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Boumatic Xpedia 360 EX Installation Instructions Manual

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Xpedia™ 360°EX
9e1006b
Installation Instructions
09-2017

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  • Page 1 Xpedia™ 360°EX 9e1006b Installation Instructions 09-2017...

  • 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 1.3.2 SUCCESSFUL MILKING ..................................6 2. SAFETY OWNER’S DUTY OF CARE ................................7 BASIC SAFETY INSTRUCTIONS ..............................8 PERSONNEL QUALIFICATION ................................
  • Page 3 5.26 FITTING THE MILK PUMP SUPPORT (SEE FIGURE 36)......................60 5.27 FITTING THE EQUIPMENT ONTO THE COLUMN (SEE FIGURE 37).................61 5.28 OPTION: FITTING THE SALOON GATE (SEE FIGURES 38 & 39)..................62 5.281 SALOON GATE POSITION WITHOUT IDENTIFICATION......................63 5.282 SALOON GATE POSITION WITH IDENTIFICATION ......................63 5.29 OPTION: FITTING THE DETECTOR ONTO THE TRACK (SEE FIGURE 40) ..............64 5.30...

  • 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

    1.3.1 DECLARATION OF CONFORMITY. EC Declaration of Conformity www.boumatic.com Emmeloord/Remicourt 10/11/ 2015 BouMatic Europe BouMatic Gascoigne Melotte Sprl. BouMatic A/S Rue Jules Melotte 31 Jernvej 2 6900 Skjern 4350 Remicourt Belgium Denmark Tel: +45 7694 5525 Fax: +45 7526 0396 Declares under its sole responsibility that the external rotary •...

  • 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 Attention ! • Please note that parts or accessories not supplied by us and instructions not provided by BouMatic are not checked or released by us either. • If such products are installed or used, this can have a negative effect on the specified properties of BouMatic products and put people and animals at risk.

  • Page 12: Delivery

    The weight per pallet varies according to the milking parlour size. The weight does not exceed 3000 kg per pallet/unit however. Do not stay under suspended loads during unloading and later assembly! BouMatic cannot be held liable for damage caused by improper unloading! 2.9 STORAGE The following rules must be observed when storing the delivered goods: Do not store the product outdoors or in areas with chemical vapours, moisture, excessive temperature and/or dirt.

  • Page 13: Description

    Installation personnel must have knowledge of the type of installation and possible risks. The instructions in this manual must be followed. BouMatic accepts no responsibility or warranty for damages resulting from improper installation and their consequential damage.

  • Page 14: Symbols

    3.2 SYMBOLS Explanation of symbols used in this manual: Grind Galvanize Left side Weld Right side Drill Grease the screws Grease Apply protective paint 3.3 RECOMMANDATIONS Before commissioning the system, it must be ensured that the installation of the system complies with the technical guidelines and national laws.

  • Page 15: Performing The Civil Engineering Works

    The purpose of this part about civil engineering works is to define the general principles of construction and the time schedule for building the shell required to install the Xpedia 360 EX External Rotary Milking Parlour. It specifies the geometric and mechanical parameters to be adopted in order to complete this shell, as well as the required characteristics of the materials (concrete and steel) for building the various parts (foundations, walls, apron, flooring).
  • Page 16 reinforcements will be set at approx. 40mm (1.57 in.) from the excavation bottom (or placed in 40mm [1.57 in.]-thick previously-cast blinding concrete). The tops of the frames of this reinforcement will therefore extend about 150mm (5.91 in.) above the foundation surface so as to be embedded in the concrete slab of the milking parlour which will be laid later. 6.
  • Page 17 11. Concreting the floor of the milking pit with BPS NF EN 206-1 C35/45 XA2 Dmax 14 S3 CL 0.65 concrete. Take particular care to observe the 5% slope from the middle of the milking pit to the circular trench and the 2% slope from the perimeter of the milking pit to the circular trench.
  • Page 18 This can be achieved by shuttering the underside of the coping and placing a 30mm expanded polystyrene sheet against the outer metal curb of the rotating apron. The platform coping, cast overhanging the supporting wall, must include at least one HBS steel fe E 500 ST 25C welded mesh positioned 30mm from the level of the finished floor of the platform.
  • Page 19 LAYOUT OF EXTERNAL ROTARY MILKING PARLOUR (SEE CROSS-REFERENCE) DMRE13011602 Page 19 9e1006b...
  • Page 20 FOUNDATION OF EXTERNAL ROTARY MILKING PARLOUR (SEE CROSS-REFERENCE) DMRE13011603 Page 20 9e1006b...
  • Page 21 LAYOUT OF CONDUITS FOR EXTERNAL ROTARY MILKING PARLOUR (See cross-reference) DMRE13011604 Page 21 9e1006b...
  • Page 22 CORRESPONDANCE TABLE FOR EXTERNAL ROTARY MILKING PARLOUR LAYOUT OF EXTERNAL ROTARY PARLOURS COWS 8522 9653 10785 11917 13049 335.5 380.0 424.6 469.2 513.7 4917 5483 6049 6615 7181 193.6 215.9 238.1 260.4 282.7 11322 12453 13585 14717 15849 445.7 490.3 534.8 579.4 624.0...
  • Page 23 Figure 1 : Layout of supports and geared motors XPEDIA EX 24 STALL XPEDIA EX 28 STALL XPEDIA EX 32 STALL Page 23 9e1006b DMRE13011606...
  • Page 24 Figure 2 : Layout of supports and geared motors XPEDIA EX 36 STALL XPEDIA EX 40 STALL DMRE13011607 Page 24 9e1006b...

  • Page 25: Installing The Measuring Equipment

    5. INSTALLATION DRAWINGS AND RECOMMENDATIONS 5.1 INSTALLING THE MEASURING EQUIPMENT Using FBN M10 X 160 anchor bolts, secure the rotary parlour shaft and make it level (see figure 4) FIGURE 4 : Page 25 9e1006b DMRI12121409...

  • Page 26: Layout And Fitting Supports 400 And 800

    5.2 LAYOUT AND FITTING SUPPORTS 400 AND 800 1. Mark out radius (R8) on the ground. 2. After consulting Figures 5 & 6 in order to determine the position of Supports 400 and 800, mark an initial point on the radius depending on the exit points of the geared motor supply conduits. 3.
  • Page 27 Figure 5 : DMRE13011609 Page 27 9e1006b...
  • Page 28 Figure 6: DMRI12121411 Page 28 9e1006b...
  • Page 29 Figure 7: DMRI12121412 Page 29 9e1006b...

  • Page 30: Layout And Fitting The Gear Motor(S)

    5.3 LAYOUT AND FITTING THE GEAR MOTOR(S) ATTENTION! FOLLOW THESE MOUNTING INSTRUCTIONS, NO OTHER MOUNTING IS ALLOWED. ANY OTHER MOUNTING OR MOUNTING POSITION CAN CAUSE DETERIORATION OF THE GEAR MOTORS. 1. Mark out Radius on the ground. (R13). 2. Mark out and drill at an equal distance from Supports 400 dimension 542mm (21.35 in.), using a Ø16mm (0.63 in.) bit, to a depth of 90mm (3.54 in.) (see Figure 8).
  • Page 31 Figure 9: DMRI16052001 Page 31 9e1006b...
  • Page 32 Once the geared motor is completely installed: - Replace the plug (2’) located beneath the cubic reducer with the breather plug. If the reducer has no dipstick button on one of its surfaces, the breather plug also has a dipstick. - After removing the dipstick-plug (2), top off the level of lubricant in the cylindrical reducer.

  • Page 33: Fitting The Track

    5.4 FITTING THE TRACK 1. Mark out the internal radius of the inner track along Support 400 and 800 (see Figure 10). 2. Fit the inner track with a tolerance to the radius of + or - 3mm (0.12 in.) and temporarily secure it. 3.
  • Page 34 Figure 10: Page 34 9e1006b...
  • Page 35 Figure 11: DMRE13011612 Page 35 9e1006b...
  • Page 36 Figure 12: DMRE13011613 Page 36 9e1006b...

  • Page 37: Layout And Fitting The Stalls

    5.5 LAYOUT AND FITTING THE STALLS 1. Fix the four diametrically opposed floor slab supports onto the top ring (see Figures 11 & 14). 2. Perfectly align the supports with the middle of the rotary with the aid of a cord, observing the radius R11, and checking that the four diagonals are the same (see Figure 14).
  • Page 38 Figure 14: DMRE13011615 Page 38 9e1006b...

  • Page 39: Fitting The Curbing (See Figure 15)

    5.6 FITTING THE CURBING (SEE FIGURE 15) Figure 15: DMRE13011616 Page 39 9e1006b...

  • Page 40: Fitting The Conduit And Meter Support (See Figure 16)

    5.7 FITTING THE CONDUIT AND METER SUPPORT (SEE FIGURE 16) Figure 16: DMRE13011617 Page 40 9e1006b...

  • Page 41: Fitting The Frame Panels (See Figure 17)

    5.8 FITTING THE FRAME PANELS (SEE FIGURE 17) Figure 17: DMRE13011618 Page 41 9e1006b...

  • Page 42: Fitting The Front Rails (See Figure 18)

    5.9 FITTING THE FRONT RAILS (SEE FIGURE 18) Figure 18: DMRE13011619 Page 42 9e1006b...

  • Page 43: Fitting The Reinforcements (See Figure 19)

    5.10 FITTING THE REINFORCEMENTS (SEE FIGURE 19) Figure 19: DMRE13011620 Page 43 9e1006b...

  • Page 44: Fitting The Beam (See Figure 20)

    5.11 CONCRETING THE ROTATING APRON ATTENTION! During concreting, the rotating apron must be prevented from turning and should be held in place by props beneath the inner and outer curbs of the rotating apron 5.12 FITTING THE BEAM (SEE FIGURE 20) Figure 20: DMRE13011621 Page 44...

  • Page 45: Layout And Fitting The Back Rail Supports (See Figure 21)

    5.13 LAYOUT AND FITTING THE BACK RAIL SUPPORTS (SEE FIGURE 21) Figure 21: DMRE13011622 Page 45 9e1006b...

  • Page 46: Fitting The Rear Rail (See Figures 22 & 23)

    5.14 FITTING THE REAR RAIL (SEE FIGURES 22 & 23) Figure 22: DMRE13011623 Page 46 9e1006b...
  • Page 47 Figure 23: DMRE13011624 Page 47 9e1006b...

  • Page 48: Fitting The Safety Gate (See Figure 24)

    5.15 FITTING THE SAFETY GATE (SEE FIGURE 24) Figure 24: DMRE13011625 Page 48 9e1006b...

  • Page 49: Fitting The Entry/Exit Cell Supports (See Figure 25)

    5.16 FITTING THE ENTRY/EXIT CELL SUPPORTS (SEE FIGURE 25) Figure 25: DMRE13011626 Page 49 9e1006b...

  • Page 50: Fitting The Start/Finish-Of-Entry Detector Supports (See Figure 26)

    5.17 FITTING THE START/FINISH-OF-ENTRY DETECTOR SUPPORTS (SEE FIGURE 26) Figure 26: DMRE13011627 Page 50 9e1006b...

  • Page 51: Fitting The Control Panel Support (See Figure 27)

    5.18 FITTING THE CONTROL PANEL SUPPORT (SEE FIGURE 27) Figure 27: Page 51 9e1006b...

  • Page 52: Fitting The Wash Hose Support (See Figure 28)

    5.19 FITTING THE WASH HOSE SUPPORT (SEE FIGURE 28) Figure 28: Page 52 9e1006b...

  • Page 53: Fitting The Evacuator (See Figure 28)

    5.20 FITTING THE EVACUATOR (SEE FIGURE 28) Figure 29: Page 53 9e1006b DMRE13011629...

  • Page 54: Fitting The Ir Detectors (See Figure 30)

    5.21 FITTING THE IR DETECTORS (SEE FIGURE 30) Figure 30 M6 H NUT M10X20 H SCREW BOX SUPPORT M10 H NUT IR EMITTER BOX M6X16 H SCREW STAINLESS STEEL M6X16 H SCREW DETECTOR BOX STAINLESS STEEL M6 H LOCKNUT STAINLESS STEEL L6 WASHER M12 NUT M12 WASHER RAIL FLANGE...

  • Page 55: Fitting The Start-Stop/Emergency Stop Switches (See Figure 31)

    5.22 FITTING THE START-STOP/EMERGENCY STOP SWITCHES (SEE FIGURE 31) Figure 31 DMRE13011631 Page 55 9e1006b...

  • Page 56: Fitting The Safety Panel (See Figure 32)

    5.23 FITTING THE SAFETY PANEL (SEE FIGURE 32) Figure 32 DMRE13011632 Page 56 9e1006b...

  • Page 57: Fitting The Jetter Cover (See Figure 33)

    5.24 FITTING THE JETTER COVER (SEE FIGURE 33) Figure 33 Page 57 9e1006b DMRE13011633...

  • Page 58: Fitting The Column Cover (See Figure 34)

    5.25 FITTING THE COLUMN COVER (SEE FIGURE 34) Figure 34 DMRE13011634 Page 58 9e1006b...

  • Page 59: Fitting The Pail Hook (See Figure 35)

    5.26 FITTING THE PAIL HOOK (SEE FIGURE 35) Figure 35 DMRE13011635 Page 59 9e1006b...

  • Page 60: Fitting The Milk Pump Support (See Figure 36)

    5.27 FITTING THE MILK PUMP SUPPORT (SEE FIGURE 36) Figure 36 DMRE13011636 Page 60 9e1006b...

  • Page 61: Fitting The Equipment Onto The Column (See Figure 37)

    5.28 FITTING THE EQUIPMENT ONTO THE COLUMN (VOIR FIGURE 37) Figure 37 Page 61 9e1006b...

  • Page 62: Option: Fitting The Saloon Gate (See Figures 38 & 39)

    5.29 OPTION: FITTING THE SALOON GATE (SEE FIGURES 38 & 39) Figure 38 DMRI12121460 Page 62 9e1006b...

  • Page 63: Saloon Gate Position Without Identification

    Figure 39 Ø49/ Ø 60 ALIGNMENT BRACKET STIFFENER M10X70 H SCREW M10X80 H SCREW 5.29.1 SALOON GATE POSITION WITHOUT IDENTIFICATION 5.29.2 SALOON GATE POSITION WITH IDENTIFICATION Please refer to the document ‘ISO RFID Systems’ (Lit. 903). Page 63 9e1006b...

  • Page 64: Option: Fitting The Detector Onto The Track (See Figure 40)

    5.30 OPTION: FITTING THE DETECTOR ONTO THE TRACK (SEE FIGURE 40) Figure 40 Page 64 DMRE13011640 9e1006b...

  • Page 65: Option: Fitting The Stainless Steel Skirts (See Figure 41)

    5.31 OPTION: FITTING THE STAINLESS STEEL SKIRTS (SEE FIGURE 41) Figure 41 DMRE13011641 Page 65 9e1006b...

  • Page 66: Option: Fitting The Milk Pipe (See Figure 42)

    5.32 OPTION: FITTING THE MILK PIPE (SEE FIGURE 42) Figure 42 DMRE13011642 Page 66 9e1006b...

  • Page 67: Option: Fitting The Trough (See Figure 43)

    5.33 OPTION: FITTING THE TROUGH (SEE FIGURE 43) Figure 43 Page 67 9e1006b DMRE14073001...

  • Page 68: Installation Of Rotary Main Cabinet

    6. INSTALLATION OF ROTARY MAIN CABINET 6.1 IMPORTANT RECOMMENDATIONS The standard equipment is designed to be connected to three-phase mains supply 400V 50/60Hz + neutral system TN. The electrical connections must only be performed by qualified personnel. Before carrying out any electrical or mechanical interventions on the rotary, the power to the installation must be switched off, the main switch of the cabinet must be set to “OFF”...

  • Page 69: Terminal Board Xpedia Rotary Main Cabinet

    6.5 TERMINAL BOARD - XPEDIA ROTARY MAIN CABINET Page 69 9e1006b...
  • Page 70 Page 70 9e1006b...
  • Page 71 Page 71 9e1006b...
  • Page 72 Page 72 9e1006b...

  • Page 73: Wiring Diagram Xpedia Rotary Main Cabinet

    6.6 WIRING DIAGRAM XPEDIA ROTARY MAIN CABINET Page 73 9e1006b...
  • Page 74 Page 74 9e1006b...
  • Page 75 Page 75 9e1006b...
  • Page 76 Page 76 9e1006b...
  • Page 77 Page 77 9e1006b...

  • Page 78: Wiring Diagram Swivel Joint

    6.7 WIRING DIAGRAM SWIVEL JOINT Page 78 9e1006b...
  • Page 79 Page 79 9e1006b...

  • Page 80: Location Of Screens And Detectors

    6.8 LOCATION OF SCREENS AND DETECTORS Page 80 9e1006b...

  • Page 81: Location Of Boxes For Stop & Slow-Down No Detaching

    6.9 LOCATION OF BOXES FOR STOP & SLOW-DOWN NO DETACHING Page 81 9e1006b...
  • Page 82 Page 82 9e1006b...

  • Page 83: Assignment Of Indicators On Controller And Control Panel

    6.10 ASSIGNMENT OF INDICATORS ON CONTROLLER & CONTROL PANEL Page 83 9e1006b...

  • Page 84: Location Of Entry & Exit Sensors

    6.11 LOCATION OF ENTRY & EXIT SENSORS Page 84 9e1006b...

  • Page 85: Wiring Diagram Cabinet For 30-38 Stall Rotary

    6.12 WIRING DIAGRAM CABINET FOR 30-38 STALL ROTARY Page 85 9e1006b...

  • Page 86: Wiring Diagram Cabinet For 20-28 Stall Rotary

    6.13 WIRING DIAGRAM CABINET FOR 20-28 STALL ROTARY Page 86 9e1006b...

  • Page 87: Further Literature

    7. FURTHER LITERATURE 7.1 BIBLIOGRAPHY Valid; November 2016 Lit. Nr. Title Language 9*871 Xpedia™ 360 IX Masonry Guidelines English; French; Dutch; German 9*875 Xpedia™ 360 EX Installation Instructions, Masonry Instr English; French; Dutch; German 9*997 Xpedia™ 360 IX Feeding System Installation English 9*1004 Xpedia™...

  • Page 88: 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 89 Page 89 9e1006b...
  • Page 90 Page 90 9e1006b...

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