adapted is less than 14 cm, the gratings must be adapted on both sides and be at least 14 cm.
- Page 30 Installing the last layer of gratings Bottom of groove matches top of flange Cutting edge Groove for last stringer for grating The groove is cut into the second flange from the cutting edge The last layer of gratings usually has to be squared off lengthwise, and a new groove therefore needs to be made that can be positioned on the last stringer (see above).
- Page 31 Final test/delivery Adjusting sheath Check all bolts around the adjusting sheath Remove all tools and sundry equipment from the floor Perform a test run of the floor Floor and control unit are reviewed with the customer Page 31 9e1034...
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Page 33: Electrical Diagrams
6. ELECTRICAL DIAGRAMS 6.1 WIRING DIAGRAM FOR 4 SPINDLE MOTORS Page 33 9e1034... -
Page 34: Cable Diagram For 4 Spindle Motors
6.2 CABLE DIAGRAM FOR 4 SPINDLE MOTORS BLUE BROWN BLUE BROWN BLUE BROWN BLUE BROWN BLUE BROWN BLUE BROWN BLUE BROWN BLUE BROWN BLACK BROWN BLUE BLUE BROWN YELLOW/GREEN BLACK BLUE BROWN Page 34 9e1034... -
Page 35: Wiring Diagram For 3 Spindle Motors
6.3 WIRING DIAGRAM FOR 3 SPINDLE MOTORS Page 35 9e1034... -
Page 36: Cable Diagram For 3 Spindle Motors
6.4 CABLE DIAGRAM FOR 3 SPINDLE MOTORS BLUE BROWN BLUE BROWN BLUE BROWN BLUE BROWN BLUE BROWN BLUE BROWN BLACK BROWN BLUE BLUE BROWN YELLOW/GREEN BLACK BLUE BROWN Page 36 9e1034... -
Page 37: Wiring Diagram For 2 Spindle Motors
6.5 WIRING DIAGRAM FOR 2 SPINDLE MOTORS Page 37 9e1034... -
Page 38: Cable Diagram For 2 Spindle Motors
6.6 CABLE DIAGRAM FOR 2 SPINDLE MOTORS BLUE BEOWN BLAU BEOWN BLUE BEOWN BLUE BEOWN BLACK BEOWN BLUE BLUE BEOWN YELLOW/GREEN BLACK BLUE BEOWN Page 38 9e1034... -
Page 39: Detailed Functional Description For Service Engineers
7. DETAILED FUNCTIONAL DESCRIPTION FOR SERVICE ENGINEERS 7.1 CONTROL UNIT The HandyFloor control unit consists of a 230VAC/24VDC transformer with rectifier and a control board for each spindle motor. The control unit is equipped with either 2, 3 or 4 transformers with control board, depending on the floor size. MOTOR SUPPLY EM208V3... -
Page 40: Steuerplatine
7.2 CONTROL BOARD Tekniske data Technical data : Forsyning 12-35Vdc (ripple max. 3 0%) Power Supply max. strøm 12A kont. 12-35 V Direct voltage (Wobble max. 30 %) 20A 30 % on / 70% off 12 A Direct current Max. current Tomgangsstrøm 10mA t ypisk 20 A 30 % on / 70 % off Aktuelt forbrug... -
Page 41: Troubleshooting In Control
7.3. CONTROL UNIT TROUBLESHOOTING The control board is equipped with an error indicator in the form of a red LED lamp that will light in case of any fault on the cable or spindle motor. The LED is visible when the cover of the control unit is removed. In case of errors on cables or spindle motors, it may occur that one or more of the spindle motors are stopped.. -
Page 42: Service And Maintenance
7.4 SERVICE AND MAINTENANCE The following must be carried out within 1 year of start-up. • The floor and the wall brackets must be cleaned. • The floor must be calibrated immediately before start of maintenance. • Move the floor down approx. 200 mm from its top position. •... -
Page 43: Decommissioning
8. DECOMMISSIONING 8.1 SPECIAL PERSONNEL QUALIFICATION REQUIRED FOR DECOMMISSIONING Decommissioning may only be performed by specially qualified personnel in accordance with the safety instruc- tions. Attention! Also see the section on “Personnel qualification“. 8.2 SAFETY INSTRUCTIONS FOR DECOMMISSIONING In order to prevent damage to property and/or life-threatening injury to people when decommissioning, the fol- lowing points must always be observed: •... - Page 44 Page 44 9e1034...
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Page 45: Spare Parts Drawings And Parts Lists
9. SPARE PARTS DRAWINGS AND PARTS LISTS 9.1 HANDYFLOOR SPARE PARTS DRAWING Page 45 9e1034... - Page 46 Pos. Item no. Description 7600086 ASSEMBLY MOUNTING FOR CORNERS AND FOR COVER OF MICROSWITCH 90670612 M8X20 UNBRAKO SCREW BUTTONHEAD ISO 7380 A2 94070605 M8 LOCK NUT STAINLESS STEEL DIN 985-A2 04-05 7600335 RAMP CPL. FOR HANDY FLOOR, WIDTH UP TO 2.0 M 04-05 7600340 RAMP CPL.
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Page 47: Lifting Units
9.2 LIFTING UNITS Page 47 9e1034... - Page 48 Pos. Réf. Description 01-28 7600550 UNITÉ DE LEVAGE COMPLETE POUR 2,0-2,5 M EN LARGEUR DE FOSSE 01-28 7600551 UNITÉ DE LEVAGE COMPLETE POUR 2,5-3,0 M EN LARGEUR DE FOSSE 01-28 7600552 UNITÉ DE LEVAGE COMPLETE POUR 3,0-3,5 M EN LARGEUR DE FOSSE 01-28 7600553 UNITÉ...
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Page 49: Control With 2 Spindle Motors
9.3 CONTROL UNIT WITH 2 SPINDLE MOTORS 5 6 7 Page 49 9e1034... -
Page 50: Control With 3 Spindle Motors
9.4 CONTROL UNIT WITH 3 SPINDLE MOTORS L1 N N 5 6 7 Page 50 9e1034... -
Page 51: Control With 4 Spindle Motors
9.5 CONTROL UNIT WITH 4 SPINDLE MOTORS L1 N 5 6 7 Page 51 9e1034... - Page 52 607600367 CONTROL 230/24VDC,F/ 2 SPINDLE MOTORS, HANDY FLOOR 2015 607600368 CONTROL 230/24VDC,F/ 3 SPINDLE MOTORS, HANDY FLOOR 2015 607600369 CONTROL 230/24VDC,F/ 4 SPINDLE MOTORS, HANDY FLOOR 2015 607600370 CONTROL 115/24VDC,F/ 2 SPINDLE MOTORS, HANDY FLOOR 2015 607600371 CONTROL 115/24VDC,F/ 3 SPINDLE MOTORS, HANDY FLOOR 2015 607600372 CONTROL 115/24VDC,F/ 4 SPINDLE MOTORS, HANDY FLOOR 2015 601225763...
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Page 53: Electrical Parts
9.6 ELECTRICAL PARTS Page 53 9e1034... - Page 54 607600373 CABLE ASSEMBLY FOR 2 SPINDLE MOTORS, HANDY FLOOR 2015 607600374 CABLE ASSEMBLY FOR 3 SPINDLE MOTORS, HANDY FLOOR 2015 607600375 CABLE ASSEMBLY FOR 4 SPINDLE MOTORS, HANDY FLOOR 2015 607600388 MOTOR CABLE 1500 MM, FOR HANDY FLOOR 603085060 2X0.75 MM2 CABLE BLACK OUTER DIAMETER 5MM 601225674 WIRE COLLECTOR 0.5-1.5 MM FOR 3 WIRES 603600050...
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Page 55: Appendix
10. APPENDIX 10.1 SERVICE SCHEDULE FOR HANDYFLOOR MODEL 2015 After 50 hrs or 1 week HandyFloor lifting unit Check whether chains are slack ¹ HandyFloor frame Check plastic gratings for cracks. Cracked gratings must be replaced. After 3000 hrs or annually HandyFloor lifting unit Check spindle motor for external damage and leaks. - Page 56 Page 56 9e1034...
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