Fullwood Packo FullClean Plus Instructions For Use Manual
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Fullwood Packo FullClean Plus Instructions For Use Manual

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Fullwood Packo FullClean Plus
Instructions for Use
Document Number:
Revision Number:
Date of Issue:
006614
D
14/08/2020

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Summary of Contents for Fullwood Packo FullClean Plus

  • Page 1 Fullwood Packo FullClean Plus Instructions for Use Document Number: 006614 Revision Number: Date of Issue: 14/08/2020...
  • Page 2 Fullwood Packo reserves the right to make changes to the manual at any time and without prior notice.
  • Page 3 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Revision Control Revision Date Details of Change 04/2011 Pages 31 09/2011 Pages 45, Writer: GIK. Completely revised. Removed references to the Fusion UPS, since this is no longer an option; there is now a lithium back-up battery on the PCB itself.

  • Page 4: Table Of Contents

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Contents Introduction ......................5 Scope ......................... 5 Glossary ......................5 Icons Used in this Manual ................... 6 Safety ......................... 7 General and Features ..................9 6.1. FullClean Plus Feature Listing ................9 6.2.
  • Page 5 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 8.2.5. LEDs ......................... 15 8.2.6. Important ICs ....................16 Hardware Installation and Wiring ..............16 9.1. General Installation Information ................ 16 9.2. Relay Contact Protection .................. 17 9.3. Circulation Cleaning Installation ................ 18 9.4.
  • Page 6 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Table 4 Available User Settings ..................31 Table 5 FullClean 1.04 GB/CZ/P Heat Based Cleaning System ........40 Table 6 Heat Based Cleaning System ................44 Table 7 Diagnostic Codes ....................55 Table 8 Service list ......................

  • Page 7: Introduction

    14/08/2020 Introduction Fullwood Packo thanks you for choosing one of our smart milking and cooling solutions. The farmer and their herd are at the heart of everything we do. That is why we are constantly pushing the boundaries of what is possible, to deliver cutting-edge technologies that will significantly improve the lives of our farmers, health of their herds and provide maximum safety and efficiency on farm.

  • Page 8: Icons Used In This Manual

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Acronym / Abbreviation Definition or Term Random Access Memory Real Clock Time Transient Voltage Suppressor United Kingdom Volts Voltage Dependent Resistor Ω Icons Used in this Manual A number of icons are used in this manual, to draw your attention to, for example, safety information.

  • Page 9: Safety

    It is the responsibility of the farmer to check his animals and the performance of the equipment. If, for any reason, the Fullwood Packo FullClean Plus system is not operational or individual animals refuse to use the system, it is the responsibility of the farmer to feed and milk the animals with alternative methods •...
  • Page 10 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 • False or incorrect operation of the system may seriously affect the animals. It is therefore necessary to double check all input and output of the system • The manufacturers guarantee does not cover damage that has been caused by incorrect installation, incorrect usage, improper treatment, inadequate cleaning and servicing or wrong input.

  • Page 11: General And Features

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 General and Features The FullClean Plus cleaning controller is a micro-processor-based system which is able to control all kind of washing systems for milking equipment, such as Circulation cleaning, Boiling water cleaning and Closed-circuit washing.

  • Page 12: The Fullclean Plus Operational Modes

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 115/230 V AC • Features related to the software: Adjustable times for each cleaning phase Automatic selection of chemicals for pre-determined wash cycle Manually step through the cleaning cycle to check the cleaning process...

  • Page 13: Firmware Versions

    This firmware version was developed for the UK FC+ Closed Circuit Washing system, the software programs output assignments covered in this manual. For information about a FullClean Plus controller with this firmware, contact Fullwood Packo Ltd. Page 11 of 58...

  • Page 14: Hardware Description

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Hardware description This section gives a description of the hardware of the FullClean Plus. 8.1. The User Interface The FullClean Plus controller cabinet is divided into two interconnected sections. The top section with the blue front label, houses the user interface of the controller. It has five keys, five indication LEDs and an LCD display.

  • Page 15: The Fullclean Plus Circuit Board

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 8.2. The FullClean Plus Circuit Board Figure 2 The FullClean Plus Main PCB with its Main Components The following components are located on the FullClean Plus PCB: 8.2.1. Connectors 8.2.1.1.

  • Page 16: X5) Expansion

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 8.2.1.5. (X5) Expansion 20-terminal ribbon cable connector used to connect optional 4-IN/OUT board. Four holes in the FullClean Plus PCB can be used to mount the 4-IN/OUT board. In that case an extra extension ring must be mounted between the top lid and the back part of the enclosure.

  • Page 17: X19) Mains (Not Applicable For 24 V Powered Models!)

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 8.2.1.11. (X19) Mains (not applicable for 24 V powered models!) 3-terminal connector for a 115/230 V AC mains power supply. The middle terminal of this connector can be used to connect an earth wire, but the terminal itself it is not connected to anything on the PCB.

  • Page 18: Important Ics

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 8.2.6. Important ICs U203: This is the EPROM of the controller, containing the firmware (built-in software). Hardware Installation and Wiring 9.1. General Installation Information This section gives all information to install the FullClean Plus controller and all its wirings to peripheral equipment.

  • Page 19: Relay Contact Protection

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 • The FullClean Plus controller can be powered by 115/230 V AC or 24 V AC/DC, depending on the PCB • The outputs of the FullClean Plus controller that control high power devices like...

  • Page 20: Circulation Cleaning Installation

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 NOTE Not protecting the relay contacts can shorten relay contact life and can have an effect on the performance of the FullClean Plus in certain conditions. When using ac valves, diodes cannot be used for relay contact protection.

  • Page 21: Boiling Water Cleaning Installation

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Figure 6 Circulation Cleaning System Wiring Schedule 9.4. Boiling Water Cleaning Installation Figure 7 shows a flow diagram of the Boiling Water Cleaning system. The principle of this cleaning system is to wash the milking equipment with boiling water which flows through the system only once.

  • Page 22: Figure 7 Boiling Water Cleaning System Flow Diagram

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Figure 7 Boiling Water Cleaning System Flow Diagram Page 20 of 58...

  • Page 23: Closed Water-Circuit Cleaning Installation

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Figure 8 Boiling Water Cleaning System Wiring Schedule 9.5. Closed Water-Circuit Cleaning Installation Figure 9 shows a flow diagram of the Closed-Circuit Washing system. The principle of this cleaning system is similar to Circulation Cleaning, but in this situation no open wash trough is used.

  • Page 24: Figure 9 Closed Circuit Washing System Flow Diagram

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Figure 9 Closed Circuit Washing System Flow Diagram Page 22 of 58...

  • Page 25: Figure 10 Closed Circuit Washing System Wiring Schedule

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Figure 10 Closed Circuit Washing System Wiring Schedule Page 23 of 58...

  • Page 26: 10. User Operation

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 10. User Operation This section explains all the user aspects of the FullClean Plus controller and provides detailed information about all operation modes. 10.1. The Operation Modes Table 3 displays the different operation modes of the FullClean Plus controller.

  • Page 27: Standby Mode

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 10.1.1. Standby Mode Figure 12 Display & LEDs in Standby Mode When a FullClean Plus controller is powered up, the alarm output is active for two seconds before entering the Standby Mode. In Standby Mode the controller by default does not read any input or activates any device.

  • Page 28: Milk Mode

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 10.1.2. Milk Mode Press to activate the Milking Mode. If this mode is activated, the controller switches on all equipment for milking like vacuum pump, milk pump, Milk Meters, automatic cluster removers etc.

  • Page 29: Errors

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Figure 15 Display & LEDs during the Cleaning Mode In the Automatic Cleaning Mode following keys can be used: • – Stop cleaning immediately and go to “Standby Mode” •...

  • Page 30: Manual Clean Mode

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 • Press “+” (cleaning) to continue with the beginning of the cleaning phase it was at the start of the error • Press escape to cancel the alarm and the blinking LEDs notification and return to...

  • Page 31: Info Mode

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Available options are (number of items depending on the type of cleaning system as set in the adjust mode): • Drain and Dry • Disinfection • Pre-rinse • Hot wash •...

  • Page 32: Figure 19 Display & Leds During The Manual Cleaning Mode

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Figure 19 Display & LEDs during the Manual Cleaning Mode The following keys can be used in Info Mode: • – Stop Info Mode and go to Standby Mode •...

  • Page 33: User Setting Mode

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 10.1.6. User Setting Mode to enter “User setting Mode”. Press Figure 20 Display & LEDs during the User Setting Mode This mode can be used by the farmer to make a number of user settings. Table 4 shows all available user settings.
  • Page 34 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 • – Decrease hour/month year value displayed setting • – Return to Standby Mode without saving setting • – Save setting and go to next parameter The FullClean Plus controller has a battery backed up memory, which means that all user and engineer settings will be kept in memory when a power failure occurs.

  • Page 35: 11. User Trouble Shooting

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 11. User Trouble Shooting This section gives an overview of possible error messages and the way the operator can solve the problem. These error messages are displayed when an error occurs during milking or cleaning.

  • Page 36: 12. Technical Operation

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 • Display 'ERR: Chemical II level': See previous item, but accounts for Chemical II • Display 'ERR: Chemical III level': See previous item, but accounts for Chemical III • Display 'ERR: Low vessel level':...

  • Page 37: How To Enter Adjust Mode

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 12.1.1. How to Enter Adjust Mode To let the FullClean Plus controller enter the Adjust Mode, the controller must be powered up with only Function-switch 8 set to “on”, see Figure 21. The address switch can be left unchanged at address 1.

  • Page 38: Handling Main Menu Items

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Simplified Menu Structure; Main Menu “General” shown with Sub Menu Figure 22 and Parameter Items Extended 12.1.3. Handling Main Menu Items Figure 23 Main Menu The Adjust Mode is build up as a menu structure where the keys on the terminal are used to scroll through the menus, to enter the submenus and to set the desired values.
  • Page 39 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 NOTE The number of available main menu items depend on the cleaning system as set in “general” > “cleaning system”. If no cleaning system (“none” = factory default) has been set, only the main menu item “general” is available.

  • Page 40: Handling Sub Menu Items

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 • Drain & dry • Options • Hot water reservoir • Hardware input assignments • Hardware valves • Hardware equipment 12.1.4. Handling Sub Menu Items If a Sub Menu is selected (by pressing “ENTER”) the terminal shows:...
  • Page 41 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Some remarks related to the complete menu structure: • When a certain cleaning system is loaded by choosing 'General' - 'Cleaning system' then all default values for this system are loaded from memory. This procedure can also be used to set all default values of a certain system •...

  • Page 42: Options And Settings Of The Heat Based Cleaning System

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 12.1.5. Options and Settings of the Heat Based Cleaning System The following tables detail the options and settings of the Heat Based Cleaning System. Table 5 FullClean 1.04 GB/CZ/P Heat Based Cleaning System...
  • Page 43 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Main Menu Sub Menu items Range Default User item Air inj. start delay mm:ss 0:00-10:00 0:25 Air inj. on-time mm:ss 0:00-10:00 0:07 Air inj. off-time mm:ss 0:00-10:00 0:13 Pulsator start delay...
  • Page 44 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Main Menu Sub Menu items Range Default User item Chemical II level X Y X= input # (0-64); Y: 0 Neither Neither, On-board, 4- IN/OUT, 16-IN Hardware Chemical III level X Y X= input # (0-64);...
  • Page 45 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Main Menu Sub Menu items Range Default User item Hardware Drink trough outlet X Y X= output # (0-64); Y: 0 Neither valves Neither, On-board, 4- (continued) IN/OUT, 16-OUT Compressed air X Y X= output # (0-64);...

  • Page 46: Table 6 Heat Based Cleaning System

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Table 6 Heat Based Cleaning System Full Clean Plus Milk Pre-rinse Hot Wash D&D Boiling Water 1.04 Cold water Hot water Recup. Inlet Hot recup. Inlet Air Inlet Chemical 1...

  • Page 47: Options And Settings Of The Circulation Based Cleaning System

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 12.1.6. Options and Settings of the Circulation Based Cleaning System The following tables detail the options and settings of the Circulation Based Cleaning System. Main Menu Sub Menu items Range...
  • Page 48 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Main Menu Sub Menu items Range Default User item Water inlet Cold & hot water, Water Cold & storage, Hot water hot water storage, None, Cold water, Hot water. Cold water fill time...
  • Page 49 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Main Menu Sub Menu items Range Default User item Circulation #2 time mm:ss 0:00-59:59 7:00 Drain time mm:ss 0:00-59:59 2:00 Milk pump start delay mm:ss 0:00-10:00 0:00 Milk pump on-time...
  • Page 50 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Main Menu Sub Menu items Range Default User item Water outlet Water spray unit, Water Water storage, Drinking trough, spray Waste. unit Drain time mm:ss 0:00-59:59 2:00 Milk Meter start delay...
  • Page 51 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Main Menu Sub Menu items Range Default User item Milk Meter on-time mm:ss 0:00-10:00 0:25 Milk Meter off-time mm:ss 0:00-10:00 2:30 ACR start delay mm:ss 0:00-10:00 0:00 ACR on-time mm:ss 0:00-10:00...
  • Page 52 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Main Menu Sub Menu items Range Default User item Wash trough lo level X Y X= input # (0-64); Y: 2 Neither Neither, On-board, 4- IN/OUT, 16-IN Wash trough hi level X Y X= input # (0-64);...
  • Page 53 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Main Menu Sub Menu items Range Default User item Hot water inlet X Y X= output # (0-64); Y: 3 On- Neither, On-board, 4- board IN/OUT, 16-OUT Water recup. Inlet X Y X= output # (0-64);...
  • Page 54 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Main Menu Sub Menu items Range Default User item A.C.R. X Y X= output # (0-64); Y: 0 Neither Neither, On-board, 4- IN/OUT, 16-OUT Pulsators X Y X= output # (0-64); Y:...
  • Page 55 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Wash program: Circulation 1.04 1. Fill wash trough 2. Draining Parlour 3. Dry Installation 4. Draining Vessel 5. Empty D-line 1. Fill wash trough 2. Draining Parlour 3. Dry Installation 4.
  • Page 56 Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 Wash program: Circulation 1.04 1. Fill wash trough 2. Draining Parlour 3. Dry Installation 4. Draining Vessel 5. Empty D-line 1. Draining Parlour 2. Dry Installation 3. Draining Vessel 4. Empty D-line...

  • Page 57: Internal Diagnostics

    Doc No: 006614 Fullwood Packo FullClean Plus Revision: Date: 14/08/2020 12.2. Internal Diagnostics The Fullclean Plus has a build-in Diagnostics Mode. It makes testing of the inputs and the outputs of the Fullclean Plus possible. To enter the Internal Diagnostics Mode: Switch OFF the power.

  • Page 58: 13. Technical Trouble Shooting

    Check alignment of cylinders and operating cams on valves and movement Change dosing tubes – taking precautions and avoiding mixing Weekly Drain water from compressor tank Thank you for choosing Fullwood Packo. Fullwood Packo, Grange Road, Ellesmere, Shropshire SY12 9DF. United Kingdom. fullwoodpacko.com Page 56 of 58...

  • Page 59: 14. Disclaimers

    Contents of this Manual: Fullwood Packo takes pride in the accuracy of information given in this manual, but due to nature of hardware and software developments, be aware that specifications and features of this product can change without notice. The information contained within this manual is correct at the date of publication only.

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