10/03-1.0 D105018

Isolator Xp

Pulsation and automatic cluster removal

Edition 1.0

Technical manual

D 480197 / D 480199 / D 480200 / D480201

D105018 2 10/03-1.0

General information

1. CopyrightThe copyright of this publication rests with Gascoigne Melotte Technology B.V.

2. NoticeAll rights reserved. No part of this publication may be reproduced, stored in a database or pub-lished in any form or in any way, electronically, mechanically, by print, photoprint or any othermeans, without prior explicit permission from Gascoigne Melotte Technology B.V.

3. Restrictions on useThis document may not be lent out, resold, rented out or handed out in any other way, bound orwith a cover, other than the way it was published, without prior permission from GascoigneMelotte Technology B.V.

4. Information and improvementsAny information in terms of comments, correction and improvements with regard to this informa-tion should be addressed to:

Gascoigne Melotte Technology B.V.Publications DepartmentP.O. Box 342140 AA Vijfhuizen

Phone: 0031-023-558 9050Fax: 0031-023-558 9051

In the event of a breakdown:

· Maintenance work to this equipment must be carried out by trained service personnel.

· Disconnect electric equipment from the mains power supply before work is carried out.

· Ensure that electric equipment is kept away from water and moisture to prevent fire risksand perilous electric shocks.

· Disconnect electric equipment from the mains power supply when changing over to a stand-by generator.

· Following the generator start-up, first check the stability of the voltage before connectingthe electronic equipment.

The exclamation mark in the warning triangle is to draw the user’s attention to the safety, opera-tional, maintenance and service instructions in this manual.

10/03-1.0 3 D105018

Warning:

Plastic materials as part of the Isolator Xp are resistant to hot water, as well as to acid andalkaline cleaning agents.

However: the chemical resistance may be adversely affected by products containing ketone,chlorinated hydrocarbons, aromatic hydrocarbons and higher alcohols. They will always befound in petroleum and paraffin-like substances, as well as in methyl alcohol, diesel fuel, etc.They can also be found in certain insecticides; some teat ointments; and sometimes inspraycan propellants.

Please make sure that such products are kept away from the plastic parts.

The resistance of metal paint used for the Isolator Xp may be adversely affected by cleaningagents for stainless steel or products like ammonia.

Please make sure that such products are kept away from the metal parts.

Gascoigne Melotte shall assume no liability of any kind for damages caused by the useof chemicals that are not recommended or sold by Gascoigne Melotte.

Furthermore, Gascoigne Melotte shall not be liable and reject any claim for injuries toanimals, consequential damages, or any other damages and losses as a result of failingto carefully observe the instructions in this manual.

D105018 4 10/03-1.0

Contents1 Safety -----------------------------------------------------------------------------------------------------62 Introduction --------------------------------------------------------------------------------------------72.1 Features Isolator Xp milk flow sensor -------------------------------------------------------------------- 73 Parts ------------------------------------------------------------------------------------------------------83.1 Isolator Xp milk flow sensor --------------------------------------------------------------------------------- 83.2 Automatic cluster removal (D480128) ------------------------------------------------------------------- 103.3 Supply transformer 9 Amp (D480166) ------------------------------------------------------------------- 123.4 Lectron TL pulsator (D494147) ---------------------------------------------------------------------------- 133.5 Remote control switch with LED (D480154) ------------------------------------------------------------ 143.6 Connection ------------------------------------------------------------------------------------------------------ 143.7 Terminology ----------------------------------------------------------------------------------------------------- 144 Switching on / off -------------------------------------------------------------------------------------175 Working --------------------------------------------------------------------------------------------------185.1 Vacuum delay -------------------------------------------------------------------------------------------------- 195.2 Initial delay ------------------------------------------------------------------------------------------------------ 195.3 Drop-off system------------------------------------------------------------------------------------------------ 195.4 Drop-off delay -------------------------------------------------------------------------------------------------- 195.5 Cluster venting delay ----------------------------------------------------------------------------------------- 195.6 Milk sweep ------------------------------------------------------------------------------------------------------ 205.7 Pulsation --------------------------------------------------------------------------------------------------------- 205.8 Pre-stimulation ------------------------------------------------------------------------------------------------- 205.9 Milk flow controlled stimulation ----------------------------------------------------------------------------- 205.10 Switch operation ---------------------------------------------------------------------------------------------- 216 Installation ----------------------------------------------------------------------------------------------226.1 Installing the Isolator Xp automatic automatic cluster removal (new or replacement installa-

tions) --------------------------------------------------------------------------------------------------------------- 226.1.1 Removing the vacuum supply lines -------------------------------------------------------------------- 226.1.2 The automatic cluster removal (ACR) ----------------------------------------------------------------- 246.1.3 Positioning the automatic cluster removal ------------------------------------------------------------ 256.1.4 Attaching the cord to the automatic cluster removal ----------------------------------------------- 266.1.5 Mounting the automatic cluster removal horizontally ---------------------------------------------- 266.1.6 Mounting the ACR vertically ------------------------------------------------------------------------------ 276.1.8 Mounting the cord ------------------------------------------------------------------------------------------- 286.2 Mounting the Isolator Xp milk flow sensor --------------------------------------------------------------- 286.2.1 Wiring the Isolator Xp milk flow sensor ---------------------------------------------------------------- 296.2.2 Sealing the cable glands ---------------------------------------------------------------------------------- 306.2.3 Mounting on low-line milking installations ------------------------------------------------------------- 316.2.4 Mounting on high-line milking installations ------------------------------------------------------------ 326.3 Lectron TL pulsator ------------------------------------------------------------------------------------------- 336.3.1 Mounting ------------------------------------------------------------------------------------------------------ 336.3.2 Wiring ---------------------------------------------------------------------------------------------------------- 346.4 Parameters ----------------------------------------------------------------------------------------------------- 346.4.1 Isolator Xp milk flow sensor Type Print ---------------------------------------------------------------- 346.4.2 Milk Sweep (DIP switch 1) -------------------------------------------------------------------------------- 366.4.3 Clawpiece shut-off time ------------------------------------------------------------------------------------ 366.4.4 Vacuum delay ------------------------------------------------------------------------------------------------ 366.4.5 End - Milking – Signal -------------------------------------------------------------------------------------- 366.4.6 Drop-off sensor adjustment ------------------------------------------------------------------------------ 37

10/03-1.0 5 D105018

6.4.7 Description drop-off adjustment ------------------------------------------------------------------------- 386.5 Inside of the Isolator Xp milk flow sensor ---------------------------------------------------------------- 396.6 LED description ------------------------------------------------------------------------------------------------ 406.7 Standard settings Isolator Xp ------------------------------------------------------------------------------- 417 Maintenance--------------------------------------------------------------------------------------------427.1 Before each milking ------------------------------------------------------------------------------------------- 427.2 Monthly ----------------------------------------------------------------------------------------------------------- 427.3 Annually ---------------------------------------------------------------------------------------------------------- 427.4 Every 3 years -------------------------------------------------------------------------------------------------- 427.5 Service diagram Isolator Xp milk flow sensor ---------------------------------------------------------- 447.6 Service diagram Lectron TL -------------------------------------------------------------------------------- 467.7 Spare parts Isolator Xp milk flow sensor ---------------------------------------------------------------- 487.8 Trouble shooting Isolator Xp milk flow sensor ---------------------------------------------------------- 508 Specifications------------------------------------------------------------------------------------------518.1 Isolator Xp milk flow sensor --------------------------------------------------------------------------------- 518.2 Automatic cluster removal (D480128) ------------------------------------------------------------------- 518.3 Supply transformer 3 Ampere (D480166) --------------------------------------------------------------- 528.4 Supply transformer 9 ampère (D480166) --------------------------------------------------------------- 528.5 Lectron TL pulsator (D494147) ---------------------------------------------------------------------------- 528.6 Supply transformer 13V DC 12 Ampère (D262623) -------------------------------------------------- 529 Storage and transport ------------------------------------------------------------------------------5310 Dismantling and the environment -------------------------------------------------------------5411 Connection diagrams------------------------------------------------------------------------------5511.1 Wiring control print ------------------------------------------------------------------------------------------- 5511.2 Milk line installation cows----------------------------------------------------------------------------------- 5711.3 Milk pipes installations goats with milking cluster retractor ---------------------------------------- 5811.4 Milk pipe installation goats highline with milking cluster retractor -------------------------------- 5911.5 Milk line installations Goats with Isolator Xp automatic cluster removal ----------------------- 60Appendix 1: Certification -----------------------------------------------------------------------------61Appendix 2: ACR3TOOL -----------------------------------------------------------------------------62

D105018 6 10/03-1.0

1 SafetyAll machines with the CE mark comply with the demands contained in EU-machinery directive89/336EEG when used for their intended purpose (see EU declaration of conformity, appendix1).

10/03-1.0 7 D105018

2 IntroductionThis document describes the working, connection and maintenance instructions for the:

· D480197 Isolator Xp milk flow sensor for standard cow

· D480199 Isolator Xp milk flow sensor goats with milking cluster retractor

· D480200 Isolator Xp milk flow sensor goat hi-line with milking cluster retractor

· D480201 Isolator Xp milk flow sensor goat with automatic cluster removal

The Gascoigne Melotte Isolator Xp milk flow sensor is an electronically controlled automaticcluster removal system which removes the milking cluster when milking is finished using inte-grated pulsation and stimulation. This system reduces the workload on the operator and practi-cally prevents any risk of under or over milking.The Isolator Xp milk flow sensor is extremely user friendly as there are no valves or switches tobe operated during milking: simply connect the milking cluster.

2.1 Features Isolator Xp milk flow sensor· The Isolator Xp milk flow sensor housing contains the milk shut-off valve, conductivity sensor

for immediate milk flow indication and the cluster removal PCB.

· The clawpiece does not need a shut-off. This makes the system suitable for practically alltypes of clawpiece.

· Gentle removal by slowly reducing the vacuum in the clawpiece before the milking clusteris actually removed by the removal system.

· Removal activated by lifting the milking cluster.

· Automatic or manual removal procedure.

· Automatic detection system if milking clusters drops off before the end of milking: closesthe milk shut-off valve and controls the automatic cluster removal.

· Automatic cluster removal with built-in solenoid valve “press button” activation.

· Accurate delay control.

· Modular system, easy to install and maintain.

· Removal moment adjustable per cow, depending on the milk characteristics.

· Milk sweep to remove any milk residue in the milk tube or clawpiece by briefly opening themilk shut-off valve.

· Pre-wash feature places any unused milk clusters in the jetter cups before milking iscompleted.

· Internal pulsation control with settable pulsation ratios

· Milk flow controlled stimulation

D105018 8 10/03-1.0

3 Parts3.1 Isolator Xp milk flow sensor

Figure 1: Isolator Xp milk flow sensor

10/03-1.0 9 D105018

1 Main cap

2 Cap seal

3 Metal screw M5 x 16, stainless steel

4 Metal screw M2.5 x 5. stainless steel

5 Plug

6 Compression spring

7 Contact

8 Airway bung

9 Airway distributor

10 Metal screw M4 x 40, stainless steel

11 Diaphragm bracket

12 Lower diaphragm

13 Valve spindle

14 Valve

15 Solenoid

16 Metal screw M4 x 16, stainless steel

17 Solenoid bracket

18 O-ring

19 Chimney

20 Upper airway seal

21 Circlip

22 Valve disc

23 Upper diaphragm

24 Shuttle

25 Sealing ring

26 Sealing ring

27 Piston

28 Valve spring

29 Printed Circuit Board

30 Bearings

31 Valve body

32 Lower airway seal

33 Lower body

34 PCB connector

35 Drop-off and Removal Stand-by LED

36 Power on / off LED

37 ACR on / off LED

38 Drop-off adjustment LED

39 Milk flow LED

40 Switch

41 Switch cover

42 Milk chamber seal

43 Shaft seal

44 Milk chamber

45 Thumb nut

46 Cap

47 Dipswitch

48 Drop-off adjustment screw

49 Nut M3

50 Insulating washer

D105018 10 10/03-1.0

3.2 Automatic cluster removal (D480128)

Figure 2: automatic cluster removal (D480128)

10/03-1.0 11 D105018

1 Metal screw M4 x 45, stainless steel

2 Cluster cap

3 Foam plastic filter

4 Solenoid

5 Metal screw M4 x 16

6 Solenoid bracket

7 Chimney

8 Shuttle

9 O-ring

10 Sealing ring

11 Bulk head

12 Connection nozzle vacuum tube

13 Screw 8B x 16

14 Rubber seal

15 Removal system line

16 Countersunk screw 8B x 19, stainlesssteel

17 Holding boss

18 Contact ring

19 Washer

20 Screw 6B x 12.7, stainless steel

21 Clamping plate

22 Diaphragm

23 Piston seal

24 Cone

25 Piston body

26 Tension pin stainless steel

27 Pulley Ø 25mm

28 Cord

29 Lower pulley holder

30 Circlip

31 Locking ring

D105018 12 10/03-1.0

3.3 Supply transformer 9 Amp (D480166)

Figure 3: supply transformer 9 Ampere (480166)

1. Rectifier 25 Amp., 100 V.

2. Heat sink

3. Glass fuse 15 Amp quick blown

4. Glass fuse holder

5. Transformer 17 V. 12 Amp

6. Output + voltage

7. Output voltage

8. Earth

9. Switch DPST, 3 Amp., 250 V

10. Cover

11. Glass fuse 1 Amp slow blown

12. Cable gland main output

13. Connection block

14. Water resistant seal

10/03-1.0 13 D105018

3.4 Lectron TL pulsator(D494147)

1 Metal screw M3 x 45, stainless steel

2 Main cap

3 Metal screw M4 x 16

4 Solenoid

5 Solenoid connectors

6 Chimney duct

7 Valve

8 Sealing ring

9 O ring

10 Mounting plate solenoid

11 Gasket

12 Cable to pulsation control unit

13 Intermediate plate

14 Diaphragm

15 Seal

16 Spindle

17 Metal screw M4 x 40, stainless steel

18 Metal screw M3 x 25, stainless steel

19 Unit TL pulsator

20 Support sleeve

21 Sealing ring

22 Pipline clamp

23 Filter

24 Sealing ring

25 Lower cap

26 Metal screw M3 x 20, stainless steel

27 Restrictor, white, inner Ø 3,5 mm

28 Cap Ø mm

Figure 4: Lectron pulsator (D494147)

D105018 14 10/03-1.0

3.5 Remote control switch with LED (D480154)

Figure 5: remote control switch (D480154)

The remote control switch is used with high-line milking installations and dairies with Lactronic3000 drain edges. The LED lights up synchronous to LED D2.

3.6 ConnectionWHITE LED +BROWN LED -YELLOW SWITCHGREEN SWITCH

3.7 Terminology

PulsationsPulsation means opening and closing the teat liners in the teat cups. This occurs when the valvesystem, the pulsator, alternately admits atmospheric air and air from the vacuum system into thechamber between the liner and cup. The teat liner opens when vacuum is created in the spacebetween the teat liner and the teat cup. If atmospheric air is allowed to enter this space the teatliner will close.Most pulsators can be classified as follows:

· Relay pulsators where a central pulsation unit controls pulsation rate and ratio.

· Stand alone pulsators with a built-in pulsation control unit.

Pulsators can control all 4 teat cups simultaneously - Simultaneous system.Pulsators can control 4 teat cups in pairs - Alternate system.

Alternate pulsation: The alternate cyclical movement of half the number of teat liners on thesame milking cluster.

Atmospheric pressure phase: How long atmospheric pressure is present in the pulsationarea (d-phase) expressed as a percentage of the entire pulsation stroke.

Cascade: A method where solenoids in the pulsators are controlled in sequence so that only acertain number of solenoids (with the Lectron 612 system usually a third of the total number) areactivated at a certain time. The aim is to reduce the vacuum demand for the pulsation compared

10/03-1.0 15 D105018

to the demand with a simultaneous setting (simultaneous activation of all the pulsators).

Compensating pulsation: Milking with a different pulsation ratio on the front and rear teats.

Equal pulsation ratio: The same pulsation ratio on the front and rear teats.

Maximum vacuum phase: How long maximum vacuum is present in the pulsation area (b-phase) expressed as a percentage of the entire pulsation stroke.

Milking phase: The part of the pulsation stroke where the teat liner is open. Milk flows out of theteat during this phase.

Pair ratio: The difference in pulsation ratio between both pairs of teat cups in the same milkingcluster, for example with alternate milking, expressed as a percentage

Pulsation characteristic: A graph illustrating the progress of the vacuum level and the vacuumsignal in the pulsation zone.

Pulsation zone: Space between the teat liner and the teat cup.

Pulsation zone vacuum registration: Each period of pulsation zone vacuum expressed asfollows:

a. Vacuum increase phase- teat liner opens

b. Maximum vacuum phase -teat liner fully opened

c. Vacuum decrease phase- teat liner closes

d. Minimum vacuum phase- teat liner fully closed

The duration of each phase, expressed as a percentage of the entire pulsation stroke, is meas-ured at points where registration cuts through the abcis (y-axis) at a level of 4 kPa below nominalvacuum and above atmospheric pressure.

Pulsation stroke: A complete cyclical movement of a teat liner.

Pulsation rate: The number of pulsations per minute.

Pulsation control unit: A mechanism that controls one or more pulsator(s). In the first instancethe mechanism is built into one pulsator (stand-alone pulsator); in the second case the installa-tion is separate and the mechanism controls several pulsators.

Pulsation ratio: The duration of a vacuum increase (a- phase) + the duration of the maximumvacuum level (b-phase) in relation to the duration of the vacuum decrease (c-phase) + the dura-tion of the minimum vacuum level (d-phase) in the space between the teat liner and teat cup(pulsation zone) expressed as a percentage of the total pulsation stroke. The pulsation ratio isexpressed as follows:

a + b x 100% : c + d x 100%a + b + c + d a + b + c + d

D105018 16 10/03-1.0

Rest phase:The part of the pulsation stroke when the teat liner is closed. There is no vacuum on the teat.

Simultaneous pulsation:The synchronous cyclical movement of all teat liners in the same milking cluster.

Pulsation air usage per milking cluster:The amount of air used by the pulsation system per milking cluster during milking.

Required average airflow:The required amount of airflow, taking into account any narrowing on the route between themilking cluster and the pulsation lines (e.g. a narrowing is caused where the pulsator is con-nected to the pulsation lines).

Figure 6: Pulsation cycle

10/03-1.0 17 D105018

4 Switching on / offThe Isolator Xp milk flow sensor can be switched on or off using the switch on the power supplyunit. With normal operation the power is never switched off.

If the Isolator Xp milk flow sensor is in Pause mode (in other words non-milking mode) the sys-tem will deactivate both solenoids (one for the Isolator Xp sensor, the other in the automaticcluster removal).

If an Aquastar Water management system is part of the installation, these actions take placeautomatically. If there is no Aquastar system present, the switch actions are done manually usingthe external switch.

D105018 18 10/03-1.0

5 WorkingThe Gascoigne Melotte Isolator Xp Automatic Cluster Removal system comprises 2 main parts:

· The Isolator Xp milk flow sensor including control system, internal pulsation and milk flow-controlled stimulation

· The automatic cluster removal

The system is controlled by the condition of the cow’s milk flow, using conductivity measuredbetween 2 probes.

The illustration below shows the front of the sensor and the position of both probes in the milkchamber, plus the 5 visible LEDs.The Isolator Xp milk automatic cluster removal measures the milk flow between both probes anduses the conductive properties of the milk; if there is milk between both probes the electricalcurrent is transmitted from one probe to the other, thereby completing the circuit.If there is no milk between the probes the current is interrupted. The percentage of time that milkis sensed between both probes is measured over a continuous time window of 30 sec.

Figure 7: LEDs

1. Power on/ off LED

2. Drop-off adjustment LED (for test purposes only)

3. Drop-off / ACR stand-by LED

4 ACR on / off LED

5. Milk flow LED (for test purposes only)

6. Probes

10/03-1.0 19 D105018

If the milking cluster in a raised position (normal if the vacuum pump is switched off), the auto-matic cluster removal is activated by lifting up the cluster. The vacuum in the milking clustersucks the diaphragm against the contact ring in the bulkhead of the system. The contact ringcompletes the circuit in the head of the ACR. This contact shuts off the vacuum to the milkingcluster removal unit and admits outside air causing the milking cluster to drop. This action startsthe vacuum delay and the initial delay.

5.1 Vacuum delayThis delay begins when the system is activated (see above) and gives the operator the opportu-nity to lower the milking cluster and prepare it for connection. During this brief period the milkshut-off valve in the Isolator Xp milk flow sensor remains closed. This delay means that as littleexcess air as possible is admitted during connection. The delay can be set from 0 to 4.5 sec-onds. The factory setting is 1.5 seconds

5.2 Initial delayDuring the initial delay the ACR signal is suppressed to prevent the milking cluster being re-moved before the milk has started to flow properly. The initial delay factory setting is 120 sec-onds for cows and 60 seconds for goats. When the initial delay has elapsed the removal systemis stand-by. The animal is milked as usual. After a certain time the milk flow decreases until therate is less than the milk flow time set in the ACR system.Vacuum to the clawpiece is then shut off and the cluster removed automatically.

5.3 Drop-off systemThis mechanism ensures that the cluster is lifted up immediately by the ACR system if it dropsoff/ is kicked off during milking. The clawpiece shut-off valve will be closed at the same time. Alight flashes on the Isolator Xp milk flow sensor to warn the operator. The drop-off signal is resetif the wash signal is activated. The drop-off signal can be switched off during sampling. Duringthe delay the user must keep the key pressed down for 4 seconds. The large LED will light up.The drop-off signal will be sensed again after the Isolator Xp milk flow sensor has been set tothe wash position.

5.4 Drop-off delayIf the milking cluster has fallen off/ been kicked off during milking the removal system will be indrop-off mode. From this mode the operator can connect the milking cluster normally (lift clusterup). This will restart the system with a delay of 20 seconds instead of 120 seconds. If the milk isnot flowing within 20 seconds, the milking cluster will be removed.

5.5 Cluster venting delayThis is the period between the milk tube valve closing until the moment the automatic clusterremoval removes the cluster from the animal. During this time the clawpiece fills up with outsideair via the vent hole. This means the teats are gently removed, comfortably lifting the clusterfrom the animal.

D105018 20 10/03-1.0

5.6 Milk sweepWhen the cluster has been lifted by the automatic cluster removal there is usually a certainamount of milk residue left behind in the clawpiece or milk tube. Briefly opening the milk tubeshut-off valve (standard setting 15 seconds after removal of the milk cluster ) admits a rush ofair which removes the last traces of milk. Set the time using ACR3TOOL.The milk sweep can be switched on or off. It is not used in jar dairies, as in this situation the jarsare vented after milking cluster removal so there is no vacuum available to open the milk tubeshut-off valve.

5.7 PulsationWhen the pulsation function has been activated, pulsation will start as soon as vacuum hasbeen created and milking has started.Standard pulsation setting at milking.

· Type of pulsation Alternate

· Pulsation ratio 60:40

· Pulsation speed /min 58

5.8 Pre-stimulationIf pre-stimulation has been activated, stimulation will start as soon as the first milk is sensed.Stimulation will stop after a set number of seconds (standard setting 20 sec).

5.9 Milk flow controlled stimulationIf the milk flow-controlled stimulation has been activated, it will start once if one of the followingconditions is met:

· The stimulation block time has elapsed (standard setting 30 sec). This time starts as soonas the first milk is sensed.

· The stimulation time window (the time parameters within which stimulation takes place)must be started (standard setting 70 sec). The milk flow during this period must be lessthan the set value (standard setting 400 gram / minute)

Stimulation stops when the set stimulation time has elapsed (standard setting 20 sec)Standard pulsation setting at stimulation:

· Type of pulsation Alternate

· Pulsation ratio 60:40

· Pulsation speed /min 200

10/03-1.0 21 D105018

5.10 Switch operationThe Isolator Xp milk flow sensor is easy to operate. The Isolator Xp milk flow sensor has a singleswitch with the followingfunctions:

· From stand-by mode (milking cluster lifted, all 3 LEDs lit up) press the switch for 1.5 seconds.This action places the Isolator Xp milk flow sensor in stand-by wash mode: The milkingcluster is lowered, but the milk tube shut-off valve remains closed. When the power hasbeen switched off, the valve will open for washing.

· If the switch is briefly pressed during the stand by wash mode, the Isolator Xp milk flowsensor will return to stand-by milking mode.

· If the switched is pressed for 1.5 seconds during the milking mode, vacuum to the milkingcluster will be shut off. During milking the cluster will be lifted off if the Isolator Xp milk flowsensor is accidentally activated.

· If the Drop-off/Removal Stand-by LED (35) flashes, press the switch for 1.5 seconds toreturn the Isolator Xp milk flow sensor to stand-by mode. If the ACR system is then started(after the cluster has been lifted) all wait /delays times are again available.

· Manual start stimulation (if set). Stimulation will start within the stimulation time window(standard 70 seconds) if the button is pressed.

· Starting stimulation when the cluster is connected. Press the button to deactivate stimulationfor the individual animal.

· Placing the Isolator Xp milk flow sensor in program mode (service purposes only). Set thesensor to stand-by wash mode. Press the button for 4 seconds until all 5 LEDs light up.Release the button. The Isolator Xp milk flow sensor can now be programmed using a PCand a programming adaptor.

· Deactivate Drop-off by pressing the button for 4 seconds during milking position. The largeLED will switch off.

D105018 22 10/03-1.0

6 Installation6.1 Installing the Isolator Xp automatic automatic cluster removal (newor replacement installations)

· The Isolator Xp milk flow sensor MUST be mounted horizontally

· Use correctly sized wiring and cabling

· All wiring connections must be watertight

· Ensure the wash/stand-by switch is functioning correctly

· The Isolator Xp milk flow sensor lid must be lubricated and sealed with Loctite Superlube,art. nr. A006004. Before tightening the screws ensure the lid seal does not stick or becomedistorted.

· Connect the vent nozzle to a clean air line or to the pulsator silencing line. See section6.3.3.

· Mount a milk tube of the correct diameter (15.5 mm ID) for the Isolator Xp milk flow sensorto the milk lines.

· Mount a milk tube of the correct length (30 mm ID) for the Isolator Xp milk flow sensor to themilk lines. (minimum 30 cm).

Pay attention to the following points:

· Correct length of the milk and pulsation tubes

· Correct attachment of the cluster to the udder

· Ensure there is a hook for the milk tube in situations where the cluster is connected fromthe side.

· Ensure the installation and sensors are cleaned thoroughly

· Ensure regular acid cleaning

· Carry out a circuit test on the installation. Test the pulsators using a pulsation tester. Savethe circuit test documents and test results of the pulsation tester.

6.1.1 Removing the vacuum supply linesThe vacuum lines supply the automatic cluster removal with vacuum in every milking position. Ifthis line is also used to support the automatic cluster removal, always use a galvanised line (11/4" or 42 mm). If the line is not used to support any equipment, a PVC line can be used instead.Always connect the vacuum supply line to the main vacuum line as shown in figure 8 and 9.

1. Circuit test point

2. Drill-on saddle to mount vacuum controller

3. T for vacuum line

4. Butterfly valve

5. End caps

10/03-1.0 23 D105018

Figure 8: Vacuum supply line

Figure 8 shows how to connect the vacuum supply line if only a vacuum pump group is used. Itis advisable to use end caps on the vacuum line so the inside of the lines can be cleaned.

Figure 9 Mounting vacuum supply line with balance tank

Figure 9 shows how to connect the vacuum supply line if the milking machine installation in-cludes a balance tank.

D105018 24 10/03-1.0

6.1.2 The automatic cluster removal (ACR)The ACR is supported by a line that may also be used as the vacuum supply line.Use a galvanized line (1 1/4" or 42mm) as an attachment line/ supply line. Attach the automaticcluster removal to the line using a bracket support (see fig. 10).Drill an 8.5 mm hole for the vacuum supply line. Mount a synthetic nozzle and then connect theautomatic cluster removal using flexible PVC piping.

Figure 10: Hanging the automatic cluster removal

If replacing an ACR system in an existing parlour with 1" or 25 mm piping, mount the bracket asshown in the drawing (see figure 11).

Figure 11: Mounting the bracket

10/03-1.0 25 D105018

6.1.3 Positioning the automatic cluster removalBefore mounting the automatic cluster removal and TLs establish the milking method used in theparlour concerned. For example, is milking done from the side or from between the hind legs?Correct positioning of the automatic cluster removal is very important to prevent hindering theanimal during removal. Install the ACR so that the pulley is aligned with the animal’s udders.Figure 12 shows the automatic cluster removal position if the clawpiece is connected betweenthe animal’s hind legs. If milking is done from the side in a herringbone parlour refer to figure 13.In a tandem milking parlour, position the automatic cluster removal as shown in figure 14.

Cut all cables to size with a slack of about 20 cm to allow corrections to be made at a later date.This also applies to the vacuum supply line.

Figure 12 / 13 / 14: Positioning the automatic cluster removal

D105018 26 10/03-1.0

6.1.4 Attaching the cord to the automatic cluster removalOpen the protection pin and remove the lower pulley holder. Place the cord around the cordholders as shown in figure 16.

Figure 15: Attaching the cord to the automatic cluster removal

6.1.5 Mounting the automatic cluster removal horizontallyIf the ACR is to be mounted horizontally, it is advisable to attach the cord guide to the bottom ofthe ACR. Drill 2 4-mm. holes in the lower CR lid as shown in the drawing below. Mount the cordguide using the screws in the guide kit. Mount the ACR horizontally using 76mm. plastic lineclamps D240810 (not included). Mount one at each end of the orange unit.

Figure 16: Attaching the cord guide

10/03-1.0 27 D105018

6.1.6 Mounting the ACR verticallyIf the ACR is mounted vertically in a dairy with I parlour/ 2 milking positions the removal cord ispulled in two directions. In this kind of situation, we advise replacing the pulley on the under-neath of the ACR with a cable guide. See ‘A’ in figure 17.

Figure 17: Attaching the cable guide

6.1.7 Attaching the clawpiece to the automatic cluster removalFigure 18 shows how to attach the clawpiece to the ACR. Estimate the correct length of thecord/extension cord before tightening the clamping ring.

Figure 18: Attaching the clawpiece

D105018 28 10/03-1.0

6.1.8 Mounting the cordFigure 19 shows how the clawpiece is attached to the automatic cluster removal. Shorten thecord to the correct length before tightening the hose clip.

Figure 19: Attaching the cord

6.2 Mounting the Isolator Xp milk flow sensorMount the Isolator Xp milk flow sensor as shown in figure 20. The sensor can be mountedvertically or horizontally to the bars of the parlour using a U-bracket/saddle combination. If the“GM-Isolator Xp” logo plate on the side of the Isolator Xp milk flow sensor is switched over, it canbe mounted in the opposite position on the other side of the milking parlour. Use 4 self-tappers to

10/03-1.0 29 D105018

attach the logo plate and bracket to the Isolator Xp milk flow sensor.

IMPORTANT

Mount the Isolator Xp milk flow sensor horizontally for correct operation.

Figure 20: Mounting Isolator Xp milk flow sensor

6.2.1 Wiring the Isolator Xp milk flow sensor

Figure 21 shows the Isolator Xp milk flow sensor from below, indicating the positions of cableglands and nozzles for the wiring and vacuum connections.

D105018 30 10/03-1.0

Figure 21 / 22: Positioning cable glands and nozzles

1. Cable glands

2. Vent

3. Vacuum connection nozzle (pulsation pipe line)

4. Connection for Servo 4-position tap in jar installations. Blocked for the milk line system

5. Clean air

6. Thumb nut

7. Milk flow sensors

Note: Each of the 4 cable glands can be used. 4 cable glands and 2 caps are supplied.Unused cable glands must be sealed off watertight.

6.2.2 Sealing the cable glandsApply Locktite® to the thread to prevent water entering i.e. from high-pressure cleaners etc. See‘A’ in figure 22. Use Locktite® type 542 or similar.

Note: After the milk flow sensor has been installed, tighten the thumb nut again under vacuum.This seals the milk chamber tightly.

10/03-1.0 31 D105018

6.2.3 Mounting on low-line milking installationsFigure 23 shows the line connections for low-line milking installations. For the vacuum connec-tion an 8.6 mm hole must be drilled in the vacuum supply line (A) with a 1/8" thread. Screw in aplastic nozzle and connect to the automatic cluster removal using a PVC tube. The length of thePVC tube used to attach the Isolator Xp milk flow sensor to the milk line (C) must be at least 30cm. to prevent milk causing blockages. Blockages in the milk lines can cause problems forprobe detection.

The Isolator Xp milk flow sensor works by sensing conductivity. It is therefore important to earththe milk lines correctly.

Figure 23: Mounting low-line milking installations

A. Vacuum supply line

B. Pulsation line

C. Clean air line

D. Milk line

IMPORTANT - A clean air line must be connected for all low-line milking installations. Thisprevents moisture entering the drop-off sensor chamber, which would otherwise cause malfunc-tioning. If the milking installation does not have a line suitable for clean pulsation air, provideseparate arrangements.

D105018 32 10/03-1.0

A pulsation silencer line may be used - assuming its diameter is not smaller than the pulsationline. In older installations a clean air line of 63mm diameter or larger can be mounted - if it is notused as a silencer line.

6.2.4 Mounting on high-line milking installationsIf the Isolator Xp system is mounted in high-line installations, a remote control switch with LEDunit is recommended (the usual operation switch will be out of reach due to the sensor’s highposition). The remote control switch with LED unit is supplied with a mounting bracket and U-bolt. Mount the switch in an easy to access position.

Note: The LED in remote control switch switches synchronous to the removal LED (37 on page21). A milk tube support is also recommended. Place this at a short distance form the Isolator Xpmilk flow sensor. Place the line in the hole in the bracket and join the top to the sensor with apiece of milk tube. Then attach the long milk tube to the lower part of the line (see figure 24).

Figure 24: Mounting high-line installation

10/03-1.0 33 D105018

A. Remote control switch+ LED

B. Pulsation line

C. Milk Line

6.3 Lectron TL pulsator

6.3.1 Mounting

The Lectron TL is mounted to the side of the boosting line. In new installations: Drill a Ø17 mm.hole in a 63 or 90 mm PVC booster line and debur the hole before mounting the Lectron TLpulsator (see Figure 25).

Figure 25: Mounting Lectron pulsator onto the lines

Centre the pulsator clamp correctly before tightening the bolt. If the clamp is not positionedcorrectly the booster line may be damaged irreparably.

Drill a Ø 25 mm. hole at the side of the booster line and screw in a 3/4" gas thread. Mount a 25 x3/4" nozzle and place the Lectron TL pulsator on it (see Figure 26). Then mount the pulsatorclamp with a screw after the “T” piece has been removed.Note: , A 25mm x 1/2" nozzle can be used with existing installations with booster lines with asmaller diameter and 1/2" galvanized T-pieces

Figure 26: Placing the Lectron TL pulsator using an adapter

D105018 34 10/03-1.0

6.3.2 WiringThe Lectron TL pulsator is supplied with a 3-metre 0.5 mm 3-core cable.Use the shrink sleeve insulation case and weld the cable joints. Use conduits for wiring.Preferably connect the Lectron TL pulsators to a silencer line. The connections concerned areon the lower lid of the Lectron TL pulsator. The silencer line not only damps the noise producedby the Lectron TL pulsator, but also supplies it with clean air. The air supply to the lines must beconnected outside the dairy in clean surroundings.Note: The diameter of the silencer (clean air) line must never be smaller than the diameter of thebooster line.

6.4 ParametersRemove the lid to access the PCB in the Isolator Xp milk flow sensor. The PCB can then beremoved from the housing.The following can be set:

· End milking signal

· Initial vacuum delay time

· Clawpiece venting delay

· Milk sweep

Make the settings using the 8 DIP switches on the print. See Figure 27.

Switch 1 : Milk sweep on/offSwitch 2 and 3 : Set clawpiece vent timeSwitch 4 and 5 : Set initial vacuum timeSwitch 6,7 and 8: Vacuum time

Make other settings using ACR3TOOL appendix 2.

Note: Ensure the PCB is replaced in the sensor housing before mounting.Note: The type of parlour determines which print in the Isolator Xp milk flow sensor must beused:

6.4.1 Isolator Xp milk flow sensor Type Print

D480197 For milking line installations cows D480180X1

D480199 For milking line installations goats with milking cluster retractor D480194x1

D480200 For milking line installations goats hi-line with milking cluster retractor D480195x1

D480201 For milking line installations goats with automatic cluster removal D480202

The times are set using the binary system via the DIP switches. If the PCB is positioned verti-cally and the large LED pointing upwards, the switch will point downwards in the OFF position(0) and upwards in the ON (1) position.

10/03-1.0 35 D105018

Figure 27: Isolator Xp milk flow sensor type print

D105018 36 10/03-1.0

6.4.2 Milk Sweep (DIP switch 1)This switch has an ON and OFF position. If Milk Sweep is ON, the milk shut-off valve is openedfor 15 seconds, after milking cluster removal. This briefly admits air into the clawpiece to removeany milk residue from the clawpiece, milk tube and milk flow sensor. If the switch is in the OFF(0) position there will be no milk sweep.

Switch 1 Milk Sweep0 OFF1 ON

6.4.3 Clawpiece shut-off timeThis is the period of time that vacuum on the clawpiece is shut off until the ACR removes thecluster from the animal’s udder. During this period outside air is admitted to the clawpiece via thevent, and the vacuum level drops. This allows comfortable and gentle removal from the animal.The time can be set from 1 to 4 seconds in 1-second steps.

Switch 2 Switch 3 Vent time in seconds0 0 1 second0 1 2 seconds1 0 3 seconds1 1 4 seconds

6.4.4 Vacuum delayThis is the period from the moment the milking cluster is lowered until actual connection of thefirst teat cup. During this period the milking cluster can be positioned under the udder. The delaytime is set correctly if the clawpiece is under vacuum just before connection to the first teat.

Switch 4 Switch 5 Vacuum delay0 0 0 seconds0 1 1,5 seconds1 0 3 seconds1 1 4,5 seconds

6.4.5 End - Milking – SignalThis is the set end-milking signal where the milk shut-off valve in the Isolator Xp milk flow sensoris closed causing the cluster to be removed from the udder. The 8 settings vary from 20 to 90 %.The milk/air ratio is a time measurement, expressed in percentages, during which probes sensethe presence of milk. Measurement is continuous in a time window of 25 seconds.Example: 50 % detection (milk present between both probes for 50% of the time during a 30second period) corresponds to a milk flow of 200 gr/minute. The vacuum on the clawpiece isshut off if the probes sense the presence of milk less than 50 % of the set time.

10/03-1.0 37 D105018

Figure 28: Setting end-milking signal

Figure 28 shows switches 6, 7 and 8 in the factory settings of resp. 0-1-0. These settingscorrespond to an end-milking signal of 200 gr/minute. These settings can be fine tuned in theparlour using other milk flow ratios.

6.4.6 Drop-off sensor adjustmentNote: Each Isolator Xp milk flow sensor installed must be adjusted as follows to determine thedrop-off moment:

1. Switch on the milking installation (check the working vacuum) and set the Isolator Xp milkflow sensor to stand-by. Switch on pulsation if central pulsation is used. Remove the cap(1) from the Isolator Xp milk flow sensor.

2. Unscrew the protection nut and loosen the drop-off setting screw (B, figure 22) until thedrop-off sensor no longer works (LED 38 goes out).

3. Mount a vacuum gauge between the long milk tube and the Isolator Xp milk flow sensormilk inlet nozzle using a 14 mm. T-piece and 14 mm. milk tube, length 100 mm.

4. Activate the Isolator Xp milk flow sensor by lifting the milking cluster.

5. Place the milking cluster on the cow standing with the teat cups spread upwards (as if thecluster had fallen off or been kicked off). After the vacuum delay has elapsed outside air willbe sucked in via the clawpiece.

6. Read off the vacuum level on the vacuum gauge. This will give a global idea of the vacuumdrop that can be expected if the clawpiece falls off the animal. This is the vacuum level withthe clawpiece in the parlour.

7. Replace the clawpiece on the long milk tube by a valve, see figure 29. Leave the clawpieceattached to the removal cord.

8. Note the vacuum level on the vacuum gauge, while the valve is closed and the Isolator Xpmilk flow sensor activated. This is the working vacuum level.

9. Calculate the adjustment vacuum level for the drop-off sensor as follows:

Working vacuum level + vacuum level with clawpiece in parlour2

10. Adjust the valve at the end of the long milk tube until the vacuum gauge indicates the valuecalculated at 9.

D105018 38 10/03-1.0

11. Adjust the drop-off screw (B in figure 25) until the drop-off LED lights up.

12. Wait 20 secs. until the milking cluster is in drop-off mode - in other words when the “milkingcluster removed” LED flashes.

13. Activate the Isolator Xp milk flow sensor (lift milking cluster), briefly remove the valve at theend of the long milk tube until the air rush in the sensor has pushed the diaphragm valve intothe right output position. Connect the valve to the milk tube again.

14. Check the vacuum gauge and adjust using the valve if necessary.

15. Adjust the drop-off screw until the drop-off LED lights up.

16. Repeat steps 10 to 15 to check the settings and adjustments

17. Tighten the locking nut

18. Replace the valve on the long milk tube by the milking cluster.

19. Place the cap on the Isolator Xp milk flow sensor againFigure 29: Replace milk tube by valve

1. Valve

2. Vacuum gauge

3. Setting screw and locking nut

6.4.7 Description drop-off adjustmentThe diagram below shows the inside of the Isolator Xp milk flow sensor .Drop-off valve C is theupper diaphragm covered by a metal disc, A is the trace contact and B is the Drop-off settingscrew, as described in the previous section ‘Drop-off sensor adjustment’.If the cluster falls, the air enters with so much force that the diaphragm is forced upwards caus-ing the metal disc to come into contact with setting screw B.This completes an electrical circuit. After a brief delay time*) the system realises that a clusterhas fallen.

10/03-1.0 39 D105018

Note: The brief delay allows the system time to determine if there is any cyclic vacuum fluctua-tion - which may occur normally during milking.

Figure 30: Drop-off sensor

6.5 Inside of the Isolator Xp milk flow sensorThe diagrams below shows a cross section of the Isolator Xp milk flow sensor. The upper figure30 shows the sensor in stand-by position. The solenoid is activated and open so vacuum ispresent in the sensor.The lower chamber is under vacuum, which forces the diaphragm and spring downwards. Thiscloses the shut-off valve: The milking cluster is not under vacuum.

Note: The vacuum on the drawing is shown in dark grey, the atmospheric air is light grey.

Figure 31: Sensor standby

D105018 40 10/03-1.0

The diagram below figure 31 shows the sensor during milking, washing and between washing.The solenoid is not activated and shuts the vacuum off. There is equal air pressure on bothsides of the upper diaphragm, a spring hold the shut-off valve open.

Figure 32: Sensor during milking, washing and between washing

6.6 LED description

Figure 33: LEDs

35 Drop-off and Removal Stand-by LED 36 Voltage ON/OFF LED 37 Take=off ON/OFF LED 38 Drop-off adjustment LED for test purposes only 39 Milk flow LED for test purposes only

10/03-1.0 41 D105018

LED 35: LED on Isolator Xp milk flow sensor in stand-by modeLED off Isolator Xp milk flow sensor in mode milkLED flashes (2.5 x/sec) milking cluster fallen: milking has not ended

LED 36: LED on Voltage onLED off Voltage off

LED 37: LED on ACR on (milking cluster is removed automatically)

LED off ACR off (milking cluster must be removed manually)LED flashes(1x/sec) (2 minutes after connection): Initial delay

(20 seconds after reconnection): Drop-off delayLED flashes (2.5 x/sec) milking cluster fallen: milking has not ended

Note: If a remote LED has been installed (high-line milk installation) it will react synchronous toLED 37

LED 38: This LED is used to adjust the drop-off moment. It reacts to the drop-off settingscrew when the drop-off sensor moment is being determined.

LED 39: This LED is on if both probes sense the presence of milk. This LED will also light upif both probes are connected to test the connections during installation.

6.7 Standard settings Isolator XpDipswitch settings:“ Switch 1 : Milk sweep = OFF Switch 2 and 3 : Clawpiece vent time setting = 2 sec“ Switch 4 and 5 : On/Off delay setting = 1,5 sec“ Switch 6, 7 and 8 : End milking signal setting = 200 gram / minute.

D105018 42 10/03-1.0

7 Maintenance7.1 Before each milkingCheck if all the vent holes in the clawpieces are open. Also check all rubber tubes and connec-tions for leaks. Attention: blockages or leaks obstruct the milk flow, which will have a negativeeffect on how the sensor determines the milk flow. This may mean that the milk cluster is takenoff too early or too late.

7.2 MonthlyLubricate the suction seal and the inside of the automatic cluster removal. Check for generalwear and tear. Also see “Demounting the ACR” page 7.2.Only use silicone oil to lubricate the suction seal. NEVER use any other type of oil or grease.

7.3 AnnuallyCheck diaphragm quality in the Isolator Xp milk flow sensor and replace if necessary. Also checkall seals, chimney ducts and valves for wear and tear. Replace if necessary.

7.4 Every 3 yearsReplace the diaphragms, seals, chimney ducts and valves on the Isolator Xp milk flow sensor.Also replace diaphragms and seals on the ACR system.

10/03-1.0 43 D105018

D105018 44 10/03-1.0

7.5 Service diagram Isolator Xp milk flow sensor

Figure 34 / 35: Service diagram Isolator Xp milk flow sensor

10/03-1.0 45 D105018

D105018 46 10/03-1.0

7.6 Service diagram Lectron TL

10/03-1.0 47 D105018

Figure 36 / 37: Service diagram Lectron TL

D105018 48 10/03-1.0

7.7 Spare parts Isolator Xp milk flow sensor

10/03-1.0 49 D105018

1 D480197 Isolator XP milk flow sensor CowD480199 Isolator Xp milk flow sensor - Goat RAMD480200 Isolator Xp milk flow sensor - Goat Hi-lineD480201 Isolator Xp milk flow sensor - Goat ACR system

2 D382764 Seal air chamber lower3 D385779 Milk chamber4 D385785 Setting screw milk chamber5 D249746 Cap. Ø76 D382762 Axle seal7 D382760 Sealing ring milk chamber8 D255663 U-bolt with saddle9 D385780 Support milk flow sensor10 D252908 Sticker11 D255719 Switch12 D480130 Housing with switch13 D480180X1 PC board sensor Isolator Xp cow

D480194X1 PC board sensor Isolator Xp GoatD480195X1 PC board sensor Isolator Xp Goat hi-lineD480202X1 PC board sensor Isolator Xp Goat ram

14 D382873 Valve15 D320726 Valve axle16 D381677 Diaphragm, lower17 D385783 Diaphragm bracket18 D385786 Bearing19 D243722 Spring20 D206707 Circlip stainless steel21 D243723 Compression spring22 D200784 Metal screw CK POZI M4 x 40 stainless steel23 D200787 CK M2.5 x 5 stainless steel24 D200733 CK M5 x 16 stainless steel25 D480175X1 Upper cap with seal26 D382779 Sealing ring For D480175x1

D382761 Sealing ring. For D38577627 D381508 Gasket seal28 D385778 Valve cover29 D382763 Air vent ring upper30 D262513 Solenoid31 D242728 O-ring32 D385784X6 Chimney line set33 D381676 Diaphragm, upper34 D255682 Valve with seal35 D242702 O-ring36 D240704 Adaptor, straight37 D480168 Line bracket. For highline milk installations38 D390682 Disc

D105018 50 10/03-1.0

7.8 Trouble shooting Isolator Xp milk flow sensor

10/03-1.0 51 D105018

8 Specifications8.1 Isolator Xp milk flow sensor

Operating voltage: 12 volt dc +/- 2 volt dc

Energy consumption: 0,25 amp.

Print input protection: 1.6-amp. fuse, slow blown

Initial delay 120 seconds

Clawpiece vent time: 1-4 seconds

Vacuum delay: 0-4.5 seconds

Take-off moment: settable: minimum 100 g/min, maximum > 300 g/min

Inlet nozzle: ø 16 mm.

Outlet nozzle: ø 16 mm.

Cable glands: 4 x pg7 with2 pg7 sealing plugs. Max. cable ø 6,25mm2

Vacuum connection nozzles: 3 x 7 mm. Ø extern

Operating vacuum 36 to 50 kpa.

Dimensions: approx. 190 x 160 x 100 mm

Weight: 750 gram.

Pulsation settable 20-255 strokes per minute (standard)

Stimulation settable 20-255 strokes per minute (standard)

Pulsation ratio settable 10-90% (standard 60% front, 60% rear)

8.2 Automatic cluster removal (D480128)Operating voltage: 12 volt dc +/- 2 volt dc

Energy consumption: 0,25 amp.

Operating vacuum 36 to 50 kpa.

Working length cord : 1 metre

Length ACR: 800 mm.

Diameter: 80 mm.

Weight: 1200 gram

Connection cable: 3.5 m 3 x 0.5mm2

Vacuum connection nozzle : 1 x 7 mm ø external

D105018 52 10/03-1.0

8.3 Supply transformer 3 Ampere (D480166)Input: 180/200/220/240 volt ac, settable

Output: 12 volt dc, 3 amp.

Input protection: 2 amp fuse (slow blown)

Output protection: 3,15 amp fuse (short circuit protection, quick blown). Thermaloverload protection up to 124 c° non-reset, on power supply.

Output connector: 2 insulated, external thumb nuts.

Dimensions: 164 x 129 x 70, class ip55

Weight: 2030 gram.

8.4 Supply transformer 9 ampère (D480166)Input: 180/200/220/240 volt ac, settable

Output: 12 volt dc, 9 amp.

Input protection: 1 amp fuse (slow blown)

Output protection: 15 amp. fuse (short circuit protection, quick blown). Thermal overloadprotection up to 124 c° non-reset, on power supply.

Output connector: 2 insulated, external thumb nuts.

8.5 Lectron TL pulsator (D494147)Operating voltage: 12 volts d.c. ± 2 volts d.c.

Energy consumption: 0.25 amp. Per coil. 0.5 amp. Per pulsator.

Operating vacuum 36 kpa - 50 kpa.

Operating temperature range: -5°c to + 45°c

Connection cable: 3 core 0.5 mm2 , length 3 m.

Dimensions: 80 x 60 x 133mm.

Weight: 0.57 kg

8.6 Supply transformer 13V DC 12 Ampère (D262623)Input: 110//230/240 Volt AC, settable

Output: 13 Volt DC, 12 Amp.

Input protection: 220V AC=1,25 Amp (slow blown) 110V AC 2,5 Amp (slow blown)

Output protection: 15 amp fuse (short circuit protection, quick blown).

Housing: IP 53

Dimensions: 205 x 150 x 145 mm

Weight: Approx. 4 Kg

10/03-1.0 53 D105018

9 Storage and transportTransport preferably in the original packaging.Storage recommended in a dry, dust-free and vibration-free environment.

D105018 54 10/03-1.0

10 Dismantling and the environmentThe Isolator Xp contains non-biodegradable parts such as metals and electronics. It is highlyrecommended that these parts are disposed of according to the prevailing legislation.

10/03-1.0 55 D105018

11 Connection diagrams11.1 Wiring control printThere is a 16-pole connector on the control print for connections. Connections are made on thecable part of the connector as shown below. The connector is then placed on the print.The print has an automatic fuse, 2 Amp. slow blown. This cannot be replaced.

1 Remote control LED - for high-line milk installations (BLUE).

2 Lectronic TL pulsator (BROWN)

3 Solenoid vacuum connection valve + *) and pulsation stop.

4 Solenoid vacuum connection valve - * ) and pulsation stop.

4 Remote control LED + for high-line milk installations (RED).

5 Automatic cluster removal - (WHITE)

5 Lectron pulsator - for safety device milking cluster retractor

6 Automatic cluster removal + (BROWN)

Lectron pulsator + for safety device milking cluster retractor

7 Chain release unit in rotary parlours or Airdip -.

8 Lectronic TL pulsator (BROWN)

8 Chain release unit in rotary parlours or Airdip+.

9 External switch for highline (YELLOW).

10 Lectronic TL pulsator (WHITE)

11 12 V.+ Power supply unit (BROWN)

12 12 V.Power supply unit (BLUE)

12 Milking cluster drop-off (CDO) detector *)

12 Wash/wait position for connection to CN9/1 in Aquastar washing device or aseparate switch

12 External switch for high-line milk installations

12 Press button Goats milking cluster retractor

13 Milking cluster Drop-off detector *)

14 Start take-off system (GREEN)

14 Press button Goats milking cluster retractor

15

16 Wash/idle position for connection to CN9/2 in Aquastar washing device or aseparate switch

Connections marked *) are factory settings.

D105018 56 10/03-1.0

Important: Pay attention when replacing covers (after wiring) that no wires or cables are trappedbetween the lid and the sensor housing. Make sure there are no cables above airway bungs (seepag. 2 - 2, number 8).

Place wiring in a (PVC) tube or cable conduit when connecting the Isolator Xp milk flow sensor tothe automatic cluster removal and the 12 V. power supply unit.

10/03-1.0 57 D105018

11.2 Milk line installation cows

Figure 40:

D105018 58 10/03-1.0

11.3 Milk pipes installations goats with milking cluster retractor

Figure 41:

10/03-1.0 59 D105018

11.4 Milk pipe installation goats highline with milking cluster retractor

Figure 42:

D105018 60 10/03-1.0

11.5 Milk line installations Goats with Isolator Xp automatic clusterremoval

Figure 43:

10/03-1.0 61 D105018

Appendix 1: CertificationEnglish / Deutsch / Français / Español / Italiano / Svenska / Nederlands

EC-Declaration of Conformity

EG- Konformitätserklärung / Déclaration de conformitë CE / Declaración de conformidad CE / Dichiarazione di conformità alledirettive CE / EG – declaration om överensstämmelse / EG conformiteits verklaring

Manufacturer / Hersteller / Constructeur / Fabricante / Costruttore / Tillverkare / FabrikantGascoigne Melotte Technology B.V.Kromme Spieringweg 289 B, 2141 BS Vijfhuizen, The Netherlands

Product name / Produktbezeichnung / Désignation du produit / Designación del producto / Denominazione del prodotto /Produktbeteckning / ProductnaamIsolator Xp

Typ / Type / Tipo D480197 / D480199 / D480200 / D480201

The named product is in conformity with the requirements of the following European Directive:Das bezeichnete Produkt stimmt mit den Vorschriften folgender Europäischer Richtlinie überein:Le produit sus-mentionné est conforme aux prescriptions de la Directive Européenne suivante :El producto designado cumple con las prescripciones de las siguientes directivas europeas:Il prodotto denominato corrisponde alle normative delle seguenti direttive CE:Produkten i fråga överensstämmer med följande EU-direktiv:Het genoemde product is in overeenstemming met de voorschriften van de volgende Europese richtlijnen:

89/392/EWG Richtlinie des Rates zur Rechtsangleichung der Rechtsvorschriften der Mitgliedsstaaten für Maschinen geändertdurch 91/368/EWG, 93/44/EWG und 93/68/EWG

89/392/EEC Council Directive on the approximation of the laws of the Member States relating to machinery amended by91/368/EEC, 93/44/EEC and 93/68/EEC

89/392/CEE Directive du Conseil visant l’harmonisation des législations des pays membres relatives aux machines modifiéepar 91/368/CEE, 93/44/CEE et 93/68/CEE

89/392/CEE Directivas del Consejo para la armonización de la legislación de los estados-miembro, relativa a maquinariamodificada por 91/368/CEE, 93/44/CEE y 93/68/CEE

89/392/CEE Direttiva del Consiglio per l’armonizzazione delle normative dei paesi CE relative alle macchine modif. da91/368/CEE, 93/44/CEE e 93/68/CEE

89/392/EEC Rådets direktiv för anpassning av medlemsstaternas rättsföreskrifter, ändrad genom91/368/EEC, 93/44/EEC och 93/68/EEC

89/392/EEG Richtlijn van de raad voor harmonisatie van de wetten van de lidstaten voor machines gewijzigd door 91/368/EEG, 93/44/EEG en 93/68/EEG

Conformity with the requirements of this Directive is testified by complete adherence to the following standards:Die Übereinstimmung mit den Vorschriften dieser Richtlinie wird nachgewiesen durch die vollständige Einhaltung folgenderNormen:La conformité aux prescriptions de cette Directive est démontrée par la conformité intégrale avec les normes suivantes :La conformidad con las prescripciones de estas directivas queda justificada por haber cumplido totalmente las siguientesnormas:La conformità alle norme di questa direttiva è garantita dal pieno adempimento delle norme seguenti :Överensstämmelse med dessa direktiv dokumenteras genom att följande standarder gäller utan inskränkning:Conformiteit met de voorschriften van deze richtlijnen wordt verklaard door volledige naleving van de volgende normen:

Nationale Normen / National Standards / Normes nationales / Normas nacionales / Norme nazionali / Nationella standarder /Nationale normen

ISO 5707

This Declaration certifies conformity with the above-mentioned Directive, but gives no assurance of properties within the meaning of the Law Concerning Product Liability.DieseErklärung bescheinigt die Übereinstimmung mit der genannten Richtlinie, ist jedoch keine Zusicherung von Eigenschaften im Sinne des Produkthaftungsgesetz.Cette déclaration certifie la conformité avec la Directive sus-mentionnée mais n’est pas une garantie de propriétés au sens de la loi sur la responsabilité du fait du produit.Esta declaración certifica la conformidad con las directivas nombradas, pero no garantiza características según la ley de responsabilidad sobre productos.La presente dichiarazione certifica soltanto la conformità alla direttiva sopracitata e non rappresenta una garanzia ai sensi della legge sulla responsibilità del produttore.Denna deklaration bekräftar överensstämmelse med ovannämnda direktiv men får inte uppfattas som försäkran om egenskaper enligt krav i Lagen om produktansvar.Deze verklaring bekrachtigd overeenstemming met de bovenstaande richtlijn, maar is geen verzekering van eigendommen binnen de wet betreffende productaansprakelijkheid.

D105018 62 10/03-1.0

Appendix 2: ACR3TOOLIntroduction

ACR3TOOL is the software needed to set or re-program the Isolator Xp milk flow sensor prints.This software is only available in English and is supplied on a 3.5" disk.

RequirementsThe following is required to be able to make settings

· PC or Laptop with Dos mode

· D706213 Program disk ACR3TOOL

· D510168 Program adapter Isolator Xp milk flow sensor

Figure 44

Method

Remove the cap of the Isolator Xp milk flow sensor.

Connect the program adapter Isolator Xp milk flow sensor to com port 1 on the PC or Laptop.Connect the other end of the cable to connector JP1 (4 pole) on the Isolator Xp milk flow sensorprint. Ensure the dot on the 4 pole connector on pen1 is connected to the connector JP1.

Start the PC or Laptop in MS-DOS mode (F8). NOT in MS-DOS mode in Windows

Before print data can be changed, the Isolator Xp milk flow sensor must be placed into monitormode, as follows:

· Press the switch on the milk flow sensor for 2 seconds until the large LED goes out.

· Press the switch for 4 seconds until the large LED lights up again.

· On LED 1 on the print is now lit up. The other LEDS are off.Monitor mode is now activePlace the disk in the disk drive.

10/03-1.0 63 D105018

The program can now be started in the following 2 ways:

· With A:\acr3tool [Enter] the program is started to change the print settings.

· WithA:\acr3tool S [Enter] the program is started to re-program the flashprom.

If acr3tool is used to start the program, the following menu will appear (depending on the type ofprint)

Isolator Xp goats cow RAM type, version: 220 removal date: 30-01-03————————————————————————————————————————Dipswitch settings:Switch 1: Milk sweep = OFFSwitch 2,3: Vacuum delay = 1500 milli secondsSwitch 4,5: Cluster venting delay = 2 secondsSwitch 6,7,8: Milk flow take off level setting = 100 gram / minute

Configuration settings:

1.Pulsation control = OFF

2.Chain release or Airdip signal = ON

3.Tracking = OFF

4.Stimulation output signal = OFF

5.Blocking drop-off detection = ON

6.Goat settings = ON

7.Stimulation control = OFF

8.Initial delay: 60 seconds

9.Vacuum shut-off delay: 3 seconds

Do you want to change configuration data? (N) ..

The following data will now appear:

· Print type (normal, servo, goat, goat hi-line, goat ram)

· The version date of the program in EEPROM

· The current dipswitch setting

To change settings:

· Type Y (Yes)

· Enter the number of the part to be changed. See options below.

D105018 64 10/03-1.0

B table 1(values to be entered) * only activated if 7 stimulation control = ON

Calculation F/R offset: Offset F/R = (pulsation ratio front – (100 – pulsation ratio rear)) / 2

Example:Pulsation ratio front 60/40 rear 60/40 Offset F/R = (60-40)/2 = 20/2 = 10% (enter 100)Pulsation ratio front 62/38 rear 62/38 Offset F/R = (62-38)/2 = 24/2 = 12% (enter 120)Pulsation ratio front 70/30 rear 60/40 Offset F/R = (70-40)/2 = 30/2 = 15% (enter 150)Only activated if dipswitch 1 is ON

10/03-1.0 65 D105018

D105018 66 10/03-1.0

B 1 table 2 - 10

If acr3tool S is used to start the program, the following menu will appear

ACR3-XP TOOLS 1.2 Copyright (c) 2003 Gascoigne-MelotteIsolator XP standard type, version: 220 removal date: 30-01-03—————————————————————————————————————— 0. Leave monitor and go to Users Program 1. Read Register 2. Write Register 3. Read EEPROM 4. Write EEPROM 5. Reprogram Users Program 6. Hardware Test 7. Reprogram EEPROM 8. User program information 9. Store EEPROM values to HD A. Copy EEPROM values from HD B. Qoff ACR3-XP TOOLSEnter menu character:

10/03-1.0 67 D105018

0 Quit Monitor program and return to user’s program

1 Read RAM data Isolator XP processor (do not use))This option is not used

2 Write RAM data Isolator XP processor (do not use)This option is not used

3 Read EEPROM data Isolator XP processor (do not use)This option is not used

4 Write EEPROM data Isolator XP processor (do not use)This option is not used

5 Reprogramming user’s programThis places the user’s program in the Isolator Xp print.

6 Print test in combination with test box (do not use)This option is not used

7 Reprogramming EEPROM Isolator XP processorThis places the selected data in the EEPROM Isolator Xp print.

8 Overview set dataAn overview is shown of all the data set on the Isolator Xp print

9 Save data EEPROM Isolator XP processor on hard disk PC or LaptopThis saves the data set in the EEPROM of the Isolator Xp on the hard disc of the PC or Laptop.This data can be transferred to the next print(s) using option A (see below).

A Copying data from PC or Laptop to EEPROM Isolator XP processorThe data saved on the hard disc of PC or Laptop can be replaced in the EEPROM of the IsolatorXp print with this option. This avoids entering all the data manually per print.

B Close program ACR3TOOLThis closes the ACR3TOOL program. However, the Isolator Xp will remain in monitor mode.