LELY Astronaut A4 Operator's Manual
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LELY Astronaut A4 Operator's Manual

Milking robot
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Lely Astronaut A4
Milking Robot
Operator Manual (Addendum)
EN - English Original
5.1004.8641.0 B
.
Lely Industries N.V.
www.lely.com

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  • Page 1 Lely Astronaut A4 Milking Robot Operator Manual (Addendum) EN - English Original 5.1004.8641.0 B Lely Industries N.V. www.lely.com...
  • Page 2 in n o vato rs in ag ric u ltu re INTENTIONALLY BLANK...
  • Page 3 Lely reserves all rights with respect to its trademarks. Any unauthorized use of any Lely-owned trademark or any use of a trademark that is confusingly similar to, or likely to cause confusion with a Lely-owned trademark, would constitute infringement of Lely’s exclusive rights. All rights reserved.
  • Page 4 in n o vato rs in ag ric u ltu re INTENTIONALLY BLANK Trademarks, Copyright and Disclaimer...
  • Page 5 in n o vato rs in ag ric u ltu re List of Included Amendments Issue Date Revision Chapter(s) Remarks (yy/mm) 2018/11 Initial release. • 2019/05 Added: Operating Instructions/Feed Unit/ Commodity • Feed Hopper. Maintenance Procedures/Calibrate the feed • Portion. •...
  • Page 6 in n o vato rs in ag ric u ltu re INTENTIONALLY BLANK List of Included Amendments...
  • Page 7 Store this manual in a safe place for future reference. All information in this manual has been compiled with care. Lely shall not be liable for errors or faults in this manual. The recommendations are meant to serve as guidelines. All instructions, pictures and specifications in this manual are based on the latest information that was available at the time of publication.
  • Page 8 Always include the type and serial numbers of your milking robot when you contact your local Lely service provider or order spare parts. Figure 1. Location CE type plate robot unit Figure 2.
  • Page 9 (PS) Product Specialist (certification valid for two years). • All the technicians certified by Lely International for the A4 needs to have completed an additional training to be certified for the A5. During training, a trainee is permitted to work for up to a maximum of six months under close supervision of a certified technician.
  • Page 10 in n o vato rs in ag ric u ltu re INTENTIONALLY BLANK Preface...

  • Page 11: Table Of Contents

    in n o vato rs in ag ric u ltu re Table of Contents Safety ....................1-1 Safety Instructions .
  • Page 12 in n o vato rs in ag ric u ltu re Cleaning ..................4-1 4.1.1 Start Cleaning .

  • Page 13: Safety

    in n o vato rs in ag ric u ltu re Safety This chapter contains safety instructions you must obey when you install, use, or do maintenance on the machine. It also explains the safety decals on the machine. Safety Instructions YOU are responsible for the SAFE operation and maintenance of your machine.

  • Page 14: Electrical Safety

    The stock of each chemical must be stored outside the robot control/compressor room according to • local rules and regulations. Contact your local Lely service provider for more information. Store the udder care products outside the robot control/compressor room, but at a different location •...

  • Page 15: Operating Safety

    Do NOT use chlorine, or other acids than phosphor and citric acid products in the cleaning system. • Lely Industries N.V. is not liable for, and does not cover under warranty, any damage or harm due to • the use of other cleaning products not meeting the Lely specifications.

  • Page 16: Signal Icons

    in n o vato rs in ag ric u ltu re SWITCH OFF the machine, disconnect and isolate the electrical power supply, release pneumatic • pressure and wait for all moving parts to stop before you do work on the machine. Take extreme care when you work near or with high-pressure pneumatic systems.

  • Page 17: Safety Decals

    in n o vato rs in ag ric u ltu re Notice Is used to address practices not related to physical injury e.g. property damage. Indicates information that may help the reader, but not hazard related. Safety Decals 1.3.1 Location of Safety Decals 1.3.1.1 Central Unit Figure 3.
  • Page 18 in n o vato rs in ag ric u ltu re Figure 4. Location of the safety decals central unit KEY: 9. Read the manual - Safety...

  • Page 19: Robot Unit

    in n o vato rs in ag ric u ltu re 1.3.1.2 Robot Unit Figure 5. Location of the safety decals robot unit KEY: 1. Pinching hazard - 2. Electrocution hazard - 3. Rotating parts, entanglement hazard - 4. Read the manual - 5. Chemical hazard - 6.

  • Page 20: M4Use (Optional)

    in n o vato rs in ag ric u ltu re 1.3.1.3 M4USE (optional) Figure 6. Location of the safety decals M4USE KEY: 1. Read the manual - 2. Temperature hazard Safety...

  • Page 21: Explanation Of Safety Decals

    in n o vato rs in ag ric u ltu re 1.3.2 Explanation of Safety Decals 1.3.2.1 Central Unit Central Unit (see page 1-5). Decal Explanation Danger: Hazardous voltage Contact will cause electric shock or burn. Disconnect power before servicing. Hazardous voltage decal (except Canada and USA) ELECTROCUTION HAZARD...
  • Page 22 in n o vato rs in ag ric u ltu re Central Unit (see page 1-5). Decal Explanation Safety Instructions: Chemical replacement Shows how to replace the chemicals. Warning: Corrosive liquid Risk for serious injury. Obey all applicable health and safety rules. Avoid contact between the liquid and your skin or eyes.

  • Page 23: Robot Unit

    in n o vato rs in ag ric u ltu re 1.3.2.2 Robot Unit Robot Unit (see page 1-7). Decal Explanation Caution: Pinch point Moving parts can crush or cut. Keep hands clear. Pinch point (except Canada and USA) Pinch point (Canada and USA) Danger: Hazardous voltage Contact will cause electric shock or burn.
  • Page 24 in n o vato rs in ag ric u ltu re Robot Unit (see page 1-7). Decal Explanation Warning: Corrosive liquid Risk for serious injury. Obey all applicable health and safety rules. Avoid contact between the liquid and your skin or eyes. Wear gloves, safety goggles and protective clothing.

  • Page 25: M4Use (Optional)

    in n o vato rs in ag ric u ltu re 1.3.2.3 M4USE (optional) M4USE (optional) (see page 1-8). Decal Explanation Caution: Hot water and steam Contact with hot water and steam may cause burns. During M4use flush, keep the M4USE cover closed and keep safe distance.

  • Page 26: Safety Decal Maintenance

    Replace safety decals that are missing or are illegible. • • Safety decals can be purchased from your local Lely service provider. Emergency Stop Buttons Central unit In case of an emergency, remove the power supply plug from the wall socket or switch off the main switch.
  • Page 27 in n o vato rs in ag ric u ltu re Figure 7. Location of the emergency stop buttons Safety 1-15...
  • Page 28 in n o vato rs in ag ric u ltu re INTENTIONALLY BLANK 1-16 Safety...

  • Page 29: Specifications

    Product/ingredient name Identifiers REACH #.01–2119485924–24. 25–35. Phosphoric acid. EC: 231–633–2. CAS: 7664–38–2. Index: 015–011–00–6. EC: 201–069–1. 5–10. Citric acid. CAS: 5949–29–1. UN specification ADR/RID UN1805. PHOSPHORIC ACID SOLUTION. The safety data sheets of the Lely products are available at https://www.lely.com/techdocs/consumables/ Specifications...

  • Page 30: Alkaline Based

    Index: 011–002–00–6. UN specification: ADR/RID UN1824. SODIUM HYDROXIDE SOLUTION. The safety data sheets of the Lely products are available at https://www.lely.com/techdocs/consumables/ 2.1.3 Brush Disinfectant Corrosive liquid. Risk for serious burns to fingers or hands. Obey all applicable health and safety rules. Avoid contact between the liquid and your skin or eyes.

  • Page 31: Reagent

    Index: 607–094–00–8. UN specification: ADR/RID UN3149. HYDROGEN PEROXIDE AND PEROXYACETIC ACID MIXTURE STABILIZED. The safety data sheets of the Lely products are available at https://www.lely.com/techdocs/consumables/ 2.1.4 Reagent Corrosive liquid. Risk for serious burns to fingers or hands. Obey all applicable health and safety rules. Avoid contact between the liquid and your skin or eyes.

  • Page 32: Tds Lens Cleaner

    Ethanol. EC: 200–578–6. CAS: 64–17–5. Index: 603–002–00–5. The safety data sheets of the Lely products are available at https://www.lely.com/techdocs/consumables/ 2.1.6 Udder care The conductivity of the udder care must be < 13mS/cm. Foaming of the udder care is not allowed.

  • Page 33: Water Supply

    Udder care must be colored. The optical- and conductivity characteristic of the udder care must be stable. The safety data sheets of the Lely products are available at https://www.lely.com/techdocs/consumables/. Water Supply 2.2.1 Building Specifications Tap connection(s): ¾”...

  • Page 34: Supply Requirements

    in n o vato rs in ag ric u ltu re 2.2.2 Supply Requirements Always use potable water (fresh tap water, not stored in a reservoir because of micro- organism growth) for internal and external use (because of food safety). Input central unit Water temperature: •...

  • Page 35: Water Specifications

    in n o vato rs in ag ric u ltu re 2.2.2.1 Water Specifications The water quality worldwide differs from area to area. The water quality can have influence on the life time of certain components (e.g. boiler, Pura) of the robots. Also the water used for the outside cleaning of the robots could harm certain components (e.g.

  • Page 36: Water Consumption

    *HAB: Heterofe Aerobe Bacteria. *APB: Acid Producing Bacteria. Lely Industries N.V. is not liable for, and does not cover under warranty, any damage or harm due to the use of water (inside or outside) of the robots not meeting the Lely specifications.
  • Page 37 in n o vato rs in ag ric u ltu re Water consumption for each RU 37 l (9.7 gal) Main cleaning (hot water). • 16 l (4.2 gal) Post-rinse. • Milking 1.31 l (0.35 gal) 0.6 l (0.16 gal) Brush cleaning.
  • Page 38 in n o vato rs in ag ric u ltu re INTENTIONALLY BLANK 2-10 Specifications...

  • Page 39: Description And Operation

    in n o vato rs in ag ric u ltu re Description and Operation Description 3.1.1 Cleaning System 3.1.1.1 Operation Cleanings and Rinses A cleaning or rinsing starts: Automatically with the settings in the E-Link or T4C. • Manually when started on the E-Link or CRS web interface. •...
  • Page 40 in n o vato rs in ag ric u ltu re USA cleaning. • Local cleaning extra water. • Local cleaning hot water. • Cluster Cleaning All parts that make contact with milk on all the robot units and the milk line in a cluster are rinsed and cleaned during a cluster cleaning.

  • Page 41: Feed Unit

    The risk of poor feed choices can lead to less robot visits and general malnutrition of the cows. Always keep a close eye on the herd and their visiting behaviour. In case of problems or for improving the feed ration, contact your nutritionist or Lely Farm Management Support.
  • Page 42 in n o vato rs in ag ric u ltu re Calibrate the FPS when the alarm No feed detected is generated. If the feed type is too soft, it can happen that the FPS does not detect the feed reliably. Ignore the alarm or switch off the FPS and frequently examine if the feed hopper works properly.
  • Page 43 in n o vato rs in ag ric u ltu re Examine the Feed Type Suitability Provide an Indication if the Feed is Suitable for the Hopper 9-9600-2821-0 9-9600-2822-0 Figure 8. Fill a cup Figure 9. Press the feed down 9-9600-2825-0 Figure 11.
  • Page 44 in n o vato rs in ag ric u ltu re Wipe away the feed on the surface that falls out of the cup. (see figure 12 on page 3-5). After wiping away the excess of feed in front of the cup, the feed will repositioning in the cup. Wipe again the excess of feed that falls out of the cup (see figure 13 on page 3-5).
  • Page 45 in n o vato rs in ag ric u ltu re Examine the Feed Suitability Different types of Feed Figure 15. Different type of feeds KEY: From left to right, the feed types become more difficult to feed. Risk indication and Feed Suitability The steeper the angle (α°), the more likely it will cause bridging problems in the feed hopper.
  • Page 46 in n o vato rs in ag ric u ltu re INTENTIONALLY BLANK Description and Operation...

  • Page 47: Operating Instructions

    in n o vato rs in ag ric u ltu re Operating Instructions Cleaning 4.1.1 Start Cleaning On the E-Link select: Button to open the quick launch bar. Button to open the second set of the quick launch buttons. Button Choose a local cleaning or a cluster cleaning: For a Lelywash, select button Lelywash.
  • Page 48 in n o vato rs in ag ric u ltu re It is not advised to perform an M4USE Flush within an hour before a cluster cleaning, to make sure the cleaning water has the optimal temperature during the cluster cleaning. On the E-Link/ X-Link select: Button A pop up window will appear, presenting one of...

  • Page 49: Start Up And Reset

    On the E-Link select: Button to open the quick launch buttons bar. Button When the ongoing milking or cleaning process is finished, the ASTRONAUT A4 stops, meanwhile button is displayed. When the milking robot is out of operation, button (start) is displayed.

  • Page 50: Put The Robot Unit In Operation With The E-Link

    in n o vato rs in ag ric u ltu re 4.2.2 Put the Robot Unit in Operation with the E-Link On the E-Link select: Button to open the quick launch buttons bar. Button During start up, button is displayed. When the milking robot is in operation, button (stop) is displayed.

  • Page 51: Maintenance

    Maintenance Preventive Maintenance Schedule The following tables show the preventive maintenance schedule for the milking robot defined by Lely. Preventive maintenance must also be done as specified by local regulations. Each task mentioned in these tables is linked to its description.
  • Page 52 in n o vato rs in ag ric u ltu re Examine the quantity of MQC-C reagent Examine the quantity of chemical products in the central unit Examine the air compressor and the air dryer Examine the robot performance list, refer to the T4C manual Weekly maintenance Task Week...

  • Page 53: Move The Robot Arm

    in n o vato rs in ag ric u ltu re Move the Robot Arm 5.2.1 Move the Robot Arm to the Service Position Take the robot unit out of operation with the E-Link (see Take One Robot Unit Out of Operation with the E-Link on page 4-3).

  • Page 54: Covers And Doors

    in n o vato rs in ag ric u ltu re Covers and Doors 5.3.1 Lower Arm Cover 5.3.1.1 Remove the Lower Arm Cover Remove the screws and watertight washers (1). Remove the cover (2). Figure 20. Lower arm cover KEY: 1.
  • Page 55 in n o vato rs in ag ric u ltu re Remove the screw (1) while holding the threaded bracket (2). Put the screw and threaded bracket on a safe place. Figure 21. Bracket with screw KEY: 1. Screw - 2. Threaded bracket Make sure the sTDS cable does not become tight or damaged when you remove the cover.

  • Page 56: Install The Mothership Cover

    in n o vato rs in ag ric u ltu re 5.3.2.2 Install the Mothership Cover Make sure the sTDS cable does not become tight or damaged when you remove the cover. Carefully position the cover on the mothership (see figure 22 on page 5-5). Tighten the two bolts (1).
  • Page 57 in n o vato rs in ag ric u ltu re Select Tasks. Select Feed portion. At Entry gate button Open. Go into the box through the entry gate. Empty the feed bin. Go out of the box through the entry gate. Measure the feed Portion The steps below must be done for all installed feeding valves.

  • Page 58: Calibrate The Feed Presence Sensor

    in n o vato rs in ag ric u ltu re 5.4.1.2 Calibrate the Feed Presence Sensor Rotating parts Moving parts can crush or cut. Keep hands, loose clothing and long hair away from moving parts during operation of the machine. The calibration process uses an average of two or three feed portions, with a maximum of ten feed portions.

  • Page 59: Mqc-C

    in n o vato rs in ag ric u ltu re Second 'Status' field Action Result Action shows Calibration done Second Status field Select the button Do the calibration (calibration succeeded). shows Standby. Store Calibration procedure for the Results. other feed pipes. Calibration Failure A pop-up window Select the button...
  • Page 60 4 to 30 ºC (29 to 86 ºF). Do not store the MQC-C solution in the central unit. At Lely consumables a large container for mixing the MQC-C reagent solution can be ordered.
  • Page 61 in n o vato rs in ag ric u ltu re Disconnect the reagent supply tube (1) from the reagent container (see figure 23 on page 5-11). Remove the reagent container from the robot unit and put it on a clean surface. Remove the cap of the reagent container.
  • Page 62 in n o vato rs in ag ric u ltu re Fill the reagent container with the MQC-C reagent solution (see figure 25 on page 5-12). Install the cap on the mixing container. Install the cap on the reagent container. Install the reagent container on the MQC-C bracket (see figure 23 on page 5-11).

  • Page 63: Clean The Waste Tube

    in n o vato rs in ag ric u ltu re Disconnect the reagent supply tube (1) with connector from the safety valve of the reagent container (see figure 26 on page 5-13). Disconnect the reagent supply tube (1) from the MQC-C.

  • Page 64: Teat Cups

    in n o vato rs in ag ric u ltu re Figure 28. Install the waste tube KEY: 1. Waste tube Install the waste tube on the MQC-C (see figure 28 on page 5-14). Make sure the waste tube is not placed to the top. Put the robot unit in operation with the E-Link.
  • Page 65 in n o vato rs in ag ric u ltu re Special Tools to Replace the Twin Tube Clamp pliers. • • Tube cutter. Figure 29. Clamp pliers Figure 30. Tube cutter Loosen the Cord Cups and Straigthen the Tilt Cups at the E-Link On the E-Link select: Tab Test.
  • Page 66 in n o vato rs in ag ric u ltu re Remove the Twin Tube Remove the bolts (2) and the locking strip (3). Slide the twin tube segregator in the direction of the teat cups. Take the twin tube segregator away. Figure 31.
  • Page 67 in n o vato rs in ag ric u ltu re Use the clamp pliers to release the clamps (1) on the connection pieces to the preformed milk tubes (see figure 33 on page 5-17). Disconnect the twin tube from the connection piece (2) to the 4effect pulsator tubes.
  • Page 68 in n o vato rs in ag ric u ltu re Clean and dry the milk collection cup (2) (see figure 36 on page 5-18). Fully connect the twin tube (1) to the milk collection cup (2) of the teat cup. Figure 36.
  • Page 69 in n o vato rs in ag ric u ltu re Use anti-seize paste on all bolts to prevent seizing. Install the second (larger) part of the twin tube cover (2) with the bolts to the smaller part of the twin tube cover with a torque of 1.5 Nm (see figure 38 on page 5-19).
  • Page 70 in n o vato rs in ag ric u ltu re At Cord cups select: LF Fixed. LR Fixed. RF Fixed. RR Fixed. Close-up for Replace the twin Tubes Install the Mothership Cover (see page 5-6). Install the Lower Arm Cover (see page 5-4). Start the local rinse procedure Start Cleaning (see page 4-1).

  • Page 71: Diagrams

    in n o vato rs in ag ric u ltu re Diagrams Gate Guard Set 6.1.1 Gate Guard Set Examples The stand poles and additional tubing for the gate guard set are not provided in the set and must be bought externally. The diameter of the stand poles must be 76 mm (2.5 in). To avoid cows are harmed, avoid protruding parts.
  • Page 72 in n o vato rs in ag ric u ltu re Figure 40. Examples of a gate guard set with self-made additional tubing KEY: 1. Gate guard set - 2. Stand pole (3x) - 3. Additional tubing (2x) - 4. Additional tubing (4x) - 5. Additional tubing (1x) Diagrams...

  • Page 73: Gate Guard Set Dimensions

    in n o vato rs in ag ric u ltu re 6.1.2 Gate Guard Set Dimensions 5 5 5 Figure 41. Gate guard set with self-made additional tubing KEY: 1. B = <235 mm (9.3 in) or >300 mm (11.8 in) - 2. B = >235 mm (9.3 in) and <300 mm (11.8 in) - 3. Extra additional tubing - 4. T- clamp - 5.
  • Page 74 in n o vato rs in ag ric u ltu re Table 2. Dimensions <235 mm (9.3 <235 mm (9.3 in). <235 mm (9.3 in). <235 mm (9.3 max. 1400 mm (55.1 in). in). >300 mm (11.8 >500 mm (19.7 in).

  • Page 75: Disposal

    Lubricants and fluids must be disposed correctly to prevent pollution of the environment. Read the safety data sheets of the used lubricants and fluids for correct disposal. All lubricants and fluids must be disposed in compliance with the local rules and regulations. Contact your local authority or local Lely service provider for further details. Disposal...
  • Page 76 in n o vato rs in ag ric u ltu re INTENTIONALLY BLANK Disposal...

  • Page 77: Index

    in n o vato rs in ag ric u ltu re Index Cluster cleaning..........3-2 Decommissioning ..........7-1 Disposal ............7-1 Emergency stop button ........1-14 Lelywash ............3-1 Local rinse............3-1 Main cleaning ............3-2 Milkline rinse.............3-2 pH value............2-7 Post-rinse............3-2 Pre-rinse ............3-2 Recycle .............7-1 Safety ...............1-1 Serial number ............7 Torque loading .............7 Type number ............7...
  • Page 78 in n o vato rs in ag ric u ltu re INTENTIONALLY BLANK Index...
  • Page 80 Lely Industries N.V. CornelisFvanFderFLelylaanF1 NL-3147FPB FMaassluis Tel +31F(0)88F-F12F28F221 Fax +31F(0)88F-F12F28F222 www.lely.com...

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