CLUSTER-FLUSHMilking Cluster Disinfection System

SWINGOVER PARLOUR

Installation Manual

Cotswold Dairy Equipment Co LtdAvenue 3 Station Lane Witney

Oxford OX28 4BP UK

Tel +44 (0)1993 774567Fax +44 (0)1993 771776

e-mail sales@cotswold-dairy-equipment.comwww.cotswold-dairy-equipment.com

CEMADE IN ENGLAND

COTSWOLDDairy Equipment Co Ltd

AIR SUPPLY

CHEMICAL ENTRAINMENT(option)

FLEXIBLEPIPERUN

HEADER TANK (Note: Level With Cylinders)

WATER INLET SYSTEM

CONNECTION TO MILK LINE (Y Piece)

PERACETIC ACID CONCENTRATIONSet dosing at 0.5%

Usage @ Twice-A-Day Milking:- 0.7 Litres / 100 Cows / Day

IMPORTANT

BEFORE installation of your new Cotswold Cluster Flush system:

ensure that all EXISTING milk shut-off valves are working

satisfactorily, (sealing fully and without leaks)

COTSWOLD CLUSTER FLUSHMilking Cluster Disinfection System

AIR 2 - 3 bar

HEADER TANK

Pressure Reducing Valve 2 - 3 Bar

Compressor7 - 8 Bar

IMPORTANTSet Cylinder Levels To Header Tank.Level Should Be 50mm Below Top

of Stainless Steel Cylinders

FOR SWING OVER PARLOURS: One controller per 2 milking clusters

24V+ -

ON-OFF

24V+ -

ON-OFF

POWERSUPPLY

To NextMilking Points etc...

MAINS IN230/240v

WATER LEVEL

SCHEMATIC

24v DCWater Supply

1 amp 20mm fuse

Drain Tap(at lowest point)

22mm (flexible)

Rigid

TOCLAW

(clear PVC11mm i/d)

ON - OFF

AIR AIR WATERWATER

TO MILK LINE &CLAW A(clear PVC10mm I/D)

TO MILK LINE &CLAW B(clear PVC10mm I/D)

Clear PVC 13mm I/D

10mm

CONTROL PANEL (one per two

milking points)

24V+ -

Do Not Install Directly

Above Electrical Equipment

A B ESC - + OK

(ALWAYS SWITCH OFF EITHER THE POWER SUPPLYOR THE CONTROLLER(s) WHEN NOT IN USE)

GATE 1VACUUM

GATE 2VACUUM

24v DCFROM PSU

FOR WIRINGSEE

ACCOMPANYINGLARGE SCALE

DRAWING

PERACETIC ACID CONCENTRATIONSet dosing at 0.5%

Usage @ Twice-A-Day Milking:- 0.7 Litres / 100 Cows / Day

INSTALLATION NOTES

ORDER OF INSTALLATION

For ease of installation we recommend the following installation sequence:-

1/ Header Tank(s)2/ Water / Plumbing3/ Set Up Water Cylinders4/ Install Airlines5/ Controllers and Electrical

WATER / CHEMICALSite the Header Tank at the same level as the cylinders. Ensure that the water level in the

(see drawing opposite).

Run 2 inch (50mm) water tube from header tank along the centre of the parlour, connecting using tees, taps and 10x16mm i/d tube. Terminate this tube with a reversed (upside-down) tee/tap so that it can be used as a drain point if required.

cylinders is set 50mm (2 inches) below the top of the stainless tube,

to every cylinder

Chemical DosingWe can supply Dosatron high accuracy dosing units if required. When dealing with chemicals, do take all recommended precautions. Before commissioning the system, ensure all unions are tight and the clusters hang correctly

Schematic Top Viewdisposition of system components for

swing-over parlour

HEADERTANK

PSU

AIR 24v WATER

CONTROLLERS

CONTROLLERS

CONTROLLERS

AIR 2 - 3 bar, (pressure reducer may be required)Use 22mm Flexible Tubing between the compressor (clean air filters should be fitted) and the first 22x22x10mm tee located adjacent to the first controller. Continue to following controllers using rigid tubing. Terminate the air line in a blanking cap.

Anti Syphon Valvesfit one valve either side of the Tee connection of air line, at the mid-point of each half (see schematics)

Pressure ReducerWe can supply a suitable pressure reducing valve if required.

ELECTRICALLocate Power Supply Unit (PSU) in a safe dry location, run 24v supply to first controller, and then daisy-chain the supply from controller to controller.

Each controller controls two milking points simultaneously.

Arrange a convenient switch to turn off the system when not in use.

CONNECTION TO MILK LINECut into the milk line and and fit the “Y” piece moulding using 13mm pvc tubing connecting to upper horizontal outlet of stainless steel cylinder.

Always switch off system when washing the parlour

= Anti Syphon

Valve

AIR

WATER24v

SHUT-OFF VALVE (for CLUSTER FLUSH)

To Claw

Flow

Flow

Unit MUST be installed vertically (as above)

Controls maximum of two (2) cluster points on either side of valve (see schematic on previous page).

ON

- O

FF

CO

NTRO

L P

AN

EL W

IRIN

G

(contr

ols

sid

es

A a

nd B

)

24V

+

-

IB(L

EFT

A)

A

B

ESC

-

+

O

K

24v Input fromPSU or previous controller

I1IB

ID

Fuse

20m

m

1 A

mp

24v

SIG

NA

LS

O

UT

T

O G

AT

ES

24v

GA

TE

SW

ITC

HR

ET

UR

NS

(Optio

n)

TRIG

GER IN

PU

TS

24v D

C

(ALW

AY

S S

WIT

CH

OF

F E

ITH

ER

TH

E P

OW

ER

SU

PP

LY

OR

TH

E C

ON

TR

OL

LE

R(s

) W

HE

N N

OT

IN

US

E)

ID(R

IGH

TB)

GA

TE

or A

CR

V

AC

UU

M

CO

NN

EC

TIO

N

VA

CU

UM

SW

ITC

H

VA

CU

UM

SW

ITC

H

Sw

itch

AIR

AIR

CO

NT

RO

LL

ER

-S

WIN

GO

VE

R A

ND

R

OTA

RY

PA

RL

OU

R

EX

HA

US

T V

EN

TE

XH

AU

ST

VE

NT

CO

TS

WO

LD

DA

IRY

EQ

UIP

ME

NT

XD

10

GA

TE

V

AC

UU

M

CO

NN

EC

TIO

N

MC

L-V

ER

SIO

NR

OTA

RY

(XD

10

in to

p r

igh

tco

rne

r o

f co

ntr

olle

r)

MCL-VERSIONROTARY

(XD10 in top rightcorner of controller)

18

SY

ST

EM

TR

IGG

ER

S V

IAG

AT

E S

WIT

CH

ES

M

AN

UA

L P

US

H B

UT

TO

NS

OR

IDIB

MA

NU

AL

PR

ES

SB

UT

TO

N

GA

TE

SW

ITC

H O

RM

AN

UA

L P

US

H B

UT

TO

N

ACCESSING TIMING PARAMETERSMCL CONTROLLER (XD10)

To open main screen, press the “- ” (minus) button twice.

To access any sub-menuPress OKThen Athen either “+” or “-” to move between sub-menus

2. Sub Menu 1 = Milk Sweep Setup

2a. When finished, press esc

3 Timer Setup - Maintenance(Change Timings)

(a) Initial DelayMilk SweepFlush DelayFirst FlushFill TimeSecond Flush

3. Maintenance HelpShows “A” Solenoid Function

4. Help - Version (call dealer)

5. Software VersionNo. eg: R5-4-M5

CLUSTER FLUSHMAIN MENU

CLUSTER FLUSH MENU(Milk Sweep Setup)Timer SetupPress OK

CLUSTER FLUSH MENU(TIMER SETUP)MaintenancePress OK

CLUSTER FLUSH MENU(MAINTENANCE)HelpPress OK

CLUSTER FLUSH MENU(HELP)VersionPress OK

CLUSTER FLUSH MENU(VERSION)Press OK

Manuals/BackFlush/MASTERFILESControllerSetup-Crouzet-MCL.pdf

IMP

OR

TA

NT

Set C

ylin

der

Leve

ls T

o H

eader

Tank.

Leve

l Should

Be 5

0m

m B

elo

w T

op

of S

tain

less

Ste

el

Cyl

inder

50m

m

(ALW

AY

S

SW

ITC

H O

FF

WH

EN

NO

T I

N U

SE

)

AIR

2 -

3 b

ar

HE

AD

ER

TA

NK

IMP

OR

TA

NT

Set C

ylin

der

Leve

ls T

o H

eader

Tank.

Leve

l Should

Be 5

0m

m B

elo

w T

op

of

Sta

inle

ss S

teel

Cyl

inders

24V

+

-

ON

-OFF

24V

+

-

ON

-OFF

PO

WER

SU

PPLY

WA

TE

R L

EV

EL

SC

HEM

ATIC

Not

To S

cale

Out

24vD

C

1 a

mp 2

0m

m f

use

Dra

in T

ap

(at

low

est

poin

t)

22m

m

(fle

xib

le)

Rig

id

CO

TS

WO

LD

CL

US

TE

R F

LU

SH

Cro

uze

t C

on

tro

ller

Eu

ro/M

CL

SW

ING

OV

ER

& R

OTA

RY

PA

RL

OU

R

TE

E O

FF

AC

R

VA

CU

UM

SU

PP

LY

TE

E O

FF

AC

R

VA

CU

UM

SU

PP

LY

TE

E O

FF

AC

R

VA

CU

UM

SU

PP

LY

CO

TS

WO

LD

DA

IRY

EQ

UIP

ME

NT

CH

EM

ICA

LS

TO

RE

(UP

TO

7 M

ET

RE

S

HO

RIZ

ON

TA

LLY

)

DO

SA

TR

ON

(O

ptio

n)

Ch

em

ica

l In

du

ctio

n U

nit

PO

WE

RS

WIT

CH

ST

OP

VA

LVE P

ress

ure

Reduci

ng

Valv

e 2

- 3

Bar

and food g

rade a

ir filt

ers

PE

RA

CE

TIC

AC

ID C

ON

CE

NT

RA

TIO

NS

et dosi

ng a

t 0.5

%U

sage @

Tw

ice-A

-Day

Milk

ing:-

0.7

Litr

es

/ 100 C

ow

s / D

ay

20

COTSWOLD CLUSTER FLUSH

Crouzet ControllerEuro/MCL

SWINGOVER & ROTARY PARLOUR

Cluster Flush Servicing page 1

Service interval: At 1 year, the following service parts should be fitted

Dosatron Service Kit

Food Grade AIr Filter (Compressor)

1 Year

InlineTap / Lever Valve 152-153

Bracket - Pressure Vessel

CF38A

Bracket - Swingover Control

Box CF100

Dosatron Service Kit DOS/KIT Food Grade Air Filters - Service Kit CF21

Other parts you may find useful to have with you when servicing a cluster Flush system.

10 mm i/d x 16mm o/d hose (30m)………………….. 151-10210mm i/d x 20mm o/d hose (30m) ...........................151-12713mm i/d Hose (30m)………………………………… 151-118Herbi Clips 16mm…………………………………… 154-153BHerbi Clips 20mm ...................................................154-154C10 MM Jubilee clips………………………………… 154-159ABrackets for pressure vessels…………………………CF 38ABrackets for swing over control box…………………...CF 100Taps………………………………………………………152-153

see overleaf for 3 Year Major Service...

Cluster Flush Servicing page 2

Service interval: At 3 years, the following service parts should be fitted (in addition to Annual Servicing)

Service Part: Cylinder Service Kit: Part No CF 99 (See picture below)

CF 99 - Replaces all the internal parts of the pressure vessel.Order one Service Part per Milking Point: example: 10 x 20 order 10, or 20 x 20 order 20

Replacing the complete vessel assembly is:Assured: Complete assembly factory-tested before dispatch.Quick: Internal parts exchanged in-place without moving vessels.Simple: No small parts to take apart. No leaky re-assembly.Warranty: We will give 3 years warranty on serviced assembly.

** See video of service procedure on our Website**

Additional Non-Return Valve:You will also need to replace the external non-return valve, which is included in the service kit.

You may want to change flexible tubes during the service30 Metres 10mm tube - 151-102B30 Metres 13mm tube – 151-11830 metres 20mm tube - 151-127

Thoroughly rinse out header tanks and pipe work with alkaline cleaner.

Check water levels: (See picture)o Water level must be level with or just below top label on the vessels.o Important - water levels above this level risk contamination of milk.

Best way to set water levels: o Set the water in the header tanks level with the overflowo Set the top label of the vessels level with the overflowo This way if the water level rises it only overflows the header tank

Prevent dust and dirt getting into the header tank.

3 Years

Non-Return ValveCF91

NRV Kit comeswith 2 x Tube Clamps

Pressure VesselService Kit

CF99