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ATI Technologies 39-5710 Manual

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Innovation In and
Out of Parlour
Auto Wash Pro Manual
Version - 1.2
Date - July 2018
Part Number - 39-5710

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Summary of Contents for ATI Technologies 39-5710

  • Page 1 Innovation In and Out of Parlour Auto Wash Pro Manual Version - 1.2 Date - July 2018 Part Number - 39-5710...

  • Page 2: Table Of Contents

    Innovation In and Out of Parlour Index Manual Version......................About the Auto Wash Pro....................The Auto Wash Pro Front Panel..................6 Installing the Auto Wash Pro................... 7 Good Practice During the Installation................8 Auto Wash Pro Control PCB Wiring Connections..............Auto Wash Pro Input/Output PCB Wiring Connections............
  • Page 3 Innovation In and Out of Parlour Index Continued Test Displays Diagnostic....................33 Test Keyboard Diagnostic....................Input/Output (I/O) Printed Circuit Board (PCB) Diagnostics..........Input/Output (I/O) Printed Circuit Board (PCB) Test Routines..........38 Control Printed Circuit Board (PCB) Serial Number.............. 42 Control Printed Circuit Board (PCB) Software Version............42 Restore Factory Settings....................

  • Page 4: Manual Version

    Innovation In and Out of Parlour Manual Versions Version 1.0 - January 2016......First Version of Manual (Control v1.20 / IO Board v1.09) Version 1.1 - February 2016.......Second Version of Manual (Control v1.20 / IO Board v1.09) Version 1.2 - July 2018..........Pump Box Update (Control v2.34 / IO Board 1.13) 4 | Auto Wash Pro Manual | v1.2...

  • Page 5: About The Auto Wash Pro

    Innovation In and Out of Parlour About the Auto Wash Pro The Auto Wash Pro from ATL is a simple and easy to use wash controller that washes the parlour automatically after each milking. It provides more consistent and efficient cleaning using less chemical than manual washing irrespective of the operator.
  • Page 6 Innovation In and Out of Parlour Front Cover 6 | Auto Wash Pro Manual | v1.2...

  • Page 7: Installing The Auto Wash Pro

    Innovation In and Out of Parlour Installing the Auto Wash Pro Control Unit and Pump Unit The Auto Wash Pro system consists of a control unit, pump unit and power supply unit. All of the units should be mounted on the wall to the side of the wash trough to avoid chemical gases and hot water vapour damaging the unit.

  • Page 8: Good Practice During The Installation

    Innovation In and Out of Parlour Good Practice During the Installation A separate mains supply and earth running directly from the consumer meter is essential. Avoid routing the mains cable to the power supply close to other supplies especially those providing intermittent current motors that are starting and stopping continually or high power heaters with thermostatic control.

  • Page 9: Auto Wash Pro Control Pcb Wiring Connections

    Innovation In and Out of Parlour Auto Wash Pro Control PCB Wiring Connections The Auto Wash Pro Control PCB wiring connections are shown in the diagram and table below. Parlour Processor IMPORTANT - DO NOT INSTALL TWO CABLES THROUGH 1 CABLE HOLE IN THE 4 PORT GLAND.

  • Page 10: Auto Wash Pro Input/Output Pcb Wiring Connections

    Innovation In and Out of Parlour Auto Wash Pro Input/Output PCB Wiring Connections The Auto Wash Pro Input/Output PCB wiring connections are shown in the diagram and corresponding table below. Plantwasher 20 22 24 26 28 30 32 34 36 38 Input/Output Board 21 23...
  • Page 11 Innovation In and Out of Parlour Auto Wash Pro Input/Output PCB Wiring Connections Number Connects To Cable Specification Hot Water Valve 1 -ve Switched Output Blue in 0.5mm 10 way Cable Provided Hot Water Valve 2 +ve Common 0.5mm CSA Hot Water Valve 2 -ve Switched Output 0.5mm CSA Cold Water Valve +ve Common...
  • Page 12 Innovation In and Out of Parlour Auto Wash Pro Input/Output PCB Wiring Connections Number Connects To Cable Specification -ve Peristaltic Pump 2 (Alkaline) Blue in 1mm 10 way Cable Provided +ve Peristaltic Pump 3 (Detergent) Purple in 1mm 10 way Cable Provided -ve Peristaltic Pump 3 (Detergent) Gray in 1mm 10 way Cable Provided +ve Peristaltic Pump 4...
  • Page 13 Innovation In and Out of Parlour Auto Wash Pro Input/Output PCB Wiring Connections Number Connects To Cable Specification Milk Pump 1 +ve Common Milk Pump 1 -ve Switched 0.5mm CSA Wash Trough Level Input Tubing Provided Vacuum Level Input Tubing Provided 13 | Auto Wash Pro Manual | v1.2...

  • Page 14: Auto Wash Pump Box 2500 Connections

    Innovation In and Out of Parlour Auto Wash Pump Box 2500 Connections The Auto Wash Pump Box connections are shown in the diagram below. 14 | Auto Wash Pro Manual | v1.2...
  • Page 15 Innovation In and Out of Parlour Auto Wash Pro Pump Box PCB Wiring Connections The Auto Wash Pro Pump Box PCB wiring connections are shown in the diagram and corresponding table below. 414243 44 Connects To Number Cable Specification Unused Orange from 0.5mm 10 way Unused Purple from 0.5mm 10 way...
  • Page 16 Innovation In and Out of Parlour Auto Wash Pro Pump Box PCB Wiring Connections Number Connects To Cable Specification Pump 4 +ve Output White from 1mm 10 way Pump 4 -ve Output Pink from 1mm 10 way -ve System Power IN Black from 1mm 10 way +ve System Power IN Red from 1mm 10 way...

  • Page 17: Auto Wash Pro Layout Diagram

    Innovation In and Out of Parlour Auto Wash Pro Layout Diagram 17 | Auto Wash Pro Manual | v1.2...

  • Page 18: Connecting The Auto Wash Pro To Contactor Switched Vacuum Pumps

    Innovation In and Out of Parlour Connecting the Auto Wash Pro to Contactor Switched Vacuum Pumps Connecting from the Plantwasher Input/Output Printed Circuit Board (PCB) Wire connects to Vacuum Pump Starter Control Plantwasher 32 34 36 38 Input/Output Board 33 35 37 39 Start 1-ve - White - Connect into connection number 33 Start 2 -ve - Black (from Black/White pair) - Connect into connection number 35...
  • Page 19 Innovation In and Out of Parlour Connecting the Auto Wash Pro to Contactor Switched Vacuum Pumps Continued Connecting to the Vacuum Motor Starter Box Red, yellow, blue and green wires are from the Vacuum Pump Starter Control Box. START (GREEN) YELLOW STOP (RED)

  • Page 20: Setting Up The Auto Wash Pro

    Innovation In and Out of Parlour Setting up the Auto Wash Pro Before it can be used, the Auto Wash Pro must be setup. This is outlined in the following pages. The Keypad There are 24 keys on the keypad. 5 are for washing programs - Pre-Milking, Milk Stone, Prog 1, Prog 2 and Prog 3 - the Milk key is for milking mode, the Auto key provides a simple single key which can be programmed to run different wash programs based on the time of day and day of week.

  • Page 21: Entering Setup

    Innovation In and Out of Parlour Entering Setup During the setup process, it is necessary to enter and modify data. Before this can be achieved, the Auto Wash Pro Control has to be put into setup using this key sequence: Setup Press the Shift + Enter keys to enter setup.

  • Page 22: The Settings Menu Structure

    Innovation In and Out of Parlour The Settings Menu Structure The settings menu is structured as shown below; Entry point into settings menu. ê key buzzer off Key Buzzer: This setting controls whether the control beeps when a key is pressed. ê...
  • Page 23 Innovation In and Out of Parlour The Settings Menu Structure Continued ê TEST DISPLAYS Test Displays: This menu item allows the user to check that all the segments in the displays are working correctly. ê TEST KEYBOARD Test Keyboard: This menu item allows the user to check all the keys on the keyboard are working correctly.

  • Page 24: The Key Buzzer Setting

    Innovation In and Out of Parlour The Settings Menu Structure Continued ê TEST DISPLAYS Test Displays: This menu item allows the user to check that all the segments in the displays are working correctly. ê The settings menu loops around onto the key buzzer setting The following pages detail the specifics of each menu item.

  • Page 25: Setting The Time

    Innovation In and Out of Parlour Setting the Time Time hh--mm--ss This sets the time on the control unit. Where HH-MM-SS will be the current system time. Setup Press the Enter key to change the time. Enter The display will now show ‘SET HOUR __’. set hour __ Enter the hour using the number keys Setup...

  • Page 26: Setting The Date

    Innovation In and Out of Parlour Setting the Date DATe DD--mm--YY This sets the date on the control unit. Where DD-MM-YY will be the current system date. Setup Press the Enter key to change the date. Enter The display will now show ‘SET DAY __’ for the day of the month. set DAY __ Enter the day of the month using the number keys Setup...
  • Page 27 Innovation In and Out of Parlour Setting the Date Continued set MONTH __ Enter the month of the year using the number keys Setup Reset Press the Enter key to save or the Cancel key to cancel Cancel Enter If the Enter key is pressed, the display will now show ‘SET YEAR __’. set YEAR __ Enter the year using the number keys Setup...

  • Page 28: Editing Programs

    Innovation In and Out of Parlour Editing Programs edit programs Setup Press the Enter key to edit the wash programs. See separate section on editing programs. Enter Editing Tasks edit tasks Setup Press the Enter key to edit the tasks. See separate section on editing tasks. Enter Conductivity Difference Setting COND DIFF 200...
  • Page 29 Innovation In and Out of Parlour Vacuum Pump Setup VAC pump setup Setup Press the Enter key to enter the vacuum pump setup menu. Enter Vacuum Pump Type vp0 type on/off This sets the type of signal required for controlling the vacuum pumps. ON/OFF leaves the outputs on for the entire time they are running.
  • Page 30 Innovation In and Out of Parlour Vacuum Minimum Setting VAC MINIMUM XX The vacuum minimum setting is used to alert the operator if the vacuum drops below the entered value during a wash program or when milking. Default Setting - 0 kPa Setup Press the Enter key to edit the value.
  • Page 31 Innovation In and Out of Parlour Washing Vacuum Level Setting WASH VAC The washing vacuum level setting is used as the vacuum level to aim for when using variable speed vacuum pumps connected to the Auto Wash Pro during any wash program. Default Setting - 46kPa Setup Press the Enter key to edit the value.

  • Page 32: Setting The Wash Trough Lock Out

    Innovation In and Out of Parlour Setting the Wash Trough Lock Out WASH T LOCK OFF This sets whether the wash trough lock prevents a wash program starting if the wash line is not in the correct position (i.e. not attached to the wash line or still attached to the milk tank) and the wash safety switch engaged.

  • Page 33: Test Displays Diagnostic

    Innovation In and Out of Parlour Calibrating the Peristaltic Pumps PUMP CALIBRATIOn Setup Press the Enter key to set the peristaltic pump calibration. See separate section on calibrating the peristaltic pumps. Enter é è Press the 2 key or the 6 key to move onto the tasks setting. Test Displays Diagnostic test displays This turns on all the display LEDs so faulty LEDs can be diagnosed.

  • Page 34: Test Keyboard Diagnostic

    Innovation In and Out of Parlour Test Keyboard Diagnostic test keyboard This enables the user to press each key individually to check they are functioning correctly. Setup Press the Enter key to go into the diagnostic routine. Enter é Reset Insert Delete Prog 4...

  • Page 35: Input/Output (I/O) Printed Circuit Board (Pcb) Diagnostics

    Innovation In and Out of Parlour Innovation In and Out of Parlour Input/Output (I/O) Printed Circuit Board (PCB) Diagnostics i/o diagnostics This enables to user to display diagnostic information on the Input/Output (I/O) PCB Diagnostics. Setup Press the Enter key to go into the diagnostic routine.
  • Page 36 Innovation In and Out of Parlour Input/Output (I/O) Printed Circuit Board (PCB) Diagnostics Continued The wash temperature screen will not display if there is an error with the temperature measurement chip. If this occurs, the screen below will display. wash t ERROR The wash temperature screen will also not display if the temperature measured is over 1000°C as it is clearly an error .
  • Page 37 Innovation In and Out of Parlour Input/Output (I/O) Printed Circuit Board (PCB) Diagnostics Continued w p1 XXXXX Internal setting w p2 XXXXX Internal setting w VREF XXXXX Internal setting w OFFSET XXXXX Internal setting C P1 XXXXX Internal setting C OFFSET XXXXX Internal setting V OFFSET...

  • Page 38: Input/Output (I/O) Printed Circuit Board (Pcb) Test Routines

    Innovation In and Out of Parlour Input/Output (I/O) Printed Circuit Board (PCB) Test Routines i/o board test This enables to user to test individual outputs by turning them on or off. Setup Press the Enter key to go into the diagnostic routine. Enter é...
  • Page 39 Innovation In and Out of Parlour Input/Output (I/O) Printed Circuit Board (PCB) Test Routines Continued END OF WASH OFF End of wash output VAC PUMP 1 Vacuum Pump 1 output VAC PUMP 2 Vacuum pump 2 output VAC PUMP 3 Vacuum pump 3 output VAC PMP STOP OFF...
  • Page 40 Innovation In and Out of Parlour Input/Output (I/O) Printed Circuit Board (PCB) Test Routines Continued OUTPUT 1 Output 1 output OUTPUT 2 Output 2 output OUTPUT 3 Output 3 output MILKING LED OFF Milking LED output WASHING LED OFF Washing LED output SSR 1 Soild State Relay 1 output...
  • Page 41 Innovation In and Out of Parlour Input/Output (I/O) Printed Circuit Board (PCB) Test Routines Continued INPUT 1 Input 2 input status PUMP 1 Chemical Pump 1 output PUMP 2 Chemical Pump 2 output PUMP 3 Chemical Pump 3 output PUMP 4 Chemical Pump 4 output Reset...

  • Page 42: Control Printed Circuit Board (Pcb) Serial Number

    Innovation In and Out of Parlour Control Printed Circuit Board (PCB) Serial Number s/n XXXXXXXXXXXX This displays the control printed circuit board (PCB) serial number. ê Press the 8 key to move onto the control printed circuit board (pcb) software version. Control Printed Circuit Board (PCB) Software Version s/W version X.

  • Page 43: Restore Factory Settings

    Innovation In and Out of Parlour Restore Factory Settings factory reset Factory settings can be restored by running this function. This function clears ALL of the settings. The data is lost and is not recoverable so use with caution. Setup Press the Enter key to proceed with the factory reset.

  • Page 44: Lock Setup

    Innovation In and Out of Parlour Exit Setup LOCK setup This enables to user to lock the setup routine and exit. Setup Press the Enter key to lock the setup routine and exit. Enter 44 | Auto Wash Pro Manual | v1.2...

  • Page 45: Editing Programs

    Innovation In and Out of Parlour Editing Programs Setup Press the Shift + Enter keys to enter setup. Shift Enter é Press the 2 key until the Edit Programs menu item is reached. edit programs Setup Setup Press the Enter key to edit the programs.
  • Page 46 Innovation In and Out of Parlour Editing Programs Continued - Available Step End Conditions s01 user stop User has to press User has to press skip or stop to skip or stop to terminate step terminate step HH - hours SS - seconds s01 t1 00--06--00.
  • Page 47 Innovation In and Out of Parlour Editing Programs Continued - Available Step End Conditions s01 CON ) 150. 0 mS Step will complete when conductivity level is greater than 150mS Can be less than (<) or greater than (>) X temperature s01 INPUT 1 ON Step will complete when input matches...
  • Page 48 Innovation In and Out of Parlour Conductivity Testing for Chemicals To test if chemicals have been added to the wash trough the system needs to compare the water conductivity before and after the chemicals have been added. For this each step has the ability to store the conductivity or compare the conductivity.

  • Page 49: Editing Tasks

    Innovation In and Out of Parlour Editing Tasks Setup Press the Shift + Enter keys to enter setup. Shift Enter é Press the 2 key until the Edit Tasks menu item is reached. edit tasks Setup Press the Enter key to edit the tasks.
  • Page 50 Innovation In and Out of Parlour Editing Tasks Continued The task trigger has two options, it can be ‘AUTO KEY’ or TIME AND DAY’. The Auto Key setting allows the user to set a time window when the task will be run when the Auto Key is pressed. The Time And Day setting is an automatically starting task at the time specified.
  • Page 51 Innovation In and Out of Parlour Editing Tasks Continued The End Time setting controls when the Auto Key task is enabled until, if the task is triggered by Time And Day, this setting is not displayed. HH - hour of the day 1 END 15--00 MM - minute...
  • Page 52 Innovation In and Out of Parlour Editing Tasks Continued Clear To toggle the day, press the Info key. The display will show the days starting letter if enabled, or a dash (_) if disabled. Info 1 days SmTWTFS S = Sunday Enabled and Flashing 1 days _mTWTFS _ = Sunday Disabled and Flashing ç...

  • Page 53: Calibrating The Peristaltic Pumps

    Innovation In and Out of Parlour Calibrating the Peristaltic Pumps Setup Press the Shift key then press the Enter key to enter the setup menu. Shift Enter é Press the 2 key until the Pump Calibration menu item is reached. pump calibration Setup Press the Enter key...

  • Page 54: Milking Mode

    Innovation In and Out of Parlour Milking Mode Pause Press the Milk key to put the system into Milk mode before milking. Milk HH - hours SS - seconds milk 01--06--32 MM - minutes The display will show ‘MILK’ and the milking time. If the Auto Wash Pro is connected to other ATL equipment (ie.

  • Page 55: Washing Mode

    Innovation In and Out of Parlour Washing Mode Press either the Pre-Milking, Milk Stone or Program 1 to 6 keys to start the system washing. Prog 4 Prog 6 Milk Prog 1 Prog 3 Milking Stone The display will show the following during washing depending upon whether the control is waiting for wash trough level, wash trough temperature, time remaining in step, and user pressing stop key.
  • Page 56 Innovation In and Out of Parlour Washing Mode Continued Time Remaining Program = Program 2 Setting Waiting For - R = Time Remaining Pg2 so3 R10. 3 4 Step Number 3 Time Remaining - MM.SS - MM = Minutes, SS = Seconds User Pressing Stop Key Program = Program 3 Setting Waiting For - US = User Stop...
  • Page 57 Innovation In and Out of Parlour Washing Mode Continued Functionality during Washing Back Press the Skip key to skip to the next step in the Wash program or to acknowledge user stop. Skip Press the Pause key to pause the current step in the Wash program. Pause Clear Press the Info key...

  • Page 58: Info Function

    Innovation In and Out of Parlour Info Function The info function provides information on milking and washing programs. The information is available all of the time (i.e. both when milking and washing programs are running or when the control is in idle). Clear Press the Info key to access the info function.
  • Page 59 Innovation In and Out of Parlour Info Function Continued Washing Length (Time) - Reports last washing length HH - hours SS - seconds Washing Length (Time) wash Ti 00--15--53 Washing length in HH-MM-SS time format MM - minutes wash ti unknown Will only report this before first washing after power up...
  • Page 60 Innovation In and Out of Parlour Info Function Continued Return Water Lowest Temperature - Reports the lowest temperature of the return water during last wash. Return Water Temperature Low RTRN W lo 35. 1 °C Return Water Temperature Return Water Current Temperature - Reports the current temperature of the return water. Return Water Temperature RTRN W 55.
  • Page 61 Innovation In and Out of Parlour Info Function Continued Temp Probe 3 Highest Temperature - Reports the highest temperature on temp probe 3 during last wash. Temp Probe 3 Temperature High Temp Probe 3 Temperature TEMP 3 HI 85. 9 °C Current Vacuum Level - Reports the current vacuum level.

  • Page 62: Monthly/ Six Monthly / Yearly Routine Maintenance

    Innovation In and Out of Parlour Monthly/ Six Monthly / Yearly Routine Maintenance Visually inspect the Auto Control box for damage. Any damage will admit water causing the premature failure of the electronics and should be fixed as soon as possible. Parlour Wash Down The Auto Wash Pro control enclosure is IP65 rated.
  • Page 63 Innovation In and Out of Parlour Troubleshooting Continued Error Fault Information TEMP 3 TEMP SXX WHITE The temp probe 3 failed to reach the required temperature during step TEXT FOR SPACING XX of the previous program. MILK PUMP COM ERR WHITE The control failed to communicate with the Milk Pump Control over TEXT FOR SPACING...

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