Fullwood M²erlin Operating Instructions for Safe Use User Manual 294130 Revision C ORIGINAL MANUAL Fullwood Limited Grange Road Ellesmere Shropshire SY12 9DF England...
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Contents Fullwood M²erlin..................1 Operating Instructions for Safe Use ............1 Contents ....................2 Icons ......................6 Health and Safety Statement ............6 Risk Assessment ....................7 General .......................
Page 3
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 2.22 Air Drying ......................15 2.23 Air Filtration ...................... 16 2.24 Noise ........................ 16 2.25 Vacuum ......................16 2.26 Water ........................ 16 2.26.1 Cold Water ......................17 2.26.2...
Page 4
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 8.1.1 Best Cattle Tagging Practice .................. 33 Pedometers ...................... 34 8.2.1 Removal of the Pedometer ..................34 8.2.2 Storage of Pedometers ................... 34 Neck tags ......................35 Introducing Animals to the New Milking System ......
Whilst Fullwood equipment will comply with all relevant directives, customers are reminded that all equipment into which Fullwood equipment is to be incorporated must comply with all applicable European directives.
All installations and maintenance should be carried out within the provisions of ’The Electricity at Work Regulations, 1989’ and by persons so qualified as defined in that act. Fullwood Limited supplies document packs with all equipment. These documents are supplied for information and should be disseminated to the relevant persons.
• Do not look directly into the laser light of the teat detection system. • Do not weld on M²erlin unless instructed to do so by Fullwood Limited, follow instructions e.g. remove all connections to PCB’s. • If welding in an area within 5m of M²erlin, turn M²erlin off and remove the main Harting connection.
The used operating fluids and material can cause adverse health effects. Suitable measures must be taken in order to prevent injuries. • Only Fullwood recommended chemicals shall be used, any other product may result in damage. • Material Safety Data Sheets (MSDS) shall be reviewed prior to use together with a risk assessment performed in accordance with COSHH regulations.
Positioning A suitable installation location for the machine prevents malfunction and accidents. • Install the machine in accordance with Fullwood plans. • Ensure sufficient lighting such that the display can be read and work can be carried out comfortably and safely.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 • of the EMERGENCY STOP command device. • of any components requiring monitoring. • Pay attention to cleanliness during all maintenance and repair work. •...
It is the responsibility of the farmer to provide a suitable alternative means of power in the event of a power cut. Note: Fullwood will not cover any damage caused by generator, substandard power supplies or third party equipment. 294130...
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 2.14 Technical Specifications • The identification plate is located inside the electrical cabinet and provides the model and important technical information. The identification plate must not be removed.
There must be sufficient room on the cow side to allow the entry/exit gates to open and close without hindrance. • Allow sufficient space for the electrical doors to open to 90°. • Refer to Fullwood installation plans/drawings for further details. 294130 Page 14 of 81...
2.19 Power Supply Specifications • Fullwood Ltd does not carry out any mains wiring. It is the responsibility of the customer to arrange for all mains wiring to be carried out by a competent contractor qualified in accordance with national and/or local legislation. This also applies to any mains electrical connections from switches of isolators to electrical equipment supplied by Fullwood Ltd.
450L/min Two machines 650L/min Each additional machine +100L/min up to 6 > 6 machines Contact Fullwood Ltd These figures are based on installations at sea level (<300m) and will change depending on altitude 2.26 Water Pressure Temperature Volume Cold Water Regulated to 1.5 Bar...
Date: 24-Mar-17 * Equivalent pressure pumped ** Subject to number of cows, site washing conditions and length of delivery line (Contact your Fullwood dealer for further details). 2.26.1 Cold Water • Cold water should be potable, i.e. fit for human consumption, according to relevant legislation.
* Figure based on Iodine. If the robot has been converted to use peracetic use the consumption figures for acid injection. 2.29 Herd Management System Fullwood Crystal is practical and easy to use Herd Management Software. Crystal controls and automates processes on the dairy farm, such as: •...
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 3. Safety Signs and Location Understanding safety signs Read user Stop machine Finger / hand Electrical Compressed Harmful manuals before trapping point Hazard chemicals removing...
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 4. Site Positioning, Fixing Levelling and Assembly • Site positioning, fixing, levelling and assembly shall only be carried out by personnel who have received the appropriate training.
Page 22
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Lift from this side Do Not Lift from this side By forklift Warning: Top Heavy Do not lift from the Arm side of the machine The crate must be lifted from the cow gate side using either the fork tubes at the top of the crate or the transport frame at the bottom of the crate.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Process Cabinet The process cabinet can be lifted from the front or the side using forks. It can also be craned using both lifting eyes at the top of the cabinet.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 6. Cow Compatibility with Robotic Milking • The size of the cow, and the condition and shape of her udder should be assessed for suitability prior to introduction.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 High and Low Reach Liner Type Low position High position 7. Starting the machine for the first time Preparation • Only appropriately trained persons shall operate the machine.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 1. Machine Stop (Black) 2. Reset (Blue) 3. Emergency Stop 4. Machine Isolator 5. Power on indication light (Note: the machine is designed to be left on at all times; the above is for first time start up).
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Pre-Milking Start Up Before cows are milked through the M²erlin, the following must be set up or calibrated to ensure the machine is safe to operate and accurate: •...
MUST NOT be used anywhere in the machine as these will cause damage Only use Fullwood Ltd approved chemicals. In addition - use 017439 - Laser Cleaning Solvent for removing lime scale from the laser lens Teat spray is sprayed automatically after the cow has finished milking via a dosing pump.
Store all chemicals in their original containers, ensuring they are not misidentified and used for the wrong application. Up to date data sheets for chemicals should be kept on site at all times, these can be obtained from your Fullwood dealer or by visiting www.fullwood.com 7.4.5 Chemical All the wash settings are set in the configurator.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 7.4.6 Changing Chemicals Put into Off line before working on chemical system. Precautions must be taken (e.g. chemical resistant mask, gloves, boots & overalls /suit) when handling chemicals.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Calibrate Feeders Ensure feed hopper is full prior to calibration and all robots on the system are off line; 1) Start the Crystal program on the PC and select Programs menu and select Configurator 2.
Page 32
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 3. The calibration screen will appear; left click on the weigh scales again: 4. The calibrate station screen will appear; click on the feed dispense button, type the weighed amount and click the Apply button.
When fitting plastic tags, ensure that the tags line up correctly on the applicator and will lock together when correctly fitted. • Ensure both parts of the plastic tag have the same number. If Fullwood tags are used, the number is only required on the female part. •...
8.2.1 Removal of the Pedometer Fullwood Ltd recommends that the strap is cut and a new one used. Once fitted, it is difficult to remove straps by prizing out the plastic wedge while attached to the cow. Allow for growth of heifers. It is recommended to remove the pedometer as a matter of routine when drying off.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Neck tags Neck tags are to be attached around the cow’s neck with an appropriate strap. The strap is to be sufficiently tightened to prevent slipping over the cows head and prevent catching on parts protruding into the barn or parlour.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Introduction • At the first milking, teats should be cleaned and foremilked by hand to stimulate a sound oxytocin based let-down response. The automatic attachment system should be initiated under operator control, moving the arm into position under the cow prior to teatcup attachment.
Page 37
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Online Clear/reset alarm Manually dispense Keep cow in box feed Separate Animal Send milk to bucket Send milk to drain Bucket Cancel Stop release cow...
Page 38
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 M²erlin rinse Acid main clean Alkaline main clean Clean cups Cold wash Luke warm wash Hot wash (Lubricate wash) First drain Second drain (dry) (pumping)
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 I/O test menu Save System information/details Conductivity (Version) Wait for Change assistance language/country Note; Not all the icons are visible by the user, some are for engineers use only.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 10.2 Milking the Cows Read in conjunction with the following HMI screen shots Put the robot in online mode (Play icon Entry gate will open (if cow is hesitating to enter, use feed to lure in the cow).
Page 41
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 When a cow enters the crate for the first time the screen will be displayed, by pressing the tick the arm will drop from the jetters and will move to a central position under the cow.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 10.4 Using the HMI When turning on the machine for the first time the program will boot up and the HMI will display the home screen.
Page 43
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Manually identifying a cow Manually identifying a cow In case a cow has no tag or a broken tag, the following screen appears when she enters the M²erlin.
Page 44
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Milking Details (Teats not attached) The circle details the teat attachment and will progress through the next six screens showing milking progress. Teat not (yet) attached...
Page 45
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Milking Details Milking Details All teats attached, flow detected (above threshold) on right rear and front teats (green background), No flow detected yet on LR...
Page 46
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Do not milk / detach / Simulate milk flow / Cancelled ACR dialogue On the milking details screen, by pressing one of the teats, the user can select if a teat:...
Page 47
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Milking Details Milking Details 75% of expected milk time reached on front teats. Milking Details All teats detached, expected yield reached. 294130 Page 47 of 81...
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 10.5 Milk Separation 10.5.1 Withheld and Undesirable Milk Where milk from a cow is known to have a withhold period (e.g. containing antibiotic or other pharmaceutical product) or is undesirable (e.g.
Page 49
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Releasing cow and pumping milk to bulk tank Releasing cow and pumping milk to bulk tank. As well as the pumping icon, and Bulk tank (milk...
Page 50
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Cleaning Progress Shows progress of the cleaning cycle The upper progress bar (A) shows the progress of the indicated step, the lower progress bar (B) shows the progress of the cleaning.
Page 51
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Milking statistics Overview of visits and milkings Screen details the following milking statistics; • Date of milking • Time of milking • Cow ID •...
Page 52
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Alarms Screen Overview of Alarms Screen details the following Alarm statistics; • Date of Alarm • Time of Alarm • Type of Alarm (info / warning / fatal / error •...
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 11. Routine Daily Maintenance Within the milking system there are a number of routine activities that should take place to ensure the efficient and effective operation of the machine and are as follows;...
Fullwood recommend that liners are replaced every 2500 cow milkings or every six months (whichever comes first). Liners should always be replaced in sets of four.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 12. Cleaning the machine PUT MACHINE INTO PAUSE BEFORE CARRYING OUT MANUAL CLEANING • Manual Cleaning of machine • It is recommended to have a written procedure in place, describing how the cleaning of the milking facilities shall be carried out.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 13. Service Schedule The robot requires four services per year to be carried out by suitably trained Technicians. An additional service is to take place at the end of every 2 year period.
Page 57
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Check laser screen is clean and calibrate Check arm movement on all axis to limits Check force sensing on all axis Check centre box position...
Page 58
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Crate Check operation of gates Change gate linkage bushes (Pre Rev 1.5) Change gate linkage bushes (Rev 1.5) Check and clean cow follower camera Miscellaneous...
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 For guidance only. Cow teats will vary in shape and size within the breed which ultimately affects the choice of liner Additional Information Liner Part No...
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 15. Fault Recognition and Rectification 15.1 General Fault Possible Cause Remedy No power to machine Isolator not on Turn on isolator E-stop has been activated...
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 15.3 Alarm Message Codes Cause (Trigger Classification Alarm Code General Description Effect Required Actions Parameters) info NO_ALARM warning/ COWINBOX Generated by Merlin when a Merlin will stop...
Page 63
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 info VACUUMOIL info VACUUM PUMP info VACUUM SENS fatal/error ARM_ General failure of arm (Not a Error will be General failure of arm System needs to be GENERAL specified known error).
Page 64
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 fatal/error ARM_FREE Merlin arm cannot reach free No Data No Data _VACUUM vacuum position. Fatal when arm is turned in, otherwise Error class. fatal/error ARM_DRAIN...
Page 65
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 has been reset by the user. fatal/error ARM_ Fatal when arm is turned in, No Data Not used by M2. No Data VACUUM otherwise Error class.
Page 66
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 info MM_SENSOR Milk meter is not seeing Milk As soon as the alarm Milk meter is not seeing Check milk meter and (0.8kg) in Merlin within the milk is triggered, the Milk (0.8kg) in Merlin...
Page 67
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 than the milking pause timeout 120 minutes). info SAMPLER_ Last bottle of the sampler has User will get a Last bottle of the Replace sampler frame FRAME_FULL been filled.
Page 68
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 is the number of emptying attempts after eating time has elapsed). info LIQUID_FILLING The filling of the liquid doesn't No Data Not used by M2.
Page 69
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 info ARM_NOFLOW_ Error on arm control box, no milk Cow will be release A certain level of flow is Check system and reset flow on Left Rear teat.
Page 70
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 system will generate an error and will stop milking cows. info ARM_USER Break off milking on arm control Cow will be release Milking is aborted by the...
Page 71
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 info EAT SENSOR Alarm raised when eating No Data sensor is activated at start of a visit, probably by roughage for the eating sensor. Calculations of the roughage station will probably fail.
Page 72
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 error BUCKET ERROR Bucket system has problems No Data No Data No Data reaching Bucket or Park position. error IDENTIFICATION Multiple cows in crate not...
Page 73
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 will go into off-line mode. fatal REJECTION The rejection valve isn't A fatal error will be The valve feedback is Check reject valve and VALVE...
Page 74
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 error COW_FOLLOWE The cow follower application has Error will be The cow follower Check cow follower and R_ERROR reported an errror. generated, milking application has reported reset alarm.
Page 75
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 cows will continue as normal. info FLASH ERROR Merlin M2 HMI cannot write to Info message will be Flash card not Verify (CHKDSK/F) or flash or cannot access flash.
Page 76
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 average milk time on that teat. info ARM_MILK Milk sensor gives incorrect value Milking will be no increase in milk yield Check arm milk flow SENSOR_LF on LF.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 16. Milk Sampling 16.1 Setting Cows for Sampling in Crystal Open Crystal, and then go Animals > Milk 2. Select the number of samples to be taken from that cow 1.
Page 78
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 In the ‘Samples take’ column modify the value to ‘1’ to set all cows to have 1 sample. Click ‘Apply’ to accept the changes. All the animals will be set to take 1 sample.
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 16.2 Connecting the Multi Sampler • Pause M²erlin ready for connection Connect the red flexible airline from the Remove the plug ‘B’ from the underside of the Sampler to the quick connect port ‘A’...
Page 80
Ref / Pt.No: 294130 Operating Instructions for Safe Use Revision: C Fullwood M²erlin Date: 24-Mar-17 Set M²erlin HMI to display menu For further operating instruction refer to the user manual for the sampler used Example of report Animal Animal Milking date...
Page 81
The original of this manual is written using British English. Translations to other languages have been done in good faith and no liability can be accepted by Fullwood Limited for loss, damage or injury caused by errors, or omissions. Contact: If you have any suggestions for improvements or amendments or have found errors in this publication, please notify Fullwood Limited Customer Services, E-mail address: customerservices@fullwood.com...
Need help?
Do you have a question about the M2erlin and is the answer not in the manual?
Questions and answers