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A3 Next LELY ASTRONAUT Milking Robot Operator Manual D-H023.0906EN English Original www.lely.com innovators in agriculture Lely Industries N.V.
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Pura, Qwes, Shuttle, T4C, Time for Cows, Viseo and Voyager are registered trademarks of the Lely Group. The right of exclusive use belongs to the companies of the Lely Group. All rights reserved. The information given in this publication is provided for information purposes only and does not constitute an offer for sale.
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innovators in agriculture LIST OF INCLUDED AMENDMENTS No: Issue Date Chapter(s) Remarks (yy/mm) 09/06 Initial Issue...
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Study and understand this information thoroughly before you operate the robot. Failure to do so could result in personal injury or damage to equipment. Please consult your local Lely service provider if you do not understand the information in this manual, or if you need additional information.
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ASTRONAUT A3 Next. At the end of each visit, all work done on the ASTRONAUT A3 Next must be written in the logbook and the logbook must be signed by the certified technician.
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Technician Training All the technicians certified by Lely Industries have completed an approved training program, and passed written and practical examinations during and at the end of the training program. The training is given by a product specialist. The examinations are done...
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innovators in agriculture Table of Contents 1. Introduction 2. Safety Introduction Signal Words Safety Instructions 2.3.1 General Safety 2.3.2 Electrical Safety 2.3.3 Installation Safety 2.3.4 Operating Safety 2.3.5 Maintenance Safety Safety Decals 2.4.1 Safety Decal Messages 2.4.2 Maintenance of Safety Decals 2-10 2.4.3 Installation of Safety Decals...
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innovators in agriculture 4.3.6 Cleaning 4-25 4.3.7 Alarm System 4-29 User Interfaces 4-30 4.4.1 X-Link Control Panel 4-30 4.4.2 CRS+ 4-38 4.4.3 PC with the T4C Farm Management Software 4-48 5. Installation MQC-C (Option) 5.1.1 Removal of the Processor and the Sampler 5.1.2 Installation of the Processor and the Sampler 6.
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innovators in agriculture 6.9.3 Display the History of Alarms 6-17 6.9.4 Clear Active Alarms 6-18 6.9.5 Suppress Active Alarms 6-18 6.10 Display the Event History 6-18 6.11 View the MQC-C Attention List (Option) 6-19 6.11.1 Examine the Attention List in T4C 6-19 7.
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innovators in agriculture 7.10.4 Replace the Cleaning Brushes 7-45 7.11 Support Systems 7-46 7.11.1 Examine the Air Compressor and the Air Dryer 7-46 7.11.2 Examine the vacuum pump oil level 7-46 7.11.3 Clean the Exterior of the Vacuum Pump 7-47 7.12 Control Systems 7-49 7.12.1 Examine the Attention Alarms...
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innovators in agriculture 8.10 Control Systems 8-16 9. Troubleshooting The Milk is moving up and down in the Milk Tube No Milk Flow in one of the Teat Cups and Twin Tubes The Milk Jar is not emptied after milking Cleaning Brushes are dirty after Brush cleaning The Udders are not clean before the Milking starts Cleaning Brushes are dry...
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1. INTRODUCTION The ASTRONAUT A3 Next Milking Robot is part of an automated milking system that milks, feeds, and monitors the health of cows. The milking system also examines the quantity and quality of the milk received from the cows, and if necessary, it separates milk that is contaminated or not to the correct standard.
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Introduction The safety alert symbol identifies important safety messages on your ASTRONAUT A3 Next Milking Robot and in the manual. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instruction of the safety message.
• Know the emergency medical center number for your area • Contact your nearest Lely service provider if you have any questions • Review safety related items with all operators frequently (annually). Safety...
• Only trained persons are permitted to operate the milking robot • Do NOT use chlorine products in the cleaning system. Lely Industries N.V. is not liable for, and does not cover under warranty, any damage or harm due to the use of other cleaning products than Astri- products in the cleaning system.
• Do not look directly into the laser light of the sTDS • Keep the working area as clean and as dry as possible • Contact your nearest Lely service provider if you have any questions • Review safety related items with all operators frequently (annually).
innovators in agriculture Safety Decals 2.4.1 Safety Decal Messages General safety messages appear in this safety messages section. Specific safety messages are in applicable parts of this manual when potential hazards may occur if the instructions or procedures are not followed. 2.4.1.1 Chemical Hazards (Swallowing/Burning) Chemical Hazards Symbol (except Canada and USA)
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innovators in agriculture 2.4.1.2 Electrocution Hazard Electrocution Hazard Symbol (except Canada and USA) Electrocution Hazard Symbol (Canada and USA) Stop the milking robot, turn off electrical power at the master panel WARNING and wait for all moving parts to stop before doing maintenance, adjustment or repair.
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innovators in agriculture 2.4.1.3 Laser Light Hazard Type one Laser Light Hazard Symbol (except Canada and USA) Type two Laser Light Hazard Symbol (except Canada and USA) Laser Light Hazard Symbol (Canada and USA) Class 2 laser product. Laser radiation. Do not look into the laser beam. CAUTION 2.4.1.4 No Admittance for Unauthorized Persons...
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Do not use a fork-lift truck at this position to lift the ASTRONAUT A3 WARNING Next Milking Robot. Use the correct lifting points on the top of the ASTRONAUT A3 Next Milking Robot. 2.4.1.6 Pinching Hazard Pinching Hazard Symbol (except Canada and USA) Pinching Hazard Symbol (Canada and USA) Danger of being pinched by moving parts.
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innovators in agriculture 2.4.1.7 Pressure Limit Pressure Limit Symbol Make sure the pressure limit shown on the decal is not exceeded. Too high CAUTION pressure may cause injury to persons and/or damage to equipment. 2.4.1.8 Temperature Hazard Type One Temperature Hazard Symbol (except Canada and USA) Type Two Temperature Hazard Symbol (except Canada and USA) Temperature Hazard Symbol (Canada and USA) Do not touch the cleaning system components until they have cooled.
Do not use mineral spirits, abrasive cleaners or other similar agents that may damage the safety decals • Replace safety decals that are missing or are illegible • Safety decals can be purchased from your local Lely service provider. 2.4.3 Installation of Safety Decals Make sure the installation surface is clean and dry.
innovators in agriculture Emergency Stop Buttons Three emergency stop buttons are installed on the milking robot. The emergency stop buttons are installed adjacent to the X-Link control panel, on the rear of the robot arm and on the caterpillar carrier. When any one of these buttons is pressed, the milking robot immediately stops operation and there is no movement of the robot arm.
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innovators in agriculture Figure 1. Position of Emergency Stop Buttons LH Model Figure 2. Position of Emergency Stop Buttons RH Model KEY: 1. 2. 3. Emergency stop buttons 2-12 Safety...
Compressor Unit Please refer to the documentation of the Compressor for more information. Note: The compressor unit must provide oil free compressed air. Lely recommends one of the following compressor units: • Atlas Copco SF2 P8-SD6, or • Atlas Copco SF4 P8-SD6, or •...
4. DESCRIPTION AND OPERATION Introduction This chapter describes the parts of the ASTRONAUT A3 Next milking robot. This chapter also explains how the parts of the ASTRONAUT A3 Next milking system operate together to milk a cow.
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innovators in agriculture The optional segregation gate (not shown) can be installed at the exit side of the box. Controlled by the milking robot and the T4C and X-Link software, the cow is sent in a specified direction when the cow leaves the box.
• Qwes-LEG (ISO) • Qwes-E (ISO) • Qwes-EAR. The installation location of the antenna in the ASTRONAUT A3 Next depends on the type of Qwes tag. The Qwes cow identification system gets input from the cow via the tag and the T4C software or X-Link database.
Feed Through The feed through is installed on the front plate. If the ASTRONAUT A3 Next has an ISO ID-system, the cow ID reader is installed on the feed through. It is a sealed plastic box with an internal antenna.
innovators in agriculture Lower arm cover The lower arm cover (1, fig. 4, page 4-6) covers the parts that are installed on the lower arm. The lower arm has parts of the milking system and the milk transport system. It must be removed before the mothership cover can be removed.
innovators in agriculture Mothership The mother ship is connected to the end of the lower arm. The mothership contains the Teat Detection System (sTDS) and the teat cups. The sTDS finds the position of the teats of the cow, and tells the TAS the correct position for the teat cups.
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The milk jar collects the milk during the milking, it also collects the water during a rinse. The milk jar is located in the machine room at the robot arm side of the ASTRONAUT A3 Next, behind the lower cover.
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The M4Use system is installed up to 5 m from the ASTRONAUT A3 Next. Figure 5. Milking system, overview...
X-Link. The attention lists generated by T4C can be found on the X-Link at the T4C tab (page 4-32). The following figure shows the parts of the MQC-C and their position on the ASTRONAUT A3 Next. Description and Operation...
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innovators in agriculture Figure 6. Overview of the MQC-C components on an RH model KEY: 1. Wall socket - 2. Sampler - 3. Astri-Cell can - 4. Processor 4.2.7.2 The Sampler The sampler is a box (a base with a cover) with pipes and electronics. It is installed on a support near the MQC-II and the milk jar.
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innovators in agriculture 4.2.7.3 The Processor The processor is a box (a base and a cover) with pumps, valves, chambers and electronics. It is installed on the milking robot frame behind the intermediate panel and is attached to the processor installation bracket. The processor has four main functions: to transport, mix, test and drain the mixture.
4.2.8 Cleaning System For correct and hygienic operation, the ASTRONAUT A3 Next must be cleaned. The outside of the milking robot is cleaned by the farmer on a day-to-day basis. The cows teats and the inner parts of the milking robot are cleaned by the milking robot.
4.2.9 Support Systems The ASTRONAUT A3 Next has the following supporting systems: • The T4C network with T4C PC • The power supply • The vacuum pump • The compressor • The milk storage tank. 4.2.9.1 T4C Network The T4C network connects all network peripherals with each other and takes care of all data exchange between the devices.
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innovators in agriculture Figure 9. T4C network overview 4.2.9.2 Power Supply The power supply system supplies power to the following systems: • 27 VDC, 20 A to the control systems • 230 VAC, 10 A to the vacuum pump system •...
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The pulsation system is used to massage the teats during milking. The vacuum pump is located in the machine room at the box side of the ASTRONAUT A3 Next. 4.2.9.4 Compressor The compressor supplies pressurized, clean and dry air to the milking system.
4.3.1.1 Detecting and Weighing When the cow enters the box of the ASTRONAUT A3 Next, it is detected by the Gravitor weighing system of the ASTRONAUT A3 Next. The Gravitor is connected to the CAN Bus network of the ASTRONAUT A3 Next.
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4.3.1.3 Positioning of the Robot Arm To position the teat cups exactly under the teats, the arm of the ASTRONAUT A3 Next is moved in 3 directions: • horizontal, forward/backward (y-direction). The robot arm is moved by a horizontal cylinder •...
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innovators in agriculture Milking lasts in most cases 4 to 15 min depending on the milk amount and the milk flow of the quarters. Figure 10. Operation of the pulsation system 4.3.2 Milk Transport The milk is first transported to the milk jar and when the milking of a cow is ready to the milk storage tank (or when the milk is not for consumption to the M4Use or the sewer).
innovators in agriculture 4.3.2.2 Milk Transport to the Milk Storage Tank Milk pump The milk pump pumps the milk or cleaning water from the milk jar to the 3-way valve and from there to either the milk tank, milk tank 2, the calf milk line, the M4USE buckets or the sewer.
All items are measured per quarter. All measurement data also used as information for the cow's condition and stored in the control system of the ASTRONAUT A3 Next. The MQC-II is connected to the CAN Bus network of the ASTRONAUT A3 Next.
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innovators in agriculture Temperature When the temperature drops below the switch temperature, the processor or the sampler switches on the heater element(s). When the temperature goes above the switch temperature, the processor or the sampler switches off the heater element(s). The switch temperature is for the processor is 5°C (41°F) and for the sampler 4°C (39.2°F).
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innovators in agriculture Drain the Mixture If all the mixture has flowed into the third chamber, the processor pumps the mixture to the sewer. 4.3.4.4 Test Results The degree of viscosity of the mixture determines the time necessary for the mixture to drain from the flow chamber to the waste chamber. The longer the flow time, the higher the class of the somatic cell count.
• Dry processor cleaning • System rinse. 4.3.5 Feeding The ASTRONAUT A3 Next makes it possible to feed every cow individually. Correct feeding of cows is essential for successful robotic milking. Concentrates provide the main stimulus for cows to visit the robot frequently.
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• On the third line: • The status is: 'Astri-L' or 'Astri-Cid' or 'Astri-Lin'. 4.3.6.2 Lely wash During a Lely wash, the following messages are displayed on the Tab [Process] in the frame Cleaning: • On the first line: • The status is: 'Lelywash'.
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innovators in agriculture 4.3.6.3 Local Rinsing If a rinsing is only for the milking robot, the following messages are displayed on the Tab [Process] in the frame Cleaning: • On the first line: • The status is: 'Local rinse'. • On the second line: •...
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innovators in agriculture 4.3.6.5 Preparation Main Cleaning Before the main cleaning can be done, the boiler must be emptied and the main cleaning must be prepared. In this case, the following messages are displayed on the Tab [Process] in the frame Cleaning: •...
innovators in agriculture 4.3.7 Alarm System Alarms are indicated by: • A sound • A LED on the CRS+ Panel • Text on the X-Link display. Some alarms will generate a phone call. This depends on the CRS+ settings. The alarm system combines the following functions: •...
innovators in agriculture 4.3.7.4 Confirmation of alarms Each alarm on the robot must be acknowledged by the user. The cause of the alarm must then be removed. User Interfaces 4.4.1 X-Link Control Panel The X-Link controls and monitors the milking robot and communicates with the T4C management software.
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The X-Link communicates with: • The T4C server through an ethernet connection • The ASTRONAUT A3 Next through a CAN Bus network connection. 4.4.1.1 Pop-up Windows The following table gives the names of the pop-up windows and a description of their function.
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innovators in agriculture Name Description (De)activate To tell the T4C that supervision must be (de)activated (this setting is stored supervision after milking is completed). Skip Lelywash/short To cancel the planned Lelywash or short rinse. rinse 4.4.1.2 Navigation in the X-Link Menu When you navigate through the X-Link menu, selected items are displayed as follows: •...
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innovators in agriculture Tab name: Settings This tab displays system settings that operators and maintenance personnel can change. There are two submenus: • Settings • Advanced settings. Operators must not change settings in the submenu Advanced settings. CAUTION The Settings submenu includes: •...
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innovators in agriculture • Alarm • Facilities • Accessories • General • Engineering. Button [Calibration robotarm]. Tab name: Indications This tab gives an overview of all reports and alarms. Refer to Alarm Handling (page 6-17). It also has a button [Refresh] to refresh the list. Tab name: System This tab shows the status of the components used in the milking robot.
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innovators in agriculture Quick Launch Buttons The quick-launch buttons enable the user to easily do the most common tasks on the milking robot. The quick-launch buttons are: Button Description In/out operation This button puts the milking robot in operation. It then changes to 'out of operation'. When this button is pushed, the robot completes the current cleaning or milking process then closes the gates to stop entry of a cow.
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Extra cleaning This button opens a dialog box to start an extra main cleaning, a Lely wash, short rinse, sTDS cleaning, Astri-L, Astri-Lin or Astri-Cid cleaning. Arm Control Buttons The arm control buttons enable the user to position the mothership in the correct position under the teats during first milking (page 6-7).
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innovators in agriculture Button Description Left Hand Description Right Hand Robot Robot Not applicable Move the robot arm 50 mm to the right of the cow Move the robot arm 50 mm Not applicable to the right of the cow Move the robot arm 25 mm Not applicable to the right of the cow...
innovators in agriculture 4.4.2 CRS+ The CRS+ is a cleaning and reporting system to: • Schedule (main) cleaning for all attached milking robots • Enable emptying the milk storage tank • Control the buffer vessel (if applicable) • Control the pre cooler (if applicable) •...
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innovators in agriculture Buttons and Indicators The keys on the keypad have the following functions: Button/Indicator Description Button [Emptying the milk tank]: to start the tank driver procedure to prepare the milk tank for being emptied. Indicator next to Off: button [Emptying Robots milking, not ready for emptying the milk the milk tank]...
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innovators in agriculture Button/Indicator Description ENTER To confirm options and entries. If the menu is longer than can be displayed an arrow up or down is displayed. Note: If there is a submenu a right arrow is displayed. Start Up and Main Menu During Start Up If you start up the system, the display shows the startup screen: Software version...
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innovators in agriculture Main Menu Alarm system > Cleaning system > > Settings > Tests Event history The status screen appears again 45 min after the last key was pushed. This is Note: also valid in any other menu. The display has a background light. The light goes off 5 min after the last key was pushed.
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innovators in agriculture Duty Counter The duty counter displays the total time the compressor is active. On the CRS+: Main Menu > Alarm system > Duty counter Mean time/milking 7 days : hh:mm Mean time/milking Today : hh:mm Time since Service 09/12/05 Time since 09/12/05...
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innovators in agriculture Alarm as shown on the CRS+ display Type of alarm NORMAL ALARM Fluctuation in val. loadcell <P1> scale NORMAL ALARM Incorrect detection Y position NORMAL ALARM Malfunction of Arm Control (<LH1>, <LH2>) NORMAL ALARM Malfunction of Laser System (<LH1>, <LH2>) CRITICAL ALARM Malfunction of Vacuum System NORMAL ALARM...
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innovators in agriculture Alarm as shown on the CRS+ display Type of alarm NORMAL ALARM M4Use position error NORMAL ALARM Rack Shuttle almost full (racknr. <US1>) NORMAL ALARM Hubble available NORMAL ALARM External alarm NORMAL ALARM Milk tank alarm NORMAL ALARM Unknown alarm NORMAL ALARM Failure position filter valve...
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Cleaning System Menu The menu displays menu options for cleaning the Cleaning system ASTRONAUT A3 Next. Main Menu > Cleaning system Start main cleaning Start main clean. Astri-Cid Start main clean. Astri-Lin Cluster rinse Open milk tank valve...
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innovators in agriculture Cleaning temp. not reached night Alarm Phone Phone settings To set the telephone number that must be called in case of an alarm. Day and night time settings To adjust the time settings that are used to warn the user in case of an alarm.
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innovators in agriculture Event history Menu displays all events: Event history > Main Menu Event history 01/25 13:29 CRS+ Overdue filling boiler time 01/25 09:48 Crs+ Timeout holding gate 11/07 11:52 CRS+ Robot too long out of operation Description and Operation 4-47...
innovators in agriculture 4.4.3 PC with the T4C Farm Management Software The PC with the Time for Cows (T4C) software is the management system for the milking system. The T4C software enables the user to examine data on each cow and to send cow specific commands to the milking robot.
innovators in agriculture 5. INSTALLATION MQC-C (Option) 5.1.1 Removal of the Processor and the Sampler Preparation Before you remove the processor and the sampler, you must do a short rinse. CAUTION Do a short rinse with the X-link. Take the milking robot out of operation with the X-Link (page 6-1). Open the multiple function box (page 7-11) Remove the middle and the lower cover (page 7-6).
innovators in agriculture Disconnect the CAN-bus connector (7) from the milking robot. (3, fig. 16, Remove the nut, washer and bolt page 5-5) from the strip (2) and the processor installation bracket (4). Remove the processor (5) from the processor installation bracket. Make sure no debris can enter the tubes and the electrical connector(s).
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innovators in agriculture Install the processor drain on the bin-bracket with a cable-tie. (1, fig. 15, Push in the lock plates page 5-5) and (3) on the wall socket connector (2) and connect the connector to the wall socket. Install the sampler Make sure no debris can enter the tubes and the electrical connector(s).
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innovators in agriculture Figure 14. Close the ball valve Installation...
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innovators in agriculture Figure 15. Disconnect the sampler tube bundle and the power/data cable Figure 16. Remove the processor Installation...
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• When the ongoing milking or cleaning process is finished the ASTRONAUT A3 Next stops, meanwhile the next button is displayed: Note: When the milking robot is out of operation the 'Start' button displayed.
innovators in agriculture 6.1.2.2 Take All Milking Robots in a Cluster out of Operation with the CRS+ On the CRS+, push button [ENTER]. Select ' ' > ' ' > ' Cleaning system Robots out of operation Push button [ENTER]. 6.1.3 Reset the Milking Robot Take the milking robot out of operation with the X-Link (page 6-1).
innovators in agriculture 6.1.4 Calibrate the Robot Arm On the X-Link, select: • Tab [Test] • [Calibrate] • Button [Calibration robotarm]. Select button [Start]. Make sure the robot arm moves up, out, up again and then forward to the maximum positions of all the cylinders. Make sure the robot arm stops at the fully forward position.
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innovators in agriculture 6.2.1.3 Shave the Udder and the Tail Shave the bottom and front sides of the udder. Shave the udder again as soon as the udder becomes hairy. Note: Cut off the tail plume a few centimetres below the last tail bone. Shave the tail above the remaining plume.
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innovators in agriculture Figure 17. The Qwes-H tag KEY: 1. Connector - 2. Qwes-H tag - 3. Numbers - 4. Ring - 5. Weight Operating Instructions...
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innovators in agriculture Figure 18. Make sure to leave a two fingers space between the cows neck and the belt 6.2.1.5 Habituation Give the animal the opportunity to remain for a few hours in the environment of the milking robot before leading her into the robot box. This allows her to get used to the noises and movements of the robot as well as the opening and closing of the gates.
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innovators in agriculture This allows the unsettled cow to enter the box slowly. For the cow to be identified, it should keep its head close to the aerial. If necessary, remain behind the cow until the animal has been identified. If necessary, give extra feed (page 6-13) to lure the cow into the box.
innovators in agriculture Figure 19. Set the teat coordinates 6.2.1.8 Feeding Ration at the feed fence First of all, the quantity of feed at the feed fence must be calculated. This ration should be enough for the cows with a lower production. The following rule of thumb can be applied: average milk production per cow minus 7.
innovators in agriculture 6.2.3 Interrupt Pre-Treatment Select Tab [Process]. In the field Attachment system, select [Interrupt pretreatment]. When the pop-up window Confirm user interruption of this visit appears, select [Stop]. 6.2.4 Reconnect the Teat Cups Select Tab [Process]. In the field Attachment syste, select [Reconnect teat cups]. When the pop-up window Confirm user interruption of this visit appears, select [Yes].
innovators in agriculture Cleaning 6.3.1 Start a Cleaning or Rinse with the CRS+ On the CRS+, select: • Main Menu > Cleaning system Select a cleaning: • For a main cleaning, select Start main cleaning • For an Astri-Lin main cleaning, select Start main clean. Astri-Lin •...
innovators in agriculture 6.3.3 Cancel a Rinse with the X-Link Select tab [Process]. In the field 'Cleaning', select button [Cancel rinse]. Robot Arm 6.4.1 Move the Robot Arm to the Home Position Wait until the robot arm stops in the home position before you do WARNING maintenance on the milking robot.
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innovators in agriculture Figure 20. The four robot arm positions for service KEY: 1. Service position 1 - 2. Service position 2 - 3. Service position 3 - 4. Service position 4 6-12 Operating Instructions...
innovators in agriculture Extra feed 6.5.1 Switch on Extra Feed On the X-Link, select: • Button to open the quick launch buttons bar. • The button changes appearance and, if there is no cow in the box, the milking robot gives extra feed every 20 seconds to lure the cow.
innovators in agriculture Empty the Milk Tank Make sure the milk hose from the milk truck is connected to the milk tank. If the milk tank has one tank one tank with bufferbarrel , or Boetech one tank with buffertank On the CRS+: push button When the LED on the left of the button is green select: •...
innovators in agriculture Select [Close]. Remove the plug (1) from the knee (2). 10. Install the nipple (3) with the hose (4) into the hole in the knee. 11. Select [Next]. 12. Make sure the value in the field Current rack number is correct. 13.
innovators in agriculture Select [ENTER]. Select [OK]. 6.8.3 Stop Sampling Stop the sampling in the T4C software (refer to the T4C manual). Select Tab [Sampling]. Select [Turn sampling off]. When the Confirm stop sampling pop-up window appears, select [Stop] . When the screen changes to Cows are not marked for sampling, "Disconnect Shuttle now, when ready press close", select [Close] in the field Valve sampling.
innovators in agriculture Alarm Handling 6.9.1 Confirm Alarms On the X-Link: Confirm the alarm on the pop-up window. Remove the cause of the alarm. If the button [ ] is displayed (page 4-34). Push [ Repeat the steps 1 to 3. 6.9.2 List Active Alarms On the CRS+:...
innovators in agriculture 6.9.4 Clear Active Alarms On the CRS+: Select: • Main Menu > Alarm system > Clear alarm list • Press [ENTER]. If the cause of the alarm is removed, a reset on the milking robot will also Note: clear the alarm on the CRS+.
innovators in agriculture 6.11 View the MQC-C Attention List (Option) 6.11.1 Examine the Attention List in T4C Examine In the T4C software: Select the survey tab Attentions. Select the applicable cow from the list. Select: • Module tab Milking • Tree item SCC or SCC chronic cases •...
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7. MAINTENANCE Introduction This chapter contains the preventive maintenance procedures for the ASTRONAUT A3 Next Milking Robot done by the operator of the milking robot. The procedures are based on the maintenance schedule (farmer), as shown in the next chapter.
Preventive Maintenance Schedule (Farmer) The following table shows the preventive maintenance schedule for the ASTRONAUT A3 Next Milking Robot defined by Lely. Preventive maintenance must also be done as specified by local regulations. Each task mentioned in this table is described further in this chapter.
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innovators in agriculture Maintenance Tasks Frequencies Hours Day Week Month Year Operating Milkings Hours Examine the quantity of Astri-L (page 7-43) Examine the compressor and air dryer Examine the robot performance list (page 7-50) Measure the weight of the feed portion (page 7-17) Measure concentration of Astri-L (page 8-12)
innovators in agriculture Preparation 7.3.1 Switch OFF the Milking Robot Take the milking robot out of operation with the X-Link (page 6-1). On the X-Link, select: • Tab [System] • Button [Change view] • Button [Shutdown]. Wait until the status of all services are not equal to Running. The status of the services 'AGS' and 'ECS' remain 'Running'.
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innovators in agriculture Wait until the status of the services is 'Init'. Select button [Start]. Wait until the startup mode window is displayed. 10. Select button [Empty boiler]. The robot arm will move. Make sure there are no obstacles in the WARNING range of the robot arm.
innovators in agriculture Figure 23. Switch OFF or ON the circuit breakers Covers and Doors 7.4.1 Remove or Install the Covers on the Robot Arm Side Middle and lower cover Both middle and lower cover must be removed to get access to the major Note: parts of the milk system.
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innovators in agriculture Remove the middle cover (fig. 29, page 7-10) from its position on the upper cover. (2, fig. 27, Push the middle cover page 7-9) with its pins into the corresponding holes (1) in the frame and push it down. Upper cover Both upper and middle cover must be opened/removed to get access to the Note:...
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innovators in agriculture Figure 25. Install the middle cover Figure 26. Remove the lower cover Maintenance...
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innovators in agriculture Figure 27. Install the lower cover Figure 28. Open or close the upper cover Maintenance...
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innovators in agriculture Figure 29. Lower and middle cover on upper cover 7-10 Maintenance...
innovators in agriculture 7.4.2 Open the Multiple Function Box Open Remove the middle cover (page 7-6). Open the upper cover (page 7-6). (1, fig. 30, Use a screwdriver to turn the locks page 7-11) 90° counterclockwise to release the cover of the multiple function box. Pull the bottom edge of the cover toward you to open the multiple function box.
innovators in agriculture 7.4.4 Remove or install the Lower Arm Cover Removal (2, fig. 31, Remove the screws page 7-12). Remove the lower arm cover (1). Installation Make sure the tubes and the cables are in the correct position and (1, fig.
innovators in agriculture Carefully move the mothership cover away from the teat cups and the mothership. Carefully put the mothership cover on the ground next to the mothership. Installation Make sure the sTDS cable does not get stuck between the mothership and the CAUTION mothership cover.
innovators in agriculture Feeding System 7.6.1 Clean the Feeding System Preparation Block the cow traffic to the milking robot before you do this WARNING procedure. Take the milking robot out of operation with the X-link (page 6-1). Select: • Tab [Test] •...
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innovators in agriculture Close-up Select: • Tab [Test] • [Box] • [Gates]. In the field Gates, select, Exit gat, [Close]. Unblock the cow traffic. Put the milking robot in operation with the X-link (page 6-1). Figure 33. Remove the hopper cover Maintenance 7-15...
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innovators in agriculture Figure 34. Remove the feed cover 7-16 Maintenance...
innovators in agriculture Figure 35. Clean the feeding system 7.6.2 Calibrate the Feed Portion Preparation Block the cow traffic to the milking robot before you do this WARNING procedure. Take the milking robot out of operation with the X-Link (page 6-1). Select: •...
innovators in agriculture Measure the Feed Portion The steps in this sub-section must be done for all installed feeding valves. Select [Feed type] Select [Start dose]. Wait until the feed unit is finished. Put a bucket on the scales. Reset the scales to zero. Remove the bucket.
innovators in agriculture Close-up Move the robot arm to the home position. Start the local rinse procedure with the X-Link (page 6-10). Put the milking robot in operation with the X-link (page 6-1). Figure 36. Clean the bleed holes 7.7.2 Clean the Outside of the Teat Cups Do not use a high pressure cleaner to clean the teat cups.
innovators in agriculture Close-up Move the robot arm to the home position. Put the milking robot in operation with the X-link (page 6-1). Start a Short Rinse (X-Link). 7.7.3 Examine the Cup Cords Preparation Take the milking robot out of operation with the X-Link (page 6-1). Move the robot arm to the service position (page 6-11).
innovators in agriculture Figure 37. Measure the cup cords 7.7.4 Examine the Teat Cup Sleeves Preparation Take the milking robot out of operation with the X-link (page 6-1). Move the robot arm to the service position (page 6-11). Select: • Tab [Test] •...
innovators in agriculture If necessary, replace the teat cup sleeves (page 7-29). Close-up In the field Cord cups, select: • LF [Fixed] • LR [Fixed] • RF [Fixed] • RR [Fixed]. Move the robot arm to the home position. Put the milking robot in operation with the X-link (page 6-1). 7.7.5 Examine the Cup Centring Preparation...
innovators in agriculture Close-up Move the robot arm to the home position. Put the milking robot in operation with the X-link (page 6-1). 7.7.6 Replace the Cup Cords Preparation Take the milking robot out of operation with the X-Link (page 6-1). Move the robot arm to the service position (page 6-11).
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innovators in agriculture In the field Cord cups, select [Fixed] for the applicable teat cup. (3, fig. 39, Make sure the cup cord page 7-26) is put through the washer (2). Pull the cup cord on the mothership side. Make sure the teat cup is firmly in the tilt cup.
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innovators in agriculture Figure 38. Remove the cup cords Maintenance 7-25...
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innovators in agriculture Figure 39. Mark the cord Figure 40. Tie the cord just behind the mark 7-26 Maintenance...
innovators in agriculture 7.7.7 Clean the Robot Arm and the Box Do not use a high pressure cleaner when you clean the robot arm and the CAUTION box.The robot arm contains many electronic parts. A high pressure cleaner may cause damage to these parts. Preparation Take the milking robot out of operation with the X-link (page 6-1).
innovators in agriculture Milking System 7.8.1 Examine the Teat Cup Liners Preparation Take the milking robot out of operation with the X-link (page 6-1). Move the robot arm to the service position (page 6-11). Examine Examine the teat cup liners for dirt and damage. If necessary, replace the teat cup liners (page 7-29).
innovators in agriculture 7.8.2 Replace the Teat Cup Liners 7.8.2.1 Replace the nylon Teat Cup Liners Special Tools • Teat cup liner installation tool (1, fig. 41, page 7-28) Preparation Take the milking robot out of operation with the X-link (page 6-1). Move the robot arm to the service position (page 6-11).
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innovators in agriculture Rub the lower part of the teat cup liner and the teat cup sleeve in with soapy water. Do not turn the installation tool when you push the teat cup liner in the teat CAUTION cup sleeve. (1, fig.
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innovators in agriculture Figure 43. Insert the new teat cup liner in the teat cup sleeve Figure 44. Install the teat cup liner in the teat cup sleeve Maintenance 7-31...
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innovators in agriculture 7.8.2.2 Replace the rubber Teat Cup Liners Special Tools • Hose scissors Preparation Take the milking robot out of operation with the X-link (page 6-1). Move the robot arm to the service position (page 6-11). Select: • Tab [Test] •...
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innovators in agriculture Pull the appendix (page 7-36) until the lock ring engages correctly in the bottom of the teat cup shell (fig. 48, page 7-35). Make sure the teat cup liner is not twisted in the teat cup shell. 10.
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innovators in agriculture Figure 46. Install the rubber teat cup liner in the teat cup shell Figure 47. Align a rubber teat cup liner 7-34 Maintenance...
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innovators in agriculture Figure 48. Make sure the lock ring engages correctly Figure 49. Hose scissors Maintenance 7-35...
innovators in agriculture Figure 50. Pull the appendix Milk Transport System 7.9.1 Examine the Twin Tubes Preparation Take the milking robot out of operation with the X-link (page 6-1). Move the robot arm to the service position (page 6-11). Select: •...
innovators in agriculture Examine Examine the twin tubes for damage. If necessary, shorten the twin tubes or replace the twin tube. Move the robot arm to 'Service-4' position (page 6-11). Put a finger in the teat cup and hold the teat cup in a position similar to the milking position.
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innovators in agriculture Use the clamp pliers (1, fig. 51, page 7-39) to release the clamp (2) on the applicable twin tube. Disconnect the twin tube from the teat cup. Use the hose scissors (3, fig. 52, page 7-39) to cut off the damaged part (2) of the twin tube.
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innovators in agriculture Figure 51. Release the clamp from the twin tube Figure 52. Cut off the damaged part of the twin tube Maintenance 7-39...
innovators in agriculture Figure 53. Make an incision in the twin tube 7.9.3 Replace the Filter Element of the Single Filter 7.9.3.1 Replace the Filter Element of the Single Filter On the X-Link, select: • Button to open the quick launch buttons bar. •...
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innovators in agriculture 13. Slide the filter sock and the spring in the filter housing until approximately 15 cm (5.90 in) of the filter sock is outside the filter housing. 14. Hold the filter housing in position below the milkline and push the filter sock fully into the tapered part of the milkline.
innovators in agriculture Figure 54. Replace the milk filter 7.9.4 Replace the Filter Element of the Twin Filter On the CRS+, push button Push [ENTER]. Hold the filter housing and remove the cap. Remove the filter housing. Remove the filter sock and the spring from the filter housing. Examine the filter sock for flakes that indicate mastitis in the herd.
The Astri-products are a chemical hazard. Always wear protective WARNING gloves when you do work on the Astri-products. Do NOT use chlorine products in the cleaning system. Lely Industries WARNING N.V. is not liable for, and does not cover under warranty, any damage or harm due to the use of other cleaning products than Astri-products in the cleaning system.
innovators in agriculture Confirm Make sure the following Astri-products are available: • Astri-Lin • Astri-Cid • Astri-L • Astri-UC (optional). If these Astri-products are not (all) available and in use, write it down on the visit report. Make sure there is sufficient Astri fluid in the containers. If necessary, replace the containers with a full one when the level is too low.
innovators in agriculture 7.10.4 Replace the Cleaning Brushes Preparation Take the milking robot out of operation with the X-link (page 6-1). Move the robot arm to the service position (page 6-11). Removal Select: • Tab [Test] • [Test menu] • [Mothership] •...
innovators in agriculture Figure 55. Replace the cleaning brushes 7.11 Support Systems 7.11.1 Examine the Air Compressor and the Air Dryer You must obey local rules and standards. For certain countries a yearly report Note: of the pressure vessel must be made. Examine Select: •...
innovators in agriculture 7.11.3 Clean the Exterior of the Vacuum Pump Preparation Block the cow traffic to the milking robot before you do this WARNING procedure. During operation the temperature of the surface of the vacuum pump may be CAUTION more than 70 ºC (158 ºF).
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innovators in agriculture Figure 56. The vacuum switch Figure 57. The light switch 7-48 Maintenance...
innovators in agriculture 7.12 Control Systems 7.12.1 Examine the Attention Alarms Examine Examine the attention alarms on the X-Link, T4C or the CRS+ as follows: • On the X-Link, select Tab [Indications]. • Push button [Refresh]. • On the T4C system, refer to the T4C manual. •...
innovators in agriculture 7.12.3 Examine the Robot Performance List In the T4C software: In the navigation bar, select 'Analysis/Reports' and 'Reports'. Double-click on Milking - Robot Performance. Icon [ ] displays a graph, icon [ ] displays a report. The graph or report opens in a new window.
8. TEST AND ADJUSTMENT This chapter contains the preventive test and adjustment procedures for the ASTRONAUT A3 Next Milking Robot. The procedures are based on the maintenance schedule (farmer) as shown in the chapter Maintenance. Covers and Doors There are no test and adjustment procedures for the covers and doors.
innovators in agriculture Reset the scales to zero. Remove the bucket. Go into the box via the exit gate. Put the feed from the feed bin in the bucket. Go out of the box via the exit gate. 10. Put the bucket with the feed on the scales. 11.
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innovators in agriculture In the field Tilt cups, select: • LF [Loose] • LR [Loose] • RF [Loose] • RR [Loose]. Untie the knot (1, fig. 58, page 8-4) of the cup cord at the mothership side. Remove the two Allen screws and centering piece (4, fig.
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innovators in agriculture Figure 58. Untie the cord Figure 59. Measure the cord length Test and Adjustment...
innovators in agriculture Figure 60. Mark the cord Figure 61. Tie the cord just behind the mark Milking System There are no test and adjustment procedures for the milking system. Test and Adjustment...
innovators in agriculture Milk Transport System 8.6.1 Manually add a Cow for Calving Refer to the T4C Operator Manual Note: In the navigation bar, select 'Data Entry' and 'Daily entry'. From the action list, select 'Calving'. Enter the cow's number in the field 'Select Cow(s)'. Select button [Select].
innovators in agriculture Figure 62. Add a calf 8.6.2 Manually add a Cow for Dry Off Refer to the T4C Operator Manual Note: In the navigation bar, select 'Data Entry' and 'Daily entry'. From the action list, select 'Dry Off'. Enter the cow's number in the field 'Select Cow(s)'.
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innovators in agriculture Complete the form. • The dry off date and time filled in is the expected date. Change the date and time if necessary. • If the medicine is not on the list, select the link 'Add Medicine' to add it.
innovators in agriculture 8.6.3 Manually add the Milk Separation of a Cow Refer to the T4C Operator Manual Note: Make sure to follow the procedure: CAUTION 1. Complete this form. 2. Do the treatment. 3. In case of a milk separation, make sure the milk separation is confirmed by the milking robot.
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innovators in agriculture Figure 64. Transfer window for milk separation 8-10 Test and Adjustment...
innovators in agriculture Cleaning Systems 8.7.1 Test the Spray Beam of the Teat Disinfection Nozzle Test Select: • Tab [Test] • [Test menu] • [Mothership] • [Other] • Disinfection nozzle [On]. Make sure the spray beam (1, fig. 65, page 8-11) is cone-shaped and provides a full spray pattern.
innovators in agriculture In the field Brush cleaning select [Off]. If necessary, clean the disinfection nozzle or replace the disinfection nozzle. 8.7.3 Measure the Concentration of Astri-L Measure Select: • Tab [Test] • [Cleaning] • [Pre treatment]. In the field Brush cleaning, select [On]. Put a large cup below the roller rinse sprayer and collect almost half a cup of Astri-L water.
innovators in agriculture Figure 66. Install the min/max thermometer 8.7.5 Adjust the Astri-Cid:Astri-Lin Ratio Adjust On the CRS+, select Main Menu > Settings > Cleaning system Cluster cleaning Ratio Astri-Cid:Astri-Lin. settings > > Use the arrow up and arrow down buttons to adjust the value. Press [Enter].
innovators in agriculture Alarm System 8.8.1 Set the CRS+ to generate an Alarm or Phone Call On the CRS+: Select: • Main Menu > Settings > Alarm system settings > Detailed settings per alarm Scroll to the alarm you want to change with the arrow keys. Push [enter].
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innovators in agriculture Figure 67. Push the test button Figure 68. Reset the save-life switch Test and Adjustment 8-15...
• An authorized electrician must test the earthing of the electrical installation of the barn (the milking robot included) and supply an official report that is given to the Lely service provider. • Earthing of the milking robot(s) must comply with current earthing regulations for barns.
Make sure the brushes are turning during brush cleaning. If the brushes are not turning, remove dirt and hair. If the brushes are still not turning, call your local Lely service provider. Make sure cleaning liquid is sprayed on the brushes during brush cleaning.
Make sure the power supply is ON (page 7-4). Make sure the circuit breakers are ON (page 7-4). If the problem remains, call your local Lely service provider. Alarm System does not generate a Phone Call during the Night Make sure the telephone system is functioning correctly.
Robot Arm falls down Make sure the compressor functions correctly. If the problem remains, call your local Lely service provider. 9.10 Robot Arm does not Connect Make sure the sTDS is clean (page 7-27). Make sure the udder is shaven.
innovators in agriculture 10.3 MQC-C Process Flow The following table shows the shapes used in the flowcharts and their meaning. Shape Meaning Start or End This symbol represents the start and the end of a flow in a flowchart. Decision This symbol represents a decision to be made.
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innovators in agriculture The targets of the references mentioned in the flowchart are not included in Note: this manual but can be found in the Installation and Maintenance Manual. 10-10 Diagrams...
MQC: Milk Quality Control Astri-UC: chemical for disinfecting the teats MQC-C: to measure the class of the somatic cell count of the milk per cow per quarter Astronaut: Lely ASTRONAUT A3 Next Milking Robot PC: Personal Computer cm: centimeter PCB: Printed Circuit Board...
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innovators in agriculture yd: yard (36 inches) Glossary of Terms...
innovators in agriculture INDEX feeding system clean the feeding system.....7-14 dosing unit..........4-4 extra feed ........6-8, 6-13 feed hoppers.........4-4 alarms feed through.........4-4 display history ........6-17 list active alarms........6-17 astri............4-12 identification ..........4-18 availability ...........7-43 cleaning products .......4-12 attention list milk filter examine ..........7-49 replace the filter element ( ....7-42 mqc-c attention list ......6-19...
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