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The Fullwood Merlin (MK4) User Manual

Technical Manual 006924 Revision A

ORIGINAL MANUAL

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Contents

The Fullwood Merlin (MK4) User Manual ................................................ 1

ORIGINAL MANUAL ................................................................................. 1

Contents ................................................................................................... 2

Important information - read this first .................................................... 6

Icons ......................................................................................................... 7

1. Introduction ................................................................................... 7

2. Revision Control ........................................................................... 7

3. Overview of Manual Content ........................................................ 7

4. General Description of Machine .................................................. 8

5. Safety Precautions ................................................................ 8

5.1 Areas of the Fullwood Merlin .............................................................................. 9 5.1.1 FRONT VIEW OF FULLWOOD MERLIN .................................................................. 9 5.1.2 REAR VIEW OF FULLWOOD MERLIN .................................................................. 10

5.2 Function of Equipment ...................................................................................... 11

5.3 Moving Parts .................................................................................................... 11

5.4 Safety/Warning Signs ....................................................................................... 12 5.4.1 General ................................................................................................................... 12 5.4.2 Laser Arm ............................................................................................................... 12 5.4.3 Chemicals/Chemical Storage .................................................................................. 13 5.4.4 Compressed Air ...................................................................................................... 14 5.4.5 Milk Pump ............................................................................................................... 15 5.4.6 Earth Bonding ......................................................................................................... 15 5.4.7 Hot Surfaces ........................................................................................................... 15 5.4.8 Electricity ................................................................................................................ 15 5.4.9 Trap Hazard ............................................................................................................ 16

6. Serial Number Identification ....................................................... 16

7. Cow Compatibility with Merlin ................................................... 17

7.1 Udder Shape Requirements ............................................................................. 18

7.2 Physical Size of Cows ...................................................................................... 18

8. Auto Identification ...................................................................... 19

8.1 Ear Transponder............................................................................................... 20 8.1.1 Best Cattle Tagging Practice .................................................................................. 20

8.2 Pedometers ...................................................................................................... 21 8.2.1 Removal of the Pedometer ..................................................................................... 22 8.2.2 Storage of Pedometers ........................................................................................... 22

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9. Introducing Animals to Merlin .................................................... 22

9.1 Preparation ....................................................................................................... 23

9.2 Introduction ....................................................................................................... 23

10. Quick set up guide to Crystal Program ..................................... 25

10.1 Navigate to and complete Base Page .............................................................. 26

10.1 Filling in the Concentrate Page ........................................................................ 27

10.1 Filling in the Milk Page ...................................................................................... 28

10.1 Filling the Quarter Page .................................................................................... 29

11. Operating Merlin from the Main Control Panel ......................... 30

11.1 Buttons on the Main Control Panel ................................................................... 30

11.2 Adding Cows .................................................................................................... 31

11.3 Pausing Merlin .................................................................................................. 31

11.4 Putting Merlin Off-line ....................................................................................... 32

11.5 Re-starting Merlin ............................................................................................. 32 11.5.1 Re-starting Merlin While Milking a Cow on Antibiotics ......................................... 32

11.6 Menu Options ................................................................................................... 33 11.6.1 Adjustments ........................................................................................................ 33 11.6.2 Robot Arm ........................................................................................................... 34 11.6.3 Test Arm ............................................................................................................. 35

12. Daily Schedule ............................................................................ 37

12.1 Manual Cleaning of Merlin ................................................................................ 38 12.1.1 Control Panel ...................................................................................................... 38 12.1.2 Holding Crate & Robotic Arm .............................................................................. 38 12.1.3 External Milking Equipment ................................................................................. 38 12.1.4 Parlour Floor ....................................................................................................... 38 12.1.5 Putting Merlin through a Manual Wash ................................................................ 38

12.2 Changing and Cleaning the Milk Filter .............................................................. 39

12.3 Cleaning the Laser ........................................................................................... 41 12.3.1 Removing Limescale ........................................................................................... 41

12.4 Cleaning Teat Roller Brushes ........................................................................... 42

12.5 Checking Vacuum Pump Oil Level (if applicable) ............................................. 44

12.6 Checking the Water Temperature .................................................................... 44

12.7 Checking All Chemical levels ........................................................................... 44

13. Milk Tank Daily Routine .............................................................. 45

13.1 Using Single Tank ............................................................................................ 45

13.2 At Milk Collection Times ................................................................................... 45

13.3 Buffer tanks ...................................................................................................... 45

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14. Weekly Routine ........................................................................... 46

15. Setting Merlin into Operation ..................................................... 47

16. Starting Milking for the 1st Time ................................................. 48

17. Arm Control ................................................................................. 50

17.1 Function of the Keys ......................................................................................... 50

17.2 Cleaning Laser ................................................................................................. 51

18. Merlin Plant Cleaning .................................................................. 51

18.1 Setting ABW Cleaning Times ........................................................................... 51

18.1 Backflush .......................................................................................................... 52

18.1 Cleaning Chemicals .......................................................................................... 52 18.1.1 Changing Chemicals ........................................................................................... 53

19. Calibrating Feeders .................................................................... 53

20. Alarms and Error Message Codes ............................................. 55

20.1 Display Format ................................................................................................. 55

20.2 Alarms Explained.............................................................................................. 56

20.3 Machine Stop and Manual E-Stop Explained ................................................... 56

20.4 Clearing Alarm History ...................................................................................... 57

20.5 Message Codes ............................................................................................... 57

20.6 Alarm While Milking .......................................................................................... 59

21. Milk Sampling .............................................................................. 59

21.1 Setting Cows for Sampling in Crystal ............................................................... 59

21.2 Milk Sampling Shuttle ....................................................................................... 61 21.2.1 Installation of shuttle into the Merlin .................................................................... 61 21.2.2 Settings in the Merlin display menu ..................................................................... 67 21.2.3 Operation of the sampler by the Merlin ................................................................ 67 21.2.4 When the sampler frame is full ............................................................................ 68 21.2.5 When sampling is finished ................................................................................... 69

21.3 Entering Shuttle Details into Merlin................................................................... 72

21.4 What to do when Frame is full .......................................................................... 72

21.5 Ending Sampling .............................................................................................. 72

21.6 Collecting Data from Crystal & Labeling Bottles ............................................... 72

22. Backup Crystal Software ............................................................ 73

23. Service Schedule ........................................................................ 74

24. Configurator Settings ................................................................. 76

24.1 Merlin User Settings ......................................................................................... 77

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24.2 Time Bar Settings ............................................................................................. 80

24.3 Adding Time Bars ............................................................................................. 81

24.4 Deleting Time Bars ........................................................................................... 82

25. Timer Program Settings ............................................................. 83

25.1 Crystal Timer .................................................................................................... 83

25.2 How to use the Timer ....................................................................................... 84

25.3 Overview Events List of the Timer .................................................................... 84

25.4 Overview of Automatic Tasks of the Timer ....................................................... 85

25.5 Add and Delete Events ..................................................................................... 86 25.5.1 Adding an Event .................................................................................................. 86 25.5.2 Deleting an Event ................................................................................................ 86

26. Frequently Asked Questions ...................................................... 87

26.1 Merlin ................................................................................................................ 87

26.2 Crystal (general) ............................................................................................... 89

26.3 Crystal (Feeding & Milking) .............................................................................. 91

27. Merlin General Information and Operating Parameters ........... 92

27.1 Mounting Dimensions, Space Requirements and Critical Building Dimensions 92

27.2 Recommended Ambient Conditions for the Different Parts of the Milking Machine ...................................................................................................................... 92

27.2.1 Merlin .................................................................................................................. 92 27.2.2 Pump Room ........................................................................................................ 92 27.2.3 Office/Computer Room ........................................................................................ 92

27.3 Minimum Electrical Power Supply and Earthing Requirements ........................ 92 27.3.1 Electrical ............................................................................................................. 92 27.3.2 Earthing............................................................................................................... 92

27.4 Minimum Water Supply and Drainage Requirements ....................................... 93

27.5 Nominal Working Pressure and Capacity of the Compressed Air System ........ 93

27.6 Effective Reserve, As Calculated and Measured ............................................. 93

28. Disclaimers .................................................................................. 94 Copyright © 2011, Fullwood Limited reserves the right to change the contents of this manual if necessary, without warning. Fullwood Limited has taken every precaution to avoid errors and omissions on the manual and equipment but does not accept any responsibility or liability for damage of any kind arising from the use of this manual or Fullwood equipment; whether this damage is direct or indirect. If you discover any inaccuracies please inform Fullwood Limited or one of its agents and we will make corrections for the next release.

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Important information - read this first

Before installing or operating the equipment, this manual and the appropriate operating instructions must be read carefully.

The equipment must be used only for the application described.

Installation of the equipment must be carried out by skilled and authorized technicians only.

Proper handling of the equipment is the basis for correct functioning.

Never remove any covers or parts off the system before the electrical power is disconnected and isolated.

Do not wash the electronic equipment with volume washers or high pressure hoses.

It is the responsibility of the farmer to check his animals and the performance of the equipment. If, for any reason, the system is not operational or individual animals refuse to use the system, it is the responsibility of the farmer to make alternative arrangements to feed and milk the animals.

Animals that need to be milked separately must be clearly identified, both in conventional milking systems and in establishments with AMS. Animals under antibiotic treatment must be marked with two red bands on their ankles before the first treatment. In establishments with AMS, these bands must be attached to the tail.

All livestock under treatment must be clearly identified throughout the whole withdrawal period. In computerized milking systems, treated cows must be registered before the treatment begins.

To avoid injury to animals and equipment, check there are no projections (pipes or anything similar) protruding in the parlour on which transponder neck bands or leg bands can get caught.

Calibration of milk meters/monitors and feed dispensers are of utmost importance in obtaining accurate milking and feeding results. If calibration is incorrect, or the wrong values have been programmed, milking results and feed distribution will remain adversely affected until calibration has been corrected.

The manufacturers guarantee does not cover direct or subsequent damage caused by incorrect installation, incorrect usage, improper treatment, inadequate cleaning or servicing, or incorrect software parameter inputs or hardware settings.

Incorrect operation of the milking or management system may seriously affect the animals in an adverse way. It is therefore necessary to double check all inputs and outputs of the system.

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Icons

Icons are used in this manual to draw the reader’s attention to specific information. These icons have the following meaning:

Failure to follow the instructions can result in severe injury to engineers, users, bystanders or livestock.

Indicates special precautions that must be taken to avoid damage to equipment.

Gives important information to prevent potential problems.

Gives advice or suggestions to make procedures easier or clearer.

1. Introduction

Thank you for choosing a Fullwood Merlin AMS. This manual is a guide to operating, functioning, maintenance and general running of your robotic milking machine. It should not be construed as making any claim or guarantee of performance. Please read this manual carefully and store them in a safe place.

2. Revision Control

Version

Date Pages Writer Checked by

0.01 06/10/2011 All J Tomlin J Tomlin

0.02 05/05/2012 All S Hughes S Hughes

A 23/12/2015 6, 38, 45 G Williams

3. Overview of Manual Content

A complete guide to all maintenance required on your plant, daily, weekly, monthly and all testing procedures for compliance with BS ISO 6690:2007 is also detailed within. All operational information is detailed in full with every aspect of the routine. The don’ts for all operator and animal welfare are also included in this manual and should be adhered to at all times without exception.

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4. General Description of Machine

The Fullwood Merlin is designed for use as a robotic milking machine for cows; any other use is strictly prohibited.

5. Safety Precautions

As when using any mechanical equipment, safety measures must be taken to avoid damage and injury to equipment, operators and livestock. Before operating Merlin, this manual and any other appropriate operating instructions have to be read carefully. Instructions given by the installing engineers must also be followed. Correct usage of the equipment is the basis for trouble-free system operation.

ENSURE THAT COW NECK STRAPS AND/OR PEDOMETERS CANNOT BECOME CAUGTH ON ANY STRUCTURES OR PROTUBERANCES.

NEVER REMOVE COVER(S) OR PARTS OF THE SYSTEM BEFORE THE ELECTRICAL POWER, COMPRESSED AIR AND WATER HAVE BEEN ISOLATED.

DO NOT FLUSH THE ELECTRONIC EQUIPMENT WITH (HIGH) PRESSURE WATER HOSES

INSTALLATION AND SERVICE OF THE EQUIPMENT MUST BE CARRIED OUT BY SKILLED AND AUTHORIZED TECHNICIANS ONLY.

NEVER USE OR ATTEMPT TO USE THIS EQUIPMENT IF YOU ARE NOT TRAINED OR PERMITTED TO DO SO.

ALWAYS KEEP HANDS, FINGERS AND LOOSE CLOTHING AWAY FROM MOVING PARTS OF THE PARLOUR

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MERLIN MUST NEVER BE OPERATED BY CHILDREN OR PERSONS UNFAMILIAR WITH THE OPERATIONS OF THE PARLOUR

MERLIN SHOULD NEVER BE OPERATED BY PERSONS UNDER THE INFLUENCE OF ALCOHOL.

ANY ABNORMAL NOISE OR MOVEMENT OF THE MERLIN SHOULD ONLY BE INVESTIGATED ONCE THE POWER IS TURNED OFF.

THE MERLIN MUST NOT BE MODIFIED WITHOUT CONSULTATION WITH SUPPLIER

5.1 Areas of the Fullwood Merlin

This section covers the areas of the Merlin, what is contained within the cabinet and functions of the key components.

5.1.1 FRONT VIEW OF FULLWOOD MERLIN

1

3

2

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No. Description Contents

1 Cabinet Main control panel and cabinet containing mains and low voltage electrical control equipment, compressed air control equipment, user interfaces. Mains electrical and compressed air isolators. Milk metering, receiving and milk pumping equipment.

2 Feeder Cabinet Dispensing feed

3 Robotic Arm Positioning device carrying teat preparation rollers, laser, teat cups, and teat spray

5.1.2 REAR VIEW OF FULLWOOD MERLIN

No. Description Contents

1 Entry Gate For cows entering Merlin

1 2

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2 Exit Gate Once milked the cows exit via this gate

5.2 Function of Equipment

MERLIN AND ITS ASSOCIATED EQUIPMENT MUST ONLY BE USED FOR THE PURPOSE OF MILKING DAIRY COWS

It is the responsibility of the user to check his animals and the performance of the equipment. If, for any reason, the Merlin system is not operational or individual animals refuse to use the system, it is the responsibility of the user to feed and milk the animals with alternative methods. Correct calibration of the milkmeter and the feed dispensers is necessary to obtain proper milking and feeding results. If for some reason calibration is wrong, or wrong values have been programmed, the milking results and feed distribution will be inaccurate. Cow health may be adversely affected. 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. Neither does it cover consequential losses resulting from above.

5.3 Moving Parts

Merlin is a fully automatic machine where commands to operate parts of the machine are generated by software. The moving parts are:

Entry and Exit gates

The cow follower

Teat cleaning rollers and its arm

The milking arm and it associated parts

The feeder assembly

Vacuum pump and motor

Milk pump and motor

Chemical dosing pumps The arm movement path from its standby position is indicated in the illustration below, along with the floor area boundary. Fullwood recommends that the owner of Merlin arrange to have this area marked. Qualified users must not enter zones around the machine without taking adequate precautions. Spectators must never enter the Merlin operating room unless under supervision of a qualified User.

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5.4 Safety/Warning Signs

Displayed on the Merlin are a series of warning signs, explained below are the signs & location on the Merlin.

5.4.1 General

Only use unsupervised if you are fully trained in all aspects of the Merlin’s working principals.

5.4.2 Laser Arm

Merlin Complies to - BS EN 60825-4:2006+A2:2011 The laser used on the Merlin is a class II; which should not damage the retina because the human blink reflex should be sufficient to provide protection.

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Measures must still be taken to avoid any undue risks to operators and livestock.

Never look directly into the laser emission aperture

This warning sign is displayed on the Merlin

laser housing; it denotes that a laser is present.

Details of laser, this label is situated on top of the mothership

Observe sign, NO guards should be removed

apart from by an approved Fullwood engineer; the Merlin’s power should be

isolated first.

5.4.3 Chemicals/Chemical Storage

DO NOT ENTER HARMFUL CHEMICALS

Chemicals should be stored in a cool, dark place. They should be kept dry and away from children and animals. They should be stored in the original container and must not be used after the expiry date as indicated on the label.

In case of accidental spillage, especially if in contact with the skin, they should be washed off immediately with plenty of cold water.

Most detergents contain caustic alkali and are, therefore, corrosive and cause burns. They should not be allowed to come into contact with aluminium. They must not be used for hand washing equipment.

Laser

Arm assembly with warning labels

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Storage drum openings should be kept tight to prevent dissipation of ingredients into the air, including teat dips and sprays.

Safety data sheets should be available on site.

The labels along with the manufacturer’s directions on the containers should be read properly by all staff.

Have an eye wash station located by the chemicals; any chemicals in the eyes should be flushed immediately for at least 15 minutes, followed by a doctor’s examination.

Any chemical detergent contacting the skin should be flushed immediately with water for 15 minutes. Remove any clothing that has been contaminated by chemical detergent and flush affected area. Obtain medical assistance at once.

Empty containers must be thoroughly rinsed and disposed of according to local environmental regulations.

5.4.4 Compressed Air

Compressed air can be highly dangerous or fatal if misused. All Users should be aware of risks involved. A compressed air supply must be treated with respect. It must never be used for cleaning purposes (blowing dust or swarf from clothing, skin, glassware or machinery) or for ventilation purposes. A jet of compressed air directed onto the body may introduce air into the bloodstream, produce blindness or other eye injuries or cause a burst eardrum. Advice on how to minimise the likelihood of more common problems is given in HS (G) 39 (revised) Compressed Air Safety, a booklet published by the health and safety Executive and available from HMSO bookshops. Also see, BS EN 1012-1:2010- Compressors and vacuum pumps. Fullwood Ltd supplies a range of compressors refer to the manual supplied.

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Note to employers - Introduce a system of maintenance for the pressure system and appoint a responsible person to ensure that it is carried out. Provide employees, including supervisors, with instruction and training about the hazards associated with the compressed air they are using.

5.4.5 Milk Pump

The milk pump should always be switched off and secured against accidental switch on when maintenance is being carried out.

5.4.6 Earth Bonding

All electrical circuits are earthed for safety.

Refers to all the points on Merlin that are earth bonded.

5.4.7 Hot Surfaces

Merlin Complies to - BS EN ISO 13732-1:2008 During a main wash (default 3 times per day), hot water will circulate around the Merlin, extreme care should be taken, as exposed areas of the stainless steel can get up to temperatures of 85°C

Warn operators of areas that may be dangerously hot.

5.4.8 Electricity

UNDER NO CIRCUMSTANCES MUST THE MAINS ISOLATOR BE BYPASSED TO ENABLE ANYONE TO ACCESS THE INSIDE OF THIS BOX WHILE THE CIRCUITS ARE LIVE

Denotes a risk of an electrical shock.

The above sign is placed on all boxes which contain mains equipment; USER MUST NOT

OPEN THESE BOXES.

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Depicted above are the mains isolators and where they are positioned on Merlin

5.4.9 Trap Hazard

The below warning label is on the cow side of the Fullwood Merlin;

Denotes Crush Hazard

6. Serial Number Identification

Each Merlin is identified with a unique serial and version number for traceability; the label is located within the main cabinet. The Serial Number Identification label the definition of each character is shown below

Mains isolator inside main

cabinet

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Fullwood Merlin Serial Number

Example: 1580LPS301BD

Sequence

Number

0000

Hand

L = Left Hand

R = Right Hand

Identification

P = Pedometer

T = Ear/Neck Tag

Crate Size

S = Standard

J = Jersey

Power

1 = 1 Phase

3 = 3 Phase

Crystalab

1 = Fitted

0 = Not Fitted

Fullquest 4QC

1 = Fitted

0 = Not Fitted

Month

A = January

B = February

C = March

D = April

E = May

F= June

G = July

H = August

J = September

K = October

L = November

M = December

Year

A = 2010

B = 2011

C = 2012

D = 2013

E = 2014

F= 2015

G = 2016

H = 2017

J = 2018

K = 2019

L = 2020

M = 2021

7. Cow Compatibility with Merlin

The size of the cow, and the condition and shape of her udder should be assessed for suitability prior to introduction.

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7.1 Udder Shape Requirements

THIS SECTION IS A GUIDE AND BY NO MEANS DEFINITIVE.

The udders should be free from excess dirt and hair, trimming of long udder/belly hair will be necessary.

The udder should be free from extra teats, bumps and swellings

Teat separation distance (A). The inner dimension between the teats must be:

front teats – minimum 12.5cm, maximum 30cm rear teats – minimum 3cm

Teat thickness (B):

minimum 1.5cm, maximum 3.5cm, Teat vertical alignment:

maximum 30o off the vertical

Teat Visibility (C):

Each pair of teats (front and rear) should be visible, without interruption, across a 3cm minimum width horizontal band.

Teat height (D): The end of any teat must be a minimum of 35cm above floor level.

Rear teat visibility (E):

Rear teat ends must be more than 3cm below the level of the lowest part of the udder.

Teat spacing – front to rear (F): Front teats should be at least 7cm before the rear teats

7.2 Physical Size of Cows

Stated below are the upper limits for the size of cow accepted by Merlin, if Merlin is intended to milk Jersey cows then it is necessary to use a modification kit.

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8. Auto Identification

Make sure that operators are properly trained and competent in the application of ear tags. Read Health & Safety Executive’s advice on the handling and housing of cattle.

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Fullwood have three options available for automatic identification;

Ear transponder

Pedometers

8.1 Ear Transponder

8.1.1 Best Cattle Tagging Practice

Ensure that the correct applicator for the model of tag is used and always follow the manufacturer’s instructions.

Fit in cool weather (where possible) to minimise infection.

Secure the cows head to prevent jerking while tagging.

Apply tags under hygienic conditions. The operator’s hands, the ear, the tag and the applicator should be clean. Disinfect as necessary using appropriate solution.

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.

The female part of the tag should always be on the inside of the ear, this will reduce the chance of the tag catching on objects. The male part of the tag should always enter from the back of the ear.

Check the ear after about 10 days for sign of damage or infection; consult your veterinary surgeon as necessary.

Store unused tags in a clean & dry container.

After attachment, check that the ear tag rotates freely.

All animals in the herd must carry the transponder in the same ear. Check with the installation engineer to see which ear is preferred. Record every transponder number against cow numbers - to enter onto the PC later. Example;

EAR TAG TRANSPONDER NUMBER

COW HERD NUMBER Herd Life Number - Ear Tag

1887 5339 77 UK FO 0140 01515

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Correct location for the ear transponder. It should be inserted in between the two main blood veins of the

ear, also half way into the ear from the outer edge.

8.2 Pedometers

Attach a pedometer to the front leg of every cow in the herd; all animals must carry the pedometer on the same leg, check with the installation engineer which leg is preferred. Record every transponder number against the cow numbers.

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The pedometer must rest on the ankle of the leg and ‘rotate’ freely. The strap should be fitted loosely. As a guide, an object the size of a finger should fit in-between the strap and the leg, as depicted below.

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. Re-attach with a new strap.

8.2.2 Storage of Pedometers

Incorrect storage of pedometers results in a reduced battery life, never store;

On their side

Upside down

Within 2 metres of an active antenna

Within 2 metres of a frequency controller device, e.g. a PC monitor

Near to a source of heat, e.g. radiator. Never blast pedometers with warm or hot water; this will have a negative effect on the function.

Incorrect Correct

9. Introducing Animals to Merlin

Moving to a new milking facility, whether conventional or robotic, can be stressful and disruptive to the performance of any herd of cows. Steps must be taken to accustom cows to the new facility and train personnel to use it correctly.

Ensure that the triangle is pointing upwards

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Where the change is from a conventional parlour to an automated system, the challenge is even greater. In addition to the potentially stressful period of training, for both cows and personnel, milking no longer occurs at predetermined times and regular intervals. Milking frequency depends on management strategies relating to housing and feeding together with their effects on the willingness of cows to visit the milking station.

9.1 Preparation

Users of automatic milking systems must not assume that they can just “leave everything to the robot”.

The herd should be inspected to identify cows with udder and/or teats that may be unsuitable for the automatic system.

In the case of late lactation cows, with potential udder and/or teat placement problems, and/or cows with high somatic cell counts or chronic mastitis, these cows must be dried-off as a method of minimising transition related problems.

The hair on the udders of the cows must be clipped or singed prior to the first visit to Merlin. This must be repeated at regular intervals, e.g. every 2 to 3 months.

The User/operator should receive introductory training on the use of the Crystal Management System. Particular attention should be given to standard reports which can aid basic understanding of the animal status during the start up period.

Up to date information for every cow in the herd must be entered into Crystal prior to introduction to the system.

Plan the introductory period over a number of manageable sessions. It is vital to try and reduce the stress to the cows caused by forcing them into unfamiliar situations.

Ideally, all cows should be walked into and through the milking station. Entry and Exit gates should be left open and the cows free to move around. This should be carried out for 2 – 3 days

For the next 3-4 days Merlin should be used as an out of parlour feed station, Feed should be used as an inducement to the cows.

If it is not possible to familiarise the cows with Merlin before the first milking, i.e. if the cows are moving to completely new premises and it is impractical to return to the old facility, it is more important than ever to proceed very gently and slowly on the first day of milking

9.2 Introduction

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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.

It may be necessary to encourage cows to enter the Merlin stall for the second and third milkings. After the third milking, the robot should be left to allow cows to attend voluntarily. By this time, it is usual for cows to visit the milking station, attracted to the possibility of feed being dispensed.

The remainder of the group should be introduced over the following days.

Following the initial introductory period, it is essential that the farm personnel ensure that cows attend the automatic milking station at regular intervals. This should be based on examination of reports indicating which cows are overdue for milking.

Check that cows are consuming their concentrate allocation – Fullwood Ltd declare that each cow should not be fed more than 8kgs of feed in any 24 hour period unless out of parlour feed stations are used in conjunction with The Fullwood Merlin.

In addition to the use of information and reports generated in Crystal, Merlin operators should also examine reports from milk buyers, herd recording organisation and other sources, e.g. milk quality reports, individual cow somatic cell counts. It is essential that, in the event of any adverse report, the causes are investigated immediately and appropriate action taken. Note:

THE MERLIN IS NOT A SUBSTITUTE FOR GOOD HUSBANDRY OR GOOD MANAGEMENT.

ALL NORMAL PREVENTATIVE MEASURES IN RESPECT OF MASTITIS CONTROL, COW HEALTH AND REPRODUCTION MUST BE MAINTAINED.

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10. Quick set up guide to Crystal Program

The Crystal program has the typical Windows on-line help facility. The following sections show the User how to enter the basic herd information required by Merlin before it can be commissioned. The following information is based on version 2.6 (To check your version click on Help>About). If this information is filled in, a cow can then be milked by the Merlin. Extra cow details may be added at a later date.

Above is the screen that Crystal automatically starts up in when you double click the Crystal icon. If you would like Crystal to start up on another screen go to System > Appearance and choose the screen that you would like crystal to start up on.

Choose preferred Crystal start up screen

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10.1 Navigate to and complete Base Page

To navigate to the base page, Animals>base.

The Base page is where all the basic cow information is stored and certain parameters have to be filled in so that an animal is recognised in Crystal.

The parameters in yellow have to be filled in otherwise Crystal will not accept the animal

4. I&R number is the herd book number, could put any unique number you like in here but this parameter has to be filled

3. Fill in Tag1 number, Tag type depends on the type of ID used in Merlin

5. Click Apply to save the changes 1. To add a new

animal press + button

2. Fill in the cow number (usually the freeze band number)

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10.1 Filling in the Concentrate Page

After the base page is completed, the Concentrate page can be filled in so that the cow can be fed when she enters the Merlin. Click on the concentrate tab.

2. Fill in the amount of feed that the cow will require in a

24 hour period – Max 8kg

4. Click Apply to save the changes

1. Check the enable box

3. Set the distribution algorithm should be set to

‘Merlin Feed’

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10.1 Filling in the Milk Page

The milk page has to be filled in, to enable the cow to be milked. Click on the Milk tab.

NOTE: Use the manual production rate to begin with, until Crystal has a 10 day history of the cow’s milk production and conductivity.

7. Click Apply to save changes

5. Set the Target Yield to 6.00kg, this can be raised for high yields

3. Check the Manual Production box

6. Normally set to Bulk (tank), but if cow on anti biaotics for example then this would be ‘Bucket’

4. Set the Manual Production rate to - 1.00kg/h

2. Choose the irregular milk Regime

1. Check the Milking enabled box

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10.1 Filling the Quarter Page

The quarter page must also be filled in. Click on the Quarter tab

2. Tick the quarters of the cow that are to be milked

1. Check the Quarter Enabled box

3. Choose the amount of time the rollers clean the teats before attachment begins, this is normally 2 unless the cow is very dirty

5. Click Apply to save the changes

4. Check the Disinfect so the cow will get teat sprayed after milking

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11. Operating Merlin from the Main Control Panel

11.1 Buttons on the Main Control Panel

ESC

Enter

Air Purge button (keep held in)

FEED - for manually releasing feed.

VAC PUMP - for manually turning on the vacuum pump.

PULSATION - for manually turning on pulsation.

RESET - Manually reset Merlin.

Merlin Status>Mode menu options

Menu Options Merlin’s Response

Pause Merlin will not milk any cows, but will wash if required

Off Line Merlin will not perform any operation

On Line Merlin normal mode - milk cows and system wash, automatically

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11.2 Adding Cows

Upon entering the Merlin, the cow is identified. Following identification, the cow's number appears on the LCD. If ‘????’ appears then the cow data has been incorrectly entered into the database, the cow is not identified and is released. However if a cow enters Merlin with no form of identification then the cow will be held in the crate for three minutes (user defined time) and the LCD will display ‘Identifying cow’ and after user defined time will say ‘releasing cow’ In the event the cow’s number is not displayed, enter its number manually:

1. Press ESC to get to the correct menu.

2. Go to Display status menu

3. Press to Cow Number

4. Manually enter cow number using

number keys

5. press Enter to confirm

11.3 Pausing Merlin

For safety, Merlin must be put into Pause or off line before any work is carried out. In Pause, Merlin will still carry out the preset main wash or washes.

6. Press ESC ESC to get to

the correct menu.

7. Go to Merlin status and

press Enter

8. Press to go to Mode:

9. Press to toggle the mode.

10. Press Enter to accept

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11.4 Putting Merlin Off-line

1. Press ESC ESC to get to

the correct menu. 2. Go to Merlin status and

press Enter

3. Press to go to Mode

4. Press to toggle the mode.


11.5 Re-starting Merlin

Unless there has been a major problem, Merlin should not need to be turned off, then back on. If an alarm has occurred, refer to section on Alarms & Error Codes. If the emergency stop button has been used to stop Merlin, then the restarting procedure is:

1. Check the cause of the emergency has been resolved

2. Twist the emergency stop button to unlatch it

3. Press the reset button on the control panel and then Merlin should restart. If the above procedure is unsuccessful then Merlin will need to be restarted. The easiest way to restart Merlin is to turn everything off at the isolator switch and then follow the start-up procedure outlined in section 16.

11.5.1 Re-starting Merlin While Milking a Cow on Antibiotics

If Merlin needs to be re-started while milking a cow on antibiotics the operator must ensure that the milk is diverted to drain, this is achieved as follows;

Set Merlin into pause mode, (see 12.3)

Perform a manual wash, (see 13.1.5)

Set Merlin to Online, (see 16)

Start Milking

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11.6 Menu Options

11.6.1 Adjustments

Milking

Cleaning height Determines how much of the teat is to be cleaned. Value is the distance lower that the arm has to be in for cleaning the teats. Height range is +50 to -50 mm

under tip height

in mm -25

Pulsetime teat spray The teat spray is pulsed; this value determines how quickly it pulses. 0-100% in percent: 50

No removal if milk pulse If a pulse of milk passes the sensor, it will not be taken off the cow. Not used. Set to zero. count more than 0

Time in which milk Time taken for a milk pulse to pass the sensor before deciding the milk flow has ended. Time range is 0-60 seconds pulses are

Measured 16 secs

Take off delay after closing clamp valve

20 Delay time from the closing of the clamp valve to the operation of the ACR cylinder. Time range is 1.0 to 10.0 seconds

Arm Type New This selects if the mothership has the retractable tube system (YES) or the non-retractable type (NO).

Release shell height 40 Number of vertical positions below the teat tip for the release of the ACR cylinder. Range 0 to 70.

Drain hose attempts 2 Number of sweep cycles performed after teat cup removal. Range 0-10. SET TO ‘0’ IF CRYSTALAB IS FITTED

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11.6.2 Robot Arm

Used by an Engineer to alter the height and angle of the arm; the height and angle for the rollers and the home position of the mothership. The first four parameters are to enable the liners to align with the cleaning cups. The home position defines the position of the mothership central to the crate. The adjustment of height of rollers should be 100 mm lower than the cleaning cups.

Robot Arm

Adjustment of height of Cleaning cups:

Adjust the height of the liners into the cleaning cups for cleaning. Range 300 to 690mm

Height= 670

Adjustment height of Cleaning tops: Usually set 20 points below the previous screen. Range

300 to 690mm Height= 650

Adjustment of angle for cleaning cups

Adjust the angle of the arm so the liners are straight inside the cleaning cups. Range +192 -89. Practical adjustment +-60

x angle = 0

Clean Laser water 20 Time for operation of water spray onto the laser screen. Range 0.1 to 10.0 seconds

Clean Laser air 20 Time for operation of air spray onto the laser screen. Range 0.1 to 10.0 seconds

Extra Y offset Search teats

0 Range 0 to 100 positions.

Extra Z offset search teats

0 Range 0 to 50 positions.

Home position Defines the position of the mothership central to the crate. Only to be changed by a qualified engineer. Mothership

Home position 0

ADC = 0 Angle= 0

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11.6.3 Test Arm

The Test arm menu is used to test the laser and the ancillaries on the arm.

Test Arm

Test position system? Yes Yes / No Select Yes and Enter

Reset switch: On The stop sensor on the carriage.

Fault step motor: Off Carriage motor

Pressure switch Off The over pressure switch on the Slina

Measure ultrasound The distance measured from the ultrasound to the cow following plate. Keep the same as shown. This is adjusted by moving the ultrasound sensor using the locking nuts.

distance 185

Height settings fast? Yes / No Set to Yes. Alters the speed that the arm travels up and down during test.

Current height is: To test the height is working correctly. Change the required height and the arm should move accordingly.

ADC=189 389mm

Required height is:

ADC=188 400mm

Angle settings fast Yes / No Set to Yes. Alters the speed that the arm travels up and down during test.

Required x position To test the angle. Change the required angle and the mothership should move left or right accordingly.

ADC=1 0mm

Angle-40 1/8 degrees

ADC=1 X nu = 0mm

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Clamp milk LF Closed / Open If vacuum pump is running, vacuum will escape from cup when clamp is open

Clamp milk RF Closed / Open

Clamp milk LR Closed / Open

Clamp milk cup RR Closed / Open

Vacuum LF

Present / Absent To check vacuum sensor operation. Open clamp valve with vacuum running then cover the cup gradually by hand until the display says:Present, take hand away and the display should say Absent.

Vacuum RF Present / Absent To check vacuum sensor operation.

Vacuum LR Present / Absent To check vacuum sensor operation.

Vacuum RR Present / Absent To check vacuum sensor operation.

Pulsator Yes / No Not in use.

Milk flow LF absent Checked with resistance across the sensor. Put a wire from one side of the flow sensor to the other and the display will change from absent to present. The display should say present when a specified resistance is put across the sensor.

Milk flow RF absent

Milk flow LR absent

Milk flow RR absent

Disinfection On / Off Test teat spray operation.

Operate cleaning rolls Yes / No Test cleaning rollers rotation. The speed is adjusted in the main cabinet.

Rollers on cups Yes / No Puts the teat rollers on top of the liners. Speed is set on the Festo CPV block.

Robot arm turn in Yes / No Turn the arm into the crate. Speed is set on the Festo CPV block.

Turn in sensor Detects:

ON

Check operation of the sensor for the arm in detection.

Milk cup RF release Yes / No To check operation. Releases the ACR cord.

Milk cup LF release Yes / No To check operation.

Milk cup RR release Yes / No To check operation.

Milk cup LR release Yes / No To check operation.

Clean laser - Water Yes / No To check operation.

Clean laser - Air Yes / No To check operation.

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12. Daily Schedule Ensure that all tasks are checked daily.

VACUUM SYSTEM

Check vacuum level Check oil level in vacuum pump

CLEANING BRUSHES

Check brushes are working correctly Visual check cleaning of brushes & chemical injection

MERLIN ARM

Check teat spray system & chemical level Wash arm & milking equipment with low pressure water Check and clean laser lens Check arm has correct park position Check air bleeds on shells

MILKING EQUIPMENT

Check teat cups, change if damaged Check condition of ACR ropes Change milk filter three times per day Check on number of milkings that the liners have done

WASHING

Check wash chemical levels Check water temperature during a main clean Check chemical pumps

CRATE

Check operation of gates

COMPRESSED AIR

Check compressor Drain Receiving vessel Check oil level in pump Check air filters

MILKMETER

Check cleanliness of milkmeter body

OTHER

Visually check complete system Check any other equipment controlled by Merlin

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12.1 Manual Cleaning of Merlin

PUT MERLIN INTO PAUSE BEFORE CARRYING OUT THE MANUAL CLEANING It is recommended to have a written procedure in place, describing how the cleaning of the

milking facilities must be carried out.

All milking equipment, lines, and surfaces that come into contact with milk, dirt or manure must be thoroughly cleaned and/or disinfected. In addition to the boiling water wash cycle for internal surfaces, manual cleaning of the Merlin is also required. No electrical equipment should be volume/pressure washed, for most applications a bucket of soapy warm water will remove all surface dirt.

12.1.1 Control Panel

Using a damp soft cloth gently rub the surfaces, no detergents. Never use a volume/pressure washer.

12.1.2 Holding Crate & Robotic Arm

Using a hose pipe (low pressure) or a bucket of soapy water and a brush, remove all debris from interior and exterior of crate and arm.

12.1.3 External Milking Equipment

Use a bucket of soapy water and a brush to remove all dirt from external milking equipment; this includes all stainless steel on show, i.e. interceptor, etc.

12.1.4 Parlour Floor

The floor of the area surrounding Merlin needs to be cleaned to keep it free from any accumulation of manure, or dirt. A volume/pressure wash clean is sufficient, providing that floors are constructed to slope to an appropriate point of drainage.

12.1.5 Putting Merlin through a Manual Wash

1. Press ESC ESC to get to the correct

menu.

2. Go to Cleaning and press Enter

3. Press to go to Merlin


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12.2 Changing and Cleaning the Milk Filter

The milk filter must be changed at least three times per day, preferably after every hot wash, procedure as follows;

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Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

The standard filter supplied is, part no. - 035131

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12.3 Cleaning the Laser

The laser is automatically cleaned by Merlin after every milking. The only manual cleaning required is to remove lime scale if and when required. Removal of lime scale is required in hard water areas more often than soft water areas.

12.3.1 Removing Limescale

1. Put Merlin into pause, refer to section 12.3 2. Select Cleaning Laser from the arm control

panel in order to lower the arm

3. Apply a small amount of clean to a soft dry cloth

Wipe lens clean, ensuring not to leave the glass smeared.

. 4. Press stop on the arm control menu 5. Put Merlin back on line to resume milking

017439 –Laser

Cleaning Solvent

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12.4 Cleaning Teat Roller Brushes

Clean the teat roller brushes daily, procedure as follows;

On the main control panel, put Merlin into

Pause, refer to 12.3 On the arm control panel, navigate to the

cleaning laser menu and press Enter .

Turn off compressed air via the isolation valve on the arm. Located behind the arm control panel.

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Turn on the compressed air

On the arm control panel, press Stop On the main control panel, put Merlin On Line, refer to 16

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12.5 Checking Vacuum Pump Oil Level (if applicable)

Ensure there is adequate amount of oil in the oil keeper.

Depicted above is oil keeper with oiler

12.6 Checking the Water Temperature

Daily - Check the thermometer reads 90oC just before Merlin performs a hot wash

12.7 Checking All Chemical levels

The following chemicals need checking daily. Change if required following chemical manufacturer’s recommendations.

Acid Cleaner

Alkali Cleaner

Teat roll disinfectant

Back flush disinfectant

Teat Spray chemical

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13. Milk Tank Daily Routine

13.1 Using Single Tank

A switch and a lamp are installed to indicate when it is permitted to connect to and empty the milk tank. The switch instructs Merlin to PAUSE and the lamp indicates the status of Merlin. The butterfly on the outlet of the tank must be closed. The bung in the tank must not be used

13.2 At Milk Collection Times

The milk must not be taken from the milk tank until the light is on. Merlin has then stopped milking and is in pause mode.

Procedure;

1. Turn the switch to collection position and wait for the lamp to turn on. 2. Connect to milk tank 3. Open the butterfly valve 4. When collection is finished the tank needs to be cleaned correctly, including the bridge

of the tank. Refer to tank instructions for correct procedure. 5. Close the butterfly valve 6. The switch can be turned to milking; Merlin will automatically start milking again.

13.3 Buffer tanks

If a milk cooling tank (buffer tank) that allows the storage of milk is installed, allowing milk collection to take place regardless of milking times, buffer tanks shall be placed between the milking system and the main bulk tank and shall be fitted with a cooling or pre-cooling system.

The use of buffer tanks must allow the inspection of the milk before this is pumped into the main bulk tank.

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14. Weekly Routine

In addition to the daily checks carried out, ensure that the following weekly checks are made.

CLEANING BRUSHES

Check condition

MERLIN ARM

Check teat spray system Check positioning of arm

MILKING EQUIPMENT

Check/adjust ACR ropes

COMPRESSED AIR

Check start & stop Procedures Check for audible air leaks

OTHER

Grease all grease nipples

COW FOLLOWER

Check and clean the cow follower plate (This must be kept clean to avoid potential cup attachment problems)

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15. Setting Merlin into Operation

To activate Merlin from a shut down state e.g. everything turned off;

Turn on compressed air supply, refer to

section for complete operations

Turn on mains electric via isolator

Ensure that emergency stop(s) are not pressed in.

Press the manual reset button (the

milk meter & arm will turn on)

On the main control panel

screen, the message should come up wait end config.

If the screen is still displaying Fullwood Fusion, turn power

off and back on again.

The screen should now read - Wait for cow

The entry gate will now open and Merlin is ready to milk. If the display changes to Milking Pause or Off Line you will need to change the mode as follows;

Press ESC once

Press to move cursor to Mode

Press to select On Line and press Enter

Press to Display Status and press Enter

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16. Starting Milking for the 1st

Time

1.Make sure that Merlin is

Online 2.Make sure that the arm control display is showing

Standby

3. The gate is open.

4. Encourage the first cow into Merlin, use manual feed button

to tempt her if needed.

5. As the cow’s transponder comes within the vicinity of

the antenna, she is identified.

6. Once identified, vacuum pump and pulsation will start & the arm display will ask you

Start Milking Yes/No? Select yes.

7. The arm display will ask; Turn in the arm Yes/No?

Select Yes

8. Using the cursors on the arm control display, position the arm so that the front teats of the cow are roughly in line with the rear teat

cups.

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9. Then the height should be set so that the lowest point of the front teats should be level

with the laser point line.

10. When the position is roughly correct, press enter to start searching for the teats.

After the milking of the cow for the first time it is not necessary to manually enter this information again. Teat position coordinates are stored within the Crystal program. If a cow stands awkwardly, Merlin will store an inaccurate set of co-ordinates. These may need to be re-set to zero using the modify button on the Merlin page of the Crystal program, refer to Crystal User Manual - 006744 After 8 to 12 hours the cow should be brought back to the Merlin.

The above sequence will need to be carried out for all cows intended to be milked by Merlin.

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17. Arm Control

The User only needs to gain access to the cleaning laser menu.

Arm assembly The arm is controlled by following the on screen instructions & using the arrow keys to

move the arm

17.1 Function of the Keys

Move to previous screen

Move to next screen Enter information

Highlight menu item or increase values

Highlight menu

item or decrease values

Exit current menu screen

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Warning: Merlin must be set into Off Line before navigation through the menu is started.

NOTE: This menu is not password restricted, all areas can be accessed. Please ensure

that Users only use the cleaning laser & adjustment laser menu’s unless under guidance from an approved Fullwood engineer.

17.2 Cleaning Laser

This setting allows unrestricted access to the laser for cleaning purposes.

Cleaning laser

Cleaning position laser NEXT? Press key!

Teat cups and arm drop enabling safe access to clean the teat cups. Press any key to exit.

18. Merlin Plant Cleaning

18.1 Setting ABW Cleaning Times An Acid Boiling Water (ABW) should be set to take place 3 times a day, spaced at even intervals. It is recommended that that a softener system is installed in hard water areas.

1. Start up the Crystal program on the PC 2. Select Programs menu and select Configurator

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3. In the left window, select Merlin#1 with the mouse 4.Select User Settings tab

5. Near the bottom of the page you will see the above lines, click on the time (value) setting for

any one of the three cleanings, type in the time and then click apply.

6. Repeat the steps for the remaining two cleanings.

18.1 Backflush

By default a backflush is initiated after every milking, to reduce the risk of cross contamination from cow to cow. After a cow has been milked, the backflush system sends a jet of water with compressed air down the liners and to waste via the foremilk rejection chambers.

18.1 Cleaning Chemicals

Merlin Main Cleaning is using a boiling water system. Normally, Merlin is set to perform a Main Clean three times in 24 hours. At alternate cleaning events, acid and alkaline chemicals are used. Teat spray is sprayed automatically after the cow has finished milking via a dosing pump; therefore teat spray for the Merlin is in 20 litre drums.

Ensure all chemicals are clearly identified, for safety, store chemical containers as per manufacturer’s instructions.

Store all chemicals in separate locations, that way ensuring they are not misidentified and used for the wrong application.

Only use Fullwood Ltd approved chemicals on Merlin, as detailed below.

DESCRIPTION FULLWOOD PART NO.

25Lt Nightwash 113003

200Lt Nightwash 113004

25Lt AMS Cleaner 113009

200Lt AMS Cleaner 113010

25Lt Prepost Iodine 113014

200Lt Prepost Iodine 113015

IBC Prepost Iodine 113016

Use all above chemicals in line with manufacturers instructions

Apply

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In addition - use 017439 - Astro Laser Cleaning Solvent for removing lime scale from the laser lens

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

18.1.1 Changing Chemicals

Put Merlin into Off line before working on chemical system, refer to section 12.4 Precautions (e.g. chemical resistant mask, gloves, boots & suit) must be taken when handling chemicals. Comply with the manufacturer’s recommendations on the labels.

19. Calibrating Feeders

It is the User’s responsibility to calibrate all feeders every time a new consignment of concentrate feed is delivered.

1. Start up Crystal program 2. Programs>Configurator The following screen will appear:

The calibration screen will appear next:

1. Left click on the weigh scales

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The calibrate station screen appears

1. Left click the weigh scales again

3. Click the Apply button

1. Click the dispense feed button

2. Type in the weighed amount

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20. Alarms and Error Message Codes

Alarms and error message codes are displayed on the main control panel in the Show Alarms menu. The 20 most recent error messages are stored therein. To access this menu;

Press - ESC, ESC

,

,

, Enter

to enter the Alarms menu The display now shows; Show Alarms Reset Alarms Clear History Move the cursor to Show Alarms, press Enter, the last 20 alarms can be viewed,

Use the up and down arrows to scroll, the most recent alarm is at the top of the list.

To return to the Alarms menu, press - ESC

To return to the main menu, press - ESC, ESC

, Enter

, Enter

20.1 Display Format

The main Merlin control panel display generates a number of messages in the following format; Interpretation of format;

DD-MM-YY Date when the message appeared

hh:mm Time when the message appeared

a Type of message (see below)

xx Code for message e.g. F1 (see below)

DD-MM-YY hh:mm axx

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F Fatal This message also results in switching the 1st (High Alarm) relay on the Merlin alarm unit and indicates a fatal error that can not be solved by Merlin itself. This message asks for immediate action of the User.

E Error This message also results in switching the 1st (High Alarm) relay on the Merlin alarm unit and indicates a problem where Merlin will try to let the current cow out of the box and wait then until the farmer to take action.

W Warning This message also results in switching the 2nd (Low Alarm) relay on the Merlin alarm unit and indicates a problem where Merlin will try to solve it himself.

I Info This message appears on the Merlin display only and indicates low priority errors.

20.2 Alarms Explained

Fatal & Error Alarms Depending on the cause, if it cannot be readily fixed, call an approved Fullwood engineer. The cause of the alarm needs to be found and rectified.

Warning Alarms

These alarms can normally be resolved by the User. Simply reset the alarm and re-start Merlin, to do this:

Press ESC to return to the Alarms menu.

Move the cursor down to Reset Alarms, press the toggle button to change from No to Yes

Press Enter

Next, press the following key sequence to return to the main

menu: ESC,

ESC, Enter

, Enter

The display should now read Wait For Cow If the above procedure has no affect, call an approved Fullwood Engineer.

20.3 Machine Stop and Manual E-Stop Explained

If the Merlin has stopped and is displaying Emergency Stop on the main control panel, this can be because the manual E-Stop button has been pressed, the low air pressure switch has activated or the milk pump has overflowed. There are two ways to determine the problem.

The Manual E-Stop button Machine stop

If the manual e-stop button has been pressed this will deactivate both the Safety relay

healthy light and the Switched 24v light as shown below

If the machine stop switch has activated due to low air pressure or milk pump overflow the

Safety relay light will be on and the Switched 24v will be off

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20.4 Clearing Alarm History

The alarm history does not normally require clearing, however in order to monitor the faults over a period of time this may be necessary. Procedure as follows:

Access the Alarms menu

Move the cursor down to Clear History

Press the toggle button from No to Yes

Press Enter ( The history has now been reset)

20.5 Message Codes

Following listing shows the possible message codes:

Code Meaning of the message code

Explanation Priority

1 Cow too long in box

When the exit gate of Merlin is opened and the cow doesn’t leave Merlin within a pre-set time(set in the Configurator) the drive-out procedure will start. When the complete drive-out procedure is ended a low alarm will be generated and a high alarm within a pre-set time.

Low

2 Feeding motor error When the feeding motor is activated longer than 60 sec. High

4 Vacuum error When the vacuum-pump does not build up the vacuum enough High

8 Merlin arm general error When Merlin arm failure appears which cannot be explained. High

9 Merlin arm communication error

When the communication with the Merlin arm is disturbed. High

10 Merlin arm command acceptation error

When the Merlin arm is not ready for the new command, (for instance the arm is not in the standby position) and a cow enters the Merlin.

High

11 Merlin arm cannot reach clean position

When the Merlin arm is not able to reach the cleaning position after x seconds.

High

12 Merlin arm cannot reach clean cups position

When the Merlin arm is not able to reach the cleaning cups position after x seconds.

High

13 Merlin arm cannot reach free vacuum position

When the Merlin arm is not able to reach the free vacuum position after x seconds.

High

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14 Merlin arm cannot reach drain tubes position

When the Merlin arm is not able to reach the drain tubes position after x seconds.

High

15 Merlin arm cannot reach standby position

When the Merlin arm is not able to reach the standby position after x seconds.

High

16 Merlin arm asks for assistance

When a cow has no teat co-ordinates or a cow is set to manual assistance and this cow enters the box.

Low

17 Merlin arm cannot turn in When the Merlin arm cannot turn in. High

18 Merlin arm cannot turn out

When the Merlin arm cannot turn out. High

19 Merlin arm vacuum detection error

When the Merlin arm does not detect vacuum. High

20 Merlin arm wagon position error

When the Merlin cannot reach the y-position. High

21 Merlin arm cannot reach teat cup position.

When the Merlin arm cannot reach the teat cup position. High

22 Merlin arm does not have any teat to connect.

When in Crystal in the quarter page no teats are market with milk this teat.

High

23 Milkmeter general error When a milkmeter error appears. High

24 Milkmeter communication error

When there is a communication error with the milkmeter. High

25 Milkmeter sensor error The milkmeter is not counting yield within 1 minute of milk flow being sensed

High

28 Milk pump error When the milk-pump pumps longer than 5 minutes. High

29 Milking abnormally ended Milking abnormally ended will only be used if Merlin does not know how the milking is ended.

High

30 Teat connection error Teat connection error, will only be used if Merlin does not know the reason for failed connection.

High

31 Power failure When there is a power failure in the Merlin arm. High

32 Milking pause too long When Merlin is set in Pause by the milk tank and this pause is longer than preset in time.

High

33 Sampler frame full When the sample frame is full. (the Merlin will continue milking after a preset time in the Configurator)

Low

36 Delivery line not ready time out

When the delivery-line to the milk tank is not available for a longer time (than set in the Configurator),

High

37 Milked too long When the milking time of a cow is longer than two times mean milk time plus two times mean dead time, the system will abort the milking.

High

38 Cleaning time-out When the cleaning takes longer than a pre-set time. High

40 Manger pan is not emptied fast enough

In case a manger pan empty sensor is installed, this error indicates that the manger pan is not emptied quick enough

High

42 Merlin arm milked too long

When the cow is milked longer than two times the mean dead time + two times the mean milk time milking will be aborted.

High

43 Merlin arm too long waiting for assistance

If after an assistance request the User does not show up within 10 min, the cow will be released.

High

44 Merlin arm can’t find udder

When the Merlin arm cannot find any teat. High

45 Merlin arm can’t find teats When the Merlin arm cannot find a teat. High

46 Merlin arm no milk-flow left rear

If after reconnection, still no milk flow is detected, the teat will be reconnected for the second (and the third time) after the mean dead time plus 15 seconds. If after the third connection still no milk flow is detected.

High 47

Merlin arm no milk-flow right rear

48 Merlin arm no milk-flow right front

49 Merlin arm no milk-flow left front

50 Merlin arm milking aborted by User

If the milking is aborted by the User. High

51 Merlin arm connection aborted by the system

If for some reason the connection is aborted by the system. High

52 Merlin arm connection time-out

If it takes more than 5 minutes to connect a cow, the connection will be aborted.

High

60 Merlin bucket unit has the last bucket filled

The bucket unit has filled all available buckets. The Merlin will continue to milk, but any milk for rejection will be sent to the

High

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drain.

61 Merlin bucket unit cannot move to required position

The bucket unit arm cannot reach the next position required. High

20.6 Alarm While Milking

If Merlin is stopped during the milking process, before the next cow is milked please ensure;

That the previous cow has safely exited the crate

The milk within the system has been diverted to the correct destination (tank, drain or wash)

21. Milk Sampling

21.1 Setting Cows for Sampling in Crystal

Open Crystal, and then go Animals > Milk

As long as the cow is able to be milked in the Merlin, the next time she is milked a sample will be taken. Or, select report 3b05

1. Click the binoculars, search for specific cow.

2. Select the number of samples to be taken from that cow

3. Click Apply

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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.

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21.2 Milk Sampling Shuttle

The shuttle when linked to Merlin is a fully automated milk sampling device.

21.2.1 Installation of shuttle into the Merlin

Place shuttle within close proximity to the Merlin. Set the Merlin into ‘Off Line’ mode. Connect the red flexible airline from the Shuttle to the quick connect port on the Merlin.

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Ensure that the sampler is level by adjusting the feet and checking against the built in spirit level. Adjustable feet are found underneath the sampler unit….

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Install the sampler clamp into the Merlin (if not already fitted). There are 2 M8 nuts and a saddle clamp that fits around the 40mm stainless tube Connect the 4mm airline to the fitting on the cylinder. M8 captive bolts for mounting to the milk line Select ‘Install’ mode from the Merlin display menu and insert the silicone tube through the sampler clamp. (The clamp will open with a distinct ‘clack’) Insert the hollow barbed fitting into the tube so that it is on the far side of the sampler.

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Remove the solid plug from the silicone bend below the receiver, and replace with the hollow plug that is attached to the clear silicone tube.

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Connect the clear silicone hose from the Shuttle to the Merlin sampler, using the plastic nipple shown. Connect the spoon to the clear silicone tube in the Shuttle.

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Place the spoon into the toothed section into position 1. Ensure that the silicone tube is routed so that it cannot catch on an obstruction. Fill the bottle frame with sample bottles. Position 1 is clearly markd

1

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Ensure that the bottle frame is installed correctly onto the 2 pins in the drawer.

21.2.2 Settings in the Merlin display menu

In the sampler menu,

Set the Frame number to 1 (for first tray)

Set the First bottle number to 1

Set the Last bottle number to 60 (or number of sample bottles used)

Select ‘On Line’ mode.

Exit the sampler menu, and then put the Merlin into ‘On line’ mode.

21.2.3 Operation of the sampler by the Merlin

When sampler is setup and on line, and the animals have been selected for sampling from the Crystal program, then the sampler works thus:

60

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If an animal enters the Merlin and is OK for milking and is also set for sampling (number of samples set in report 3b05) then the arm will attach as normal. However, during the milking phase the sampler will open and close (at preset intervals) to allow air into the milk receiver in order to agitate the milk. When the milking is finished, the milk will be pumped away until the milk level goes just below the high level milk sensor. The vacuum pump will then switch off, the sampler clamp opens, and the milk will flow into the sampler spoon for a preset time. After the set time has finished, the vacuum pump will start up and any excess milk in the sampler spoon is drawn back into the milk receiver. The sampler clamp will then close and the remaining milk in the receiver is pumped away. The sampler tray will then pull downwards and the milk in the spoon is dropped into the sample bottle below. The Merlin will then allow the next cow to be milked. After another preset time, the sampler tray will lift again, and the spoon will step forwards 2 places so that it is then above bottle 2,3,4,5, etc…

21.2.4 When the sampler frame is full

An alert to the user is automatically generated when the sample tray is full and requires changing – Alarm E33. The sampling menu will also require updating: Frame number is set to 2,3,4,5 etc... The start bottle number is set back to 1 The spoon also has to be set back to position 1. After this has been completed, the alarm is erased and milking continues. Once a tray of samples is removed from the sampler, then each bottle has to be identified with the number of the cow. This can be obtained from Crystal. Report 3b04. This report shows all milkings for the last 3 days, along with the recorded frame number and recorded bottle number. Reference this data to the actual samples.

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21.2.5 When sampling is finished

Set the sampler mode to ‘Install’.

Disconnect the silicone tube from the receiver elbow and replace with the solid barbed pin.

Remove the silicone tube from the clamp.

Disconnect the air tube from the quick release fitting on the Merlin.

Remove the silicon tube from the spoon.

Remove the spoon from the sampler.

Set the sampler mode to ‘Off-line’ Using the plastic syringe provided with the sampler, clean the entire length of silicon tube with hot water and a suitable detergent.

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Disassemble the spoon and clean it with hot water and detergent Unscrew the top and bottom of the spoon.

And you end up with 2 pieces Remove small ‘o’ ring from plunger

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Remove plunger from bottom assembly

Clean entire assembly, taking care that the swivel pin is also cleaned. Swivel pin – this can be cut down to obtain a larger volume of sampled milk.

Re-assemble in reverse order, and store with the sampler

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Clean the sampler and store in a dry location. Remove the sampler clamp and disconnect the air tube and store with the sampler (this will stop the cylinder from corroding due to not being used for long periods)

For installation and setup procedures, refer to manual supplied with the shuttle

21.3 Entering Shuttle Details into Merlin

Refer to section 12 for main control panel instructions.

Set the Number of Sample Bottles present on the main display panel

Set the Start Bottle Number

Set the Frame Number

Set the Sampling Mode to On Line

21.4 What to do when Frame is full

When the frame is full of samples, an alarm E33 is generated and Merlin calls you to change the frame. Replace the frame with another one, and move the spoon back to position 1, increase the Frame number on the main control panel menu by 1. The settings for the start bottle number and amount of bottles will stay the same as when sampling started. The alarm will be erased and the milking will continue.

21.5 Ending Sampling

In the main control panel, change the Sampling Mode to Off line.

21.6 Collecting Data from Crystal & Labeling Bottles

The sampling data is collected in crystal and can be retrieved in print reports, by selecting 3b04. There are 3b04 reports, one will be sent to the floppy drive, and the other will show on the PC display.

1. Open Crystal 2. Select Reports > Print Reports

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3. Select 3b in the left hand window, the menu

then appears on the right hand side, select 3b04, and then the print icon in the bottom left

of the screen. Using the milk control report the sample bottles can now be labeled.

See 006792 for detailed instructions on the use of the sampler

22. Backup Crystal Software

IT IS THE USER’S RESPONSIBILITY TO ENSURE THE SAFETY OF THE HERD’S DATA

The Merlin data generated by Crystal must be regularly backed up. Fullwood Ltd recommend to backup to an external device (e.g. writable CD drive, zip tape drive, USB stick), in case the computer develops a fault or has to be replaced.

FULLWOOD LTD CANNOT BE HELD RESPONSIBLE FOR LOSS OF DATA, OR ANY CONSEQUENTIAL LOSSES

Animal number

Milking time of cow

Recorded production for that milking

Recorded frame number that sample was taken in

Sample bottle number

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23. Service Schedule

A service schedule should be set up with a Fullwood approved dealer. The Merlin requires servicing 4 times a year at regularly spaced intervals.

List of tasks to be carried out Service Number

Service Number 1 2 3 4

Milking Equipment Minutes

Check teat cups, change if damaged 20 20 20 20

Calibrate 4QC 20 20

Check air bleeds in milk & vacuum chambers 5 5 5 5

Check/adjust ACR ropes 30 30 30 30

Change diaphragm on milk flow sensor (not in first year) 5

Check operation Milk meter 2 2 2 2

Change Flap valve 5 5 5 5

Change milk pump seals 15 15 15 15

Change long milk tubes 20

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Change Jetter cups 2

Check/Clean spray ball in receiver vessel 2 2 2 2

Visual Check 5 5 5 5

Change milk filter O-rings 5

Milk Meter

Check operation of milk meter 5 5 5 5

Replace rubber gasket & valve 10

Change air filter 2


Merlin Arm

Check teat spray system 5 5 5 5

Check for air leaks on compressed air 10 10 10 10

Clean Laser 1 1 1 1

Check position of arm 10 10 10 10

Grease all parts necessary 15 15

Check calibration S-lina, Pressure switch and movement 10 10

Check parking, home position 2 2 2 2

Check parking position in relation to washer jets 2 2 2 2

Check S-lina movements 10 10

Replace bushes and Bearing 60

Check bushes and Bearing (Visual operation) 2 2 2 2

Check fasteners on arm 2 2 2 2

Check turn speed 2 2 2 2


Washing

Check for limescale build up 5 5

Check water temperature during a main clean 10 10

Check acid & alkaline pumps. 5 5

Check quantity pumped 2 2 2 2

Check air purge 2 2

Check operation of all Burkett and APV valves 2 2 2 2

Check results from the farm with the milk quality 5 5 5 5

Check for water leaks 5 5 5 5

Change large Peristaltic pump tube. 5


Feeding System

Calibrate feeders (Farmer operation) 2 2 2 2


Cleaning Brushes

Check brushes working correctly 5 5 5 5

Check if brushes park in correct position 5 5 5 5

Check cleaning of brush & chemical injection 5 5 5 5

Change small peristaltic pump tube 5 5

Vacuum System

Check vacuum pump oil system 5 5 5 5

Check vacuum level/regulate 5 5 5 5

Check & adjust vacuum gauge 5 5 5 5

Check oil filter in exhaust if fitted 10 19 10 10

Check air capacity of vacuum pump 15

Clean Servac & service. 5 5 5

Fit new Servac 5

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Over all visual check 5 5 5 5

Pulsation System

Measure and record pulsation characteristics 15 15 15 15

Change pulsation tubes 10

Clean Pulsator air filter 2 2 2 2

Replace Pulsator silencers 2

Over all visual check 5 5 5 5

Compressed Air

Change compressed air filter 15

Check compressor 5 5

Check operation of auto drain 5 5 5 5

Check oil level in pump 5 5

Check start & stop pressures 10 10 10 10

Check Merlin regulator setting 1 1 1 1

Crate

Check operation of gates 5 5

Check cow follower 5 5

Other

Test Earth on Merlin 5

Check any other equipment controlled by Merlin 10 10 10 10

Check RCCB works with test button 1 1 1 1

Fill in report 15 15 15 15

Visually check complete system watch milking 45 45 45 45

no of minutes 359 399 427 464

TOTAL - Hours 5.9 6.6 7.1 7.6

24. Configurator Settings

This section details User settings and how to change the time tables.

1. Start up Crystal program 2. Programs>Configurator

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In Configurator the following screen will appear. Click on Merlin #1 and on the right hand side of the screen the Merlin User settings are shown.

24.1 Merlin User Settings

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1 Time table On/Off: Which time table is used to set Merlin Off or on?

2 Time table period: Which time table is used to set Merlin in “in period” (How to set time tables will be explained in section 19.2)

3 Out period decision value: Percentage of the set value on which the Merlin decides to milk a cow if the Merlin is not in period

4 In period decision value: Percentage of the set values on which Merlin decides to milk a cow if the Merlin is “in period”.

5 Finish feeding: Set to Yes or No. Yes means that the animal can finish her complete meal before she is let out of the Merlin

6 Silo number #1: Silo number for feed-type A

7 Feed stop before next: During set time before a cow can be milked again the cow will not be able to be fed in the out of parlour feeder

8 Merlin precool stop dly: Running time of the pre-cooler after the milk pump has stopped pumping.

9 Milk pause timeout: When the Merlin is set in pause by the milk tank longer than the set time, an alarm will be generated

10 Min hours between milking: Minimum time between two not failed milkings of a cow

11 Max exp. yield (% of Targ): The expected yield is maximised to set percentage of target yield.

12 Sampler alarm duration: The set time after a Merlin has generated an alarm 33, Merlin will start milking again

13 Cow in box warning: If a cow is in the Merlin longer than the set time an alarm will be generated.

14 Abnormal milk, hold animal in box:

15 Abnormal milk destination:

16 Main clean #1: When hot wash 1 begins.

17 Main clean #2: When hot wash 2 begins

18 Main clean #3: When hot wash 3 begins

There are more User settings which are hidden and are viewed if configuration advanced is ticked.

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These extra User settings are detailed in the image below.

1 Abnormal milk, hold animal timeout

2 Drive out start delay: When the exit gate is opened and the cow does not leave the Merlin after the set time drive out will start

3 Drive out on time: The compressed air will be on for XX seconds

4 Drive out interval time: Time between two drive-outs

5 Max number of outdrives: Number of drive-outs before an alarm is generated

1. Click on Configuration

2. Click on advanced

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24.2 Time Bar Settings

Time bars are used to disable or enable an item in a configuration, (i.e. a feeding station, a selection gate, Merlin etc). Time bars are made in configurator and can be linked to specific items in the configuration. In order to make a time bar, left click on the clock in the bottom left of configurator screen, as depicted below:

Once this is done the following screen will appear:

The default time bar in the configurator is named “Always” and when chosen, this time bar is enabled from 00:00 to 24:00.

Left click on time settings

Indication of how many items in the configuration are linked to this time bar

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24.3 Adding Time Bars

To add a new time bar, follow procedure below:

Go through the steps above and a time bar will appear. To expand the time period, left click on the period and drag the mouse to the desired time.8 To split an active time period, right click on the period and the program will ask if you want to split the active time period, left click on yes. The time period will be split and the split periods may be altered by left clicking and dragging the time bar

3. Type in the new name

and click Apply

1. Left click on the + button, a new time bar will appear named “Timebar #2”

2. Rename the Timebar by right clicking here

1. Right click on

the Timebar

2. It will ask you if you want to add an active time period, left click on yes

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24.4 Deleting Time Bars

2. It will ask you if you want to delete this Timebar, left click on yes

1. Left click on

the minus sign

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25. Timer Program Settings

25.1 Crystal Timer

The Crystal Timer is a timetable program that runs certain actions at pre-set times, e.g. the crystal feed calculations, an external program and automatic printing of animal reports etc. When Crystal is installed, the timer function is added as a PC application in the configuration, so when the distributor is started, (starts automatically when PC is switched on), the timer starts as well, so it should always be active. The timer can be viewed by following the procedure detailed below:

1. Open crystal program 2. Select Programs>Timed actions

The following screen will appear:

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25.2 How to use the Timer

Under the Events menu there are four options for the tasks, as follows:

New - enables a new event to be added

Delete - deletes that event

Show/Hide Details - shows or hides the details of the selected task

Start now - this option starts the selected timer task

25.3 Overview Events List of the Timer

The image below depicts the events list, a description is given for each column.

1. The name of the event or task. 2. The frequency of the task. 3. The time the task will start. 4. Shows if the task is active at the moment. 5. When the event was performed last. 6. When the event will be performed next.

1 2 3 4 5 6

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25.4 Overview of Automatic Tasks of the Timer

To look at the details of a task, either click on Events>Show/Hide details or click on the details button on the bottom left of the window (magnifying glass). The screen below can now be viewed.

This button is used to select actions for the timer. If pressed the Select Actions box will appear, as shown below.

These fields is used for setting the time and day(s) that the task is carried out

This field is used for selecting the frequency of the task

This field is used for selecting the external program that can be run by the timer

The Select Actions box shows the available tasks that can be performed by the timer

To select, highlight a task by left clicking on an action in the available actions box. Then left click on the arrow key, the action will move to the selected actions box. This will be the task that the timer will carry out.

Click OK to save the changes

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25.5 Add and Delete Events

25.5.1 Adding an Event

Press the button.

Click on button to see details of the new event.

Give a unique name to the event with a maximum of 20 characters.

Select the frequency of the event

Select the time of the event The event has now been added, next, the required action has to be selected, to do this click on the select button and follow the instructions in section 20.4.

25.5.2 Deleting an Event

Press the button.

Crystal will now ask if you are sure, click Yes.

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26. Frequently Asked Questions

26.1 Merlin

Q 1. Applying one of the liners, but keeps pulling it off instantly.

Detecting no vacuum. Is the vacuum working? Is there an air leak in the milk tube? Is the vacuum at the right level?

Q 2. One liner lying on the floor with the vacuum on.

Vacuum sensor constantly detecting vacuum. Needs adjusting or it is broken.

Liner twisted inside.

Q 3. Not detecting a milk flow on one quarter.

Check the milk flow sensor is clean. Check the calibration of the sensor. Check the pulsation, tubes and the liner.

Q 4. The arm doesn’t seem to follow the cow correctly.

Check the ultrasonic sensor.

Q 5. Milk pump seems to take a long time to pump the milk away.

Change the flap valve. Check the seals in the milk pump. Check the rubber gasket around the milk pump housing. Check the filter isn’t blocked. Check the butterfly valve has opened correctly.

Q 6. Milk leaking onto the floor.

Check the air pressure is at 6 bar. Check the APV valve plunger inside for damage.

Q 7. A cow enters Merlin and the entry gate stays open.

Check the photocell is working at a distance of 70cm from the floor. Check the signal is coming back to the FwCC.

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Q 8. A cow enters Merlin but is not identified.

Check the cow has a transponder/pedometer. Check the range from the antenna.

Q 9. A cow enters Merlin and rejected after identification.

Check the cow number is displayed on the main control panel, if not, the cow is not in the database or the transponder/pedometer has failed. If it is displayed the cow isn’t ready for milking, check the yield expected on the display.

Q 10. The arm sometimes doesn’t reach the position required.

Check the air pressure in Merlin Check the positioning valves in the arm are working and check the

resistance. Check the angle sensor is reading the angle.

Q 11. The arm turns in too fast. The arm does not turn in smoothly.

Check the speed adjustment on the solenoid. Check the air pressure. Check non-of the tubes are kinked over.

Q 12. The teats are being cleaned too low.

Check the settings in the arm control box for the clean height under tip.

Q 13. Milking too long on one quarter.

Check the sensors are clean. Check the settings for the milk flow sensors.

Q 14. The milkmeter has water left inside after a wash.

Check the settings of the milkmeter. Check the voltage of the PSU to the milkmeter. Check the milkmeter is level.

Q 15. Milk meter looks dirty.

Check the chemicals are being taken into the system. Check the water heater temperature.

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26.2 Crystal (general)

Q 1 Can the PC be turned off and for how long?

The Crystal program is not necessary to keep the system in the barn fully operational. So Crystal can be closed and the PC can be switched off. The Crystal system stores data necessary for daily operation to a data server controller in the FusionNet system outside of the PC.

How long the PC can be switched off is depending on the size of the data storage in the barn system and the number of recordings per day. As an example the listing below shows the 24 hour data storage in terms of animals per system in a Fusion Data Server without memory expansion:

-300 animals (6 Merlins, 3 milkings/animals, 6 visits/animal, activity, 3 milkings/day) -400 animals (milking parlour, IP and OOP feed, activity, 3 milkings/day) - 500 animals (milking parlour, OOP feed, activity, 3 milkings/day. These are just examples and very much depending on system configurations

Q.2 Lactation graphs are not shown?

If lactation graphs are not available, check the following: Is the lactation module activated in the Crystal dongle in PC? In that case the main

menu item 'Animals - Lactation' and 'Animals - All lactations' appear grey in the menu list. If that is the case then ask the system supplier for more information.

If the graph page is available but the graph itself is empty then check: Whether the animal has a calving date. The lactation graph need a starting point,

which is the date of the last calving, or the birth date in case of the feed intake of young animals.

Whether any recorded data is available for this animal in each individual Animal page.

Q.3 Why are some fields yellow or grey instead of black?

The default colours of data field depend on the type of data element: • Yellow fields are required fields, which mean that a value must be entered. • Grey fields are read only and show information calculated or determined by the

system. They can not be changed by the User. • White fields are editable fields (settings) which can be used to enter data.

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Q.4 What to do when moving from the barn to grazing?

To keep in mind regarding analysis of milk, conductivity and activity data: • Animals going to pasture will show different conductivity levels because the feed

contents changes. This means that the first few days the conductivity averages of each animal has to tune itself. To find attention animals first check the group changes in the main menu 'Group - Compare group' before checking individual animals.

• Activity levels change, because animals walk to the field and back again and they are more active in the field then in the barn. To find attention animals first check the group changes in the main menu 'Group - Compare group' before checking individual animals.

• In both cases it remains possible to view the different day or night-time levels in the individual graphs by clicking the setting 'Show sessions' in the left hand bottom side of the graph page.

To keep in mind regarding feed settings: • When animals go out into the field, then the total time per day to visit feeding

stations is much lower, because the feeding station can not be accessed and the time the stations can be visited, fewer animals can be serviced.

• So in case of a wait time feed algorithm take care that the number of meals per day are adapted to the total accessible time of the feeding stations. The number of meals can be changed on individual level in the menu 'Animals - Feed modules' or on group level in the menu 'Group - Feed pages'. If the number of meals is set to be changed automatically, then the table in the right-hand bottom corner of the main menu 'Module - Feed modules' should be changed.

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26.3 Crystal (Feeding & Milking)

Q.1 Change of feed or milk settings not accepted?

The following steps could be taken in case feed or milk settings are not accepted by the system: The new setting is higher then limits set in the corresponding module settings. The

module settings can be checked by clicking the toolbox icon in the individual pages or by the corresponding module in the main menu 'Module'.

If that is not the case, then the Crystal data is not synchronized with the data stored in the Fusion Data Server in FusionNet. In that case contact the system supplier to sync both databases.

Q.2 Number of meals does not change automatically?

Check the following issues to change the number of feed meals automatically: Open the main menu 'Module - Concentrate settings' (or any other feed class

module settings).\ Fill in the table in the right-hand bottom corner of this page. This table determines

the relationship between the daily allowance and the number of meals and wait time between meals when a feed calculation takes place.

To activate the automatic number of meals calculation open the menu 'Browse - Animals' and select the list "5a02: Feed settings" and set "C. Automatic meal calc" in the last column. (Alternatively this can also be done using the setting "Automatic meal calculation" on individual level in the menu 'Animals - Concentrate feeding' or on group level in the menu 'Group - Concentrate feeding'

Notes: Recalculation of meals is performed automatically every day by Crystal

background at a preset time. This can be set in the Timer application which can be opened by the main Crystal menu 'Programs - Timed Actions'. The timed actions list contains by default an action called "Crystal feed calculations".

If the meal settings do not change automatically then it is possible that: a) The Crystal background program is not running (or PC switched off) at the

time set.

b) An error occurred during the transaction. This is indicated by a "!" in the second last column of the Timed Actions table. To find the reason for this error check the menu 'Help -Log' in the Timer program.

Q.3 What is the difference between “Wait time” and “Merlin” feeding?

The distribution algorithm determines how the feed allowance is distributed over the day. There are two ways of feeding: Merlin feed: This option is based on saving feed during the day. The longer the period in

between two visits the more the animal can eat. In case of a Merlin in combination with concentrate feeding stations always use this option.

Wait time: This option is based on different meals during the day, with a wait time between

those meals. This is the same way of feeding as in the Fusion and Farmfeed system under Dos.

mk:@MSITStore:C:/Fusion/HELP/crystal/ENG/Crystal.chm::/GroupMilkMenu.html

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27. Merlin General Information and Operating Parameters

The following information is given in compliance with BS ISO 5707:2007; details of minimum requirements for a fully operational plant are detailed.

27.1 Mounting Dimensions, Space Requirements and Critical Building Dimensions

There must be sufficient room on the cow side of Merlin to allow the entry/exit gates to open and close without hindrance.

On the operator side there must also be sufficient room for the arm to turn out.

27.2 Recommended Ambient Conditions for the Different Parts of the Milking Machine

27.2.1 Merlin

Merlin(s) should be kept clean with dust and dirt kept to a minimum. Electrical enclosures are rated as dust tight and water splash resistant.

Merlin will perform optimally between -5°C and 40°C.

The Servac regulator should be mounted in an area that has a low dust level

27.2.2 Pump Room

The compressor must be in a well-ventilated environment, free from dust, acids, and vapours, explosive or flammable gases. Ambient temperature of between 0°C and +35°C.

27.2.3 Office/Computer Room

The computer room should be dry, damp proof, frost proof, clean and dust free. This room will house items like the data server which can only operate in such conditions.

27.3 Minimum Electrical Power Supply and Earthing Requirements

27.3.1 Electrical

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 to isolators to electrical equipment supplied by Fullwood Ltd.

27.3.2 Earthing

It is the responsibility of the customer to ensure that their contractor earth bonds all metal parts of the installation.

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Merlin must be earthed according to local legislation. Starting up Merlin without proper earthing will render the warranty null and void.

27.4 Minimum Water Supply and Drainage Requirements

Plumbing work must be carried out by a suitable qualified contractor to be engaged by the customer.

Two cold water taps are required for the operation of Merlin.

An adequate supply of water heated to >90°C is required.

Minimum water pressure to be 150kPa

Provisions must be made for foul drainage, either by connection to a properly constructed septic tank or cesspool, constructed in accordance with current Dairy Hygiene Regulations. Drainage shall be through trapped gullies with water seals and rodent proof grid covers.

Drainage must be provided from the plant room to connect to the soiled water system.

All water from roofs and open yards, not subject to fouling, shall be piped to existing storm drains through gulley traps.

27.5 Nominal Working Pressure and Capacity of the Compressed Air System

The amount of compressed air required for the Merlin(s) to run all functions properly is dependent on equipment and numbers of units.

Contact Fullwood Ltd or an approved dealer for information

27.6 Effective Reserve, As Calculated and Measured

Removing a long milk tube under vacuum should not result in any significant vacuum fluctuation. If two long milk tubes are removed, a slight fall of less than 1 kPa may be noted. When the long milk tubes are re-attached, the vacuum should rapidly recover. This test should be done periodically to ensure satisfactory effective vacuum reserve.

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28. Disclaimers

Fullwood Ltd assumes no liability for damage to any products resulting from disregard of information contained in this manual. All mains electrical work should be performed by a suitably qualified electrician in accordance with the relevant national and/or local regulations, any other relevant regulations and any relevant local bylaws. Fullwood Ltd will not accept responsibility for loss or damage caused by a force majeure e.g. lightning strikes. Fullwood Ltd will not accept responsibility for milk contaminated by antibiotics. Purchasers are advised to take out suitable insurance to cover electronic equipment such as equipment covered in this manual against lightning strikes. Compressed air is extremely dangerous. Installers and Users of compressed air equipment should be familiar with any relevant safety regulations. Standards and recommendations are available from BSI or HMSO. BS EN 1012-1:1997 - Compressors and vacuum pump. All owners or occupiers of premises are responsible for the water systems within the premises. The extent of these responsibilities is described in detail in section 73 of the Water Industry Act, 1991 or such other equivalent legislation. An appropriate guide for agricultural premises is available from the Water Bylaws Scheme (Tel. 01495 248454 UK only) Fullwood Ltd reserves the right to change the contents of this manual without notice. Whilst every precaution has been taken to ensure the information is correct, Fullwood Ltd does not except responsibility or liability for damage of any kind arising from the use of this

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