01/99.-3.1 D021004/E

STARWATER MANAGEMENT SYSTEM

OPERATING INSTRUCTIONS

GASCOIGNE MELOTTE

EDITION 3.1

D021004/E 01/99.-3.1

GASCOIGNE MELOTTE

PUBLICATION INFORMATION

1. COPYRIGHT

Copyright in this publication is vested in:-

GASCOIGNE MELOTTE

2. DISCLOSURE

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or

transmitted, in any form or by any means, electronic, mechanical, photocopying, recording and/or

otherwise without the prior written permission of GASCOIGNE MELOTTE.

3. LIMITATIONS OF USE

This book may not be lent, resold, hired out or otherwise disposed of by way of trade in any form

of binding or cover other than that in which it is published, without the prior consent of

GASCOIGNE MELOTTE.

4. ENQUIRIES AND AMENDMENTS

All enquiries regarding comment, correction or amendment to this publication should be addressed

to:-

The Technical Publications Manager

GASCOIGNE MELOTTE

Rankine Road

Daneshill

Basingstoke

Hampshire

RG24 8PP

Tel.: 01256 394300

Fax: 01256 460684

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GASCOIGNE MELOTTE

WARNING

CHECK THE VOLTAGE OF THE CONTROL BOX BEFORE CONNECTING TO THE MAINSSUPPLY.

BEFORE OPENING ANY ELECTRICAL EQUIPMENT, ALWAYS DISCONNECT FROM THEMAINS SUPPLY.

TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, DO NOT EXPOSE ANY OF THEELECTRICAL EQUIPMENT TO WATER OR MOISTURE.

THE WIRES IN THE MAINS LEAD OF THE POWER SUPPLIES ARE COLOURED INACCORDANCE WITH THE FOLLOWING CODE:

BLUE to N (Neutral)BROWN to L (Live)YELLOW/GREEN TO E (Earth)

DO NOT ALLOW LARGE SURGES OF ELECTRICAL CURRENT TO MAKE CONTACT WITHTHIS EQUIPMENT - E.G. WELDING ON STALLWORK.

ALWAYS ISOLATE ALL ELECTRONIC EQUIPMENT TOTALLY FROM THE MAINS SUPPLYIF LARGE CURRENTS ARE APPLIED TO THE MILKING MACHINE.

IF A STAND-BY GENERATOR IS USED TO SUPPLY MAINS VOLTAGE, FIRST DISCONNECTALL ELECTRONIC EQUIPMENT TOTALLY FROM THE MAINS. START THE GENERATORAND CHECK THE STABILITY OF THE GENERATED CURRENT BEFORE CONNECTING THEELECTRONIC EQUIPMENT.

THE EXCLAMATION MARK WITHIN A TRIANGLE IS INTENDED TO ALERT THE USER TOIMPORTANT OPERATING AND MAINTENANCE OR SERVICE INSTRUCTIONS IN THISLITERATURE.

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GASCOIGNE MELOTTE

WARNING

GASCOIGNE MELOTTE USE HIGH PERFORMANCE, MODERN ENGINEERING PLASTICS INTHE CONSTRUCTION OF MILKING EQUIPMENT. THE MATERIALS CHOSEN ARE THE BESTAVAILABLE FOR ANY GIVEN APPLICATION.

THE PLASTICS USED IN THE AQUASTAR WATER MANAGEMENT SYSTEM HAVE GOODRESISTANCE TO HOT WATER, ACID AND ALKALI MILKING MACHINE DETERGENTS ANDDISINFECTANTS EVEN AT HIGH TEMPERATURES.

HOWEVER, CHEMICAL RESISTANCE CAN BE AFFECTED BY PRODUCTS CONTAININGKETONES, CHLORINATED HYDROCARBONS, AROMATIC HYDROCARBONS AND HIGHERALCOHOLS, WHICH ARE ALWAYS PRESENT IN PETROL, PARAFFIN, METHYLATED SPIRITS,DIESEL FUEL ETC. THEY ARE ALSO PRESENT IN VARYING CONCENTRATIONS INPRODUCTS SUCH AS FLY SPRAYS, SOME TEAT DIP SOLUTIONS AND ARE SOMETIMESUSED AS PROPELLANTS IN AEROSOL CANS.

GREAT CARE MUST BE TAKEN TO ENSURE THESE PRODUCTS DO NOT COME INTOCONTACT WITH PLASTIC COMPONENTS ON MILKING MACHINES.

GASCOIGNE MELOTTE WILL NOT ACCEPT RESPONSIBILITY FOR EQUIPMENTDAMAGED BY CHEMICALS.

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NOTES ON CIRCULATION CLEANING

Always refer to the chemical suppliers instructions and note safety procedures.

After milking, clean the clusters and wash jetters externally with a hot sanitant solution.

Set the complete milking machine for washing and CHECK THE HOT WATER SUPPLYTEMPERATURE COMPLIES WITH THE CHEMICAL MANUFACTURERSRECOMMENDATIONS.

The first flush water must discharge to drain until the returning water is clear.

Circulate the sanitant solution for approximately 10 minutes ENSURING THAT THE CORRECTTEMPERATURE IS MAINTAINED.

Flush the plant with clean, cold water and ENSURE THE PLANT DRAINS COMPLETELY. Insome cases the addition of a hypochlorite solution of 25 ml per 40 litres of water is required.

Examine the plant once a week to check for deposits. Pay particular attention to rubber tubing, the insideof liners and receiver jar deflector plates (where fitted).

To remove milkstone, use an approved brand of milkstone remover. Follow the instructions carefully.

Clean and disinfect any part of the equipment that is not normally in contact with milk, e.g. supplementarypipeline vacuum interceptor vessels, at least once a month. Flush through after cleaning with clean, coldwater.

NEVER MIX DAIRY CHEMICALS. IT IS EXTREMELY DANGEROUS

Cleaning deteriorates the nitrile rubber of the liners therefore it is essential to use agood quality detergent and follow the dilution instructions on the container.

INCREASING THE RECOMMENDEDDILUTION RATIO NEVER IMPROVES THE

SANITIZATION EFFECT.

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CIRCULATION CLEANING WITH MR2000 MILK METERS

It is important to understand that the MR 2000 milk meter has been designed to be FLOOD WASHEDin the normal milk flow direction and that the software controls the pattern of washing each meter insequence.

The cycle for washing EACH MR 2000 milk meter is as follows.

Initially, the top chamber is closed for 52, 68, 84 or 100 seconds, depending on the cycle time. Thisallows THE TOP CHAMBER TO FLOOD AND OVERFLOW DOWN THE BYPASS TUBE intothe measuring chamber, through the open outlet valve and out of the meter via the bottom chamber. Seediagram A. To ensure good agitation in the top chamber when flooding, THE AIRBLEED HOLE INTHE TOP COVER OF THE MILK METER MUST BE KEPT CLEAN.

After the set time, the top chamber outlet opens and water floods down into the measuring chamber andoverflows through the bypass tube into the bottom chamber and out of the meter. See diagram B.

This flooding lasts for 4 seconds. After a further 4 second delay it floods again for a further 4 seconds toallow the meter to empty prior to repeating the cycle.

The above milk meter wash cycle is SEQUENCED with a 4 second delay between each milk meter tolimit the number of milk meters that are flooding at any one time.

At the end of the wash and between each solution change, the meter will DRAIN UNDER GRAVITYproviding the wash sequence continues without a fresh solution entering at the meter and SUFFICIENTVACUUM IS MAINTAINED TO OPERATE THE METER VALVE.

It is essential that there is sufficient water available to allow ALL THE MILK METERS TO FLOOD(see diagrams) If compartmental cleaning is installed, only 75% of the water is required as both halvesof the parlour are washed alternately.

NOTE: To ensure the conductivity probes in the top chamber remain effective, it is recommended tocirculate an acid descaling solution once a week. Follow the instructions carefully.

A B

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1 2 3

STOPEE

Start milking by pushing :

Ensure the milk line is in the bulk tank

1 2 3

STOPE

E

E

E

Start washing by pushing :

Preset 2

Preset 3

etc.

Preset 1

Ensure the milk line is connected to thechangeover valve

1 2 3

STOPE

Stop milking or washing bypushing :

STOP

3

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STOP

INDICATOR LIGHTS

Indicator lights : Eight indicator lights are positioned directly below the display. Each indicator lightis denoted by a symbol identifying its purpose. Definitions of each symbol follow below.

Light no. Definition

1. When a preset program using the cleaning agent in container no. 1 (nominallyalkali) has been selected, this LED lights up. If the chemical in the container islow this LED will flash when a program using this chemical is selected. ThisLED also flashes to indicate that the dosing pump is pumping.

2. When a preset program using the cleaning agent in container no. 2 (nominallyacid) has been selected, this LED lights up. If the chemical in the container is lowthis LED will flash when a program using this chemical is selected. This LEDalso flashes to indicate that the dosing pump is pumping.

3. When a preset program using the cleaning agent in container no. 3 (nominallysanitant) has been selected, this LED lights up. If the chemical in the container islow this LED will flash when a program using this chemical is selected. ThisLED also flashes to indicate that the dosing pump is pumping.

4. Low temperature warning for main cleaning wash water. Lights up when watertemperature falls below a preset limit (set to your requirements by your dealer)Remains lit until a new instruction is given to the system. (This is an optionalfeature not available on the standard Aquastar system).

5. Accelerated quick check for servicing purposes.

6. Lights up after pressing the STOP key. Indicates that the system is in stand-bymode.

7. The system is in wash mode. Lights up after pressing the WASH key followed bythe E key. The light will flash when the wash water in the wash trough has reachedits preset level and continues flashing until the wash program has been completed.

8. The system is in milking mode. Lights up after pressing the MILK key followedby the E key and flashes until the milking has been completed.

1

2

3

4

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FUNCTION KEYS

MILK key:

PROD appears on the display after pressing the MILK key. The wash controller willswitch to milking mode after pressing the E key. Codes on the display indicate whichmilking phase is active. The milking mode is ended after pressing the STOP key.The milk key is also used to manually run the milk pump, press the key twice and hold itdown to start and run the milk pump.

WASH key:

By pressing the WASH key once, preset program 1 is selected. rst1 appears in thedisplay. The program is started by pressing the E key. The phases of the program thenappear on the display. These are denoted by a flashing P and then a code number.

By pressing the WASH key repeatedly, the other preset programs can be selected:

Press twice : preset 2 : rst2 on display.Press three times : preset 3 : rst3 on display.Press four times : preset 4 : rst4 on display.Press five times : preset 5 : rst5 on display.

The selected program is started by pressing the E key.Once a program has been selected (but not started), to skip stages within the program press the arrowkey. Every time the arrow key is pressed, the next stage is selected. The first phase number of the stagewill appear on the display. After pressing the E key, the selected stage of the preset program will bestarted. The system will complete the entire preset program starting from the selected stage.

If the wash key is pressed while the Aquastar is in MILKING mode, the pickup valve(s) will open for aslong as the key is pressed.

STOP Key:

Pressing the STOP key once stops the program in progress and causes the word STOP toappear on the display. Pressing the STOP key also clears incorrect data, if incorrect dataentry has occurred.When the STOP key is pressed and held down the version and serial numbers appear onthe display.

E(nter) Key:

Pressing the ENTER key confirms the desired command or selection. The milk andwash programs will only start AFTER pressing the E key.

STOP

E

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7g

4d

5e

6f

3c

THE RIGHT KEYPAD.

Data can be recalled and entered or programs started by using the right keypad.

Key :

Displays the number of hours on the vacuum pump. Function N=1.

Aquastar as a rough guide milk volume counter. Press key 2 to display the approximatevolume of milk that has been pumped by the milk pump. The total is calculated bymultiplying a calibration figure in the Aquastar control box by the amount of time thatthe Aquastar detects the milk pump to be running.

You can start wash programs with the 3 key instead of the WASH key. Select whichprogram you want by pressing the 3 key 1,2,3,4 or 5 times. If you use the 3 key ratherthan the wash key, a single cleaning stage can be selected and executed (i.e. to only runa non circulating flush of a particular program). An F will appear on the display beforethe first program phase number instead of a P.Once a program has been selected (but not started) with the 3 key, the stage can beselected by pressing the arrow key. Each time the arrow key is pressed the programjumps to the next stage. The first phase number will appear on the display. The selectedstage of the preset program will be started after pressing the E key. If the program hasbeen started using the 3 key then ONLY the selected stage of the program will becompleted and the wash controller will return to the stand-by mode.

Displays the contents of container no. 1 (nominally alkali) in litres. Press ARROW keyto display the amount of chemical agent for each washing. Function N=3.

Displays the contents of container no. 2 (nominally acid) in litres. Press ARROW key todisplay the amount of chemical agent for each washing. Function N=6.

Displays the contents of container no. 3 (nominally sanitant) in litres. Press ARROWkey to display the amount of chemical agent for each washing. Function N=9.

Displays clock time. The display switches between [r=25] and the clock time.By pressing the ARROW key the other 32 clock functions can be selected (r=26 to 57).Each clock function can be used to set an automatic program start. This allows washingto be started automatically at a preset time. i.e. a sanitizing flush prior to milking.

r=26 is the number of the day, which can be set after entering the user password. For example: Sundayis day 1 and Saturday is day 7, (numbering can be set to start from any week day). Functions r 27 to 57can be used to set an automatic program start. Proceed as follows :

❏ 1st digit : Input the day number on which the cleaning must start.❏ 2nd and 3rd digits : Input a number between 1 and 24 which corresponds with the number input

in function 8. It is possible to program up to 24 different automatic starts. (See Key 8 for moredetails).

❏ 4th digit: Input the preset program number (1,2,3,4 or 5). If the number 6 is input then the systemwill automatically switch to the milking mode.

EXAMPLE: The setting r= 2.01.3 could mean:Start on Monday (day 2) at 5:30 (time programmed in function r=01) using preset program 3.

0

2b

6

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Displays the time at which a wash program can be started automatically.Up to 24 start times can be programmed (r=01 to r=24). See the “time code table” and“Starting a program automatically” towards the back of this book.

The 9 key can be used to directly access the S programs.

The arrow key has two different functions. To access the S and T functions the arrow keyand 1 key must be pressed. Once you are in one of the programs the arrow key is used toselect successive functions.

The correction key. This key is used during data entry. By pressing the C key, all data inthe display is erased. It is possible to make changes in (program) settings using the Ckey.

Display or change program settings (A-1 to 99).

Input operators password.

Used to skip to another program number in the T or S programs.

Displays todays next automatically starting program phase (only if installed). Ifdisplay shows 0000, no automatic program start is due for today. To cancel anautomatic program start shown on display, press C key followed by 1.

C

8h

9j

1a

3c

9j

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SETTING THE OPERATORS PASSWORD

The operators password is set in function A-49. The following example shows how to set the passwordto a nominal figure of 1 2 3 4.

1a

Press then followed by

this gives you access to function A-49. The display flashes between A=49 and - - - -.

Press followed by the operators code.

Press to confirm. The operators password is now set at 1 2 3 4.

USING THE OPERATORS PASSWORD

As a user of the Aquastar system, to gain access to certain functions and to change the clock time theoperators password must be entered into the control box. Follow the procedure below to enter the codeset in function A-49 (above).

Press the display will toggle between S= 1 and no. Press then the

operators password. e.g. and to confirm.

If entered correctly the control box will display the time, incorrect entry will result in an error codebeing displayed. The operator will now have access to the N functions and will also be able to changethe clock time.

NOTE : When the system is delivered the operators password is set at a default value of 1.

It is possible to set the control box so that there is no need to enter an operators password to gain accessto the above functions. Your dealer or service representative can do this simply by adding the value 128in function A-04. N.B. the operators password can only be overridden in this way AFTER entering aservice password.

9j

9j

4d E

C 1a

2b

3c

4d

E

3c C

1a

2b

3c

4d E

8

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0

4d

4d

5e

4d

4d

N FUNCTIONS

This program group is accessed by pressing the key. The arrow key can be used be scrollthrough the N functions.

REMARK : THE OPERATORS PASSWORD MUST BE ENTERED BEFORE ANY CHANGESCAN BE MADE TO THE FOLLOWING FUNCTIONS.

N= 1 The total number of hours that the vacuum pump has been running. From standby mode,this time can be displayed by pressing key on the right hand keypad. It can be

reset to zero after entry of the service password. It is automatically reset to zero when 9999running hours are reached.

N= 3 Contents of container 1 (nominally alkali) in litres, accurate to two decimal places. Thesystem decreases this number as the chemical is used. From standby mode the currentcontents in the container can be displayed simply by pressing key

When a new chemical container is added to the system this function must be set to theamount of chemical in the container. NOTE : The new volume must be entered in centilitrese.g. For a 25 litre chemical container enter the value 2500.

N= 4 The dose of the chemical in container 1 used per cleaning in litres. This value can bedisplayed by pressing followed by

N= 5 The number of times that chemical pump 1 pulses each time a wash program using chemical1 is selected. This value is accessed by pressing the arrow key again. i.e.

N=6 Contents of container 2 (nominally acid) in litres, accurate to two decimal places. Thesystem decreases this number as the chemical is used. From standby mode the currentcontents of the container can be displayed simply by pressing key

When a new chemical container is added to the system this function must be set to theamount of chemical in the container. NOTE : The new volume must be entered in centilitrese.g. For a 25 litre chemical container enter the value 2500.

N= 7 The dose of the chemical in container 2 used per cleaning in litres. From standby mode thisvalue can be displayed simply by pressing followed by

N=8 The number of times that chemical pump 2 pulses each time a wash program using chemical2 is selected. This value is accessed by pressing the arrow key again. i.e.

5e

5e

9

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6f

6f

6f

N= 9 Contents of container 3 (nominally sanitant) in litres, accurate to two decimal places. Thesystem decreases this number as the chemical is used. From standby mode the currentcontents of the container can simply be displayed by pressing key

When a new chemical container is added to the system this function must be set to theamount of chemical in the container. NOTE : The new volume must be entered in centilitrese.g. For a 25 litre chemical container enter the value 2500.

N= 10 The dose of the chemical in container 3 used per cleaning in litres. From standby mode thisvalue can be displayed simply by pressing followed by

N=11 The number of times that chemical pump 3 pulses each time a wash program using chemical3 is selected. This value is accessed by pressing the arrow key again. i.e.

N= 12 Chemical container low warning. This number indicates the number of cleanings left in thechemical containers when the low chemical warning is displayed and can be adjusted togive more (or less) warning time that the chemicals containers are low.

N= 13 Number of times a particular preset program X (programmed in N-15) should run beforeanother preset program Y (programmed in N-16) automatically starts.

N=14 Displays the number of times that the program in N-15 has been executed. This value canalso be changed manually, to promote the execution of program Y.

N=15 Number of the preset program X. 0 = function disabled, 1 to 5 = preset programs.

N=16 Number of the preset program Y. 0 = function disabled, 1 to 5 = preset programs.

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CALIBRATING THE DOSING PUMPS

5e

4d

C

1a

CE

1a

2b

3c

0

PROTECTIVE CLOTHING, GLOVES AND EYE PROTECTION MUST BE WORN WHENHANDLING DAIRY CHEMICALS.

NOTE : Before calibrating the dosing pumps it is very important to prime them first. If necessary thecalibration process can be run as set out below until the pumps are primed. Once primed the propercalibration process can be carried out.

Calculate the amount of chemical you need to add to the wash trough for each type of chemical.

When the system is installed and ready to run, the dosing pumps must be calibrated to pump the correctvolume of chemical. Select the dosing pump calibration function by pressing the key. S= 9 isdisplayed alternating with Pr-C (Press C).

Press the key, select which chemical pump you want to calibrate by entering

or on the keypad followed by

The vacuum pump is automatically switched on by starting the calibration function, you must now waitwhile the vacuum builds up, when the system is ready for calibration the display shows Pr-0 (Press 0).Place the outlet tube of the dosing pump into a suitable measuring beaker, press and hold

The dosing pump will run and the beaker will start to fill with chemical, the number of pulses the dosingpump has made is displayed on the screen. When the required volume (calculated previously) has beenpumped, release key 0, the display will show END and the number of pulses the dosing pump made.Enter this number in N-5, N-8 or N-11 depending on which chemical pump was calibrated using thefollowing method :-

CHANGING THE NUMBER OF TIMES THE CHEMICAL DOSING PUMPS PULSE

First enter the operators passcode.

Access the correct N function for the chemical pump you want to affect. i.e. for chemical pump 2 accessfunction N-8, either by pressing or by pressing the key, followed by pressing the

arrow key several times until function N-8 is shown on the display.

N-8 is displayed , alternating with the current value set in N-8. Press the key to cancel thecurrent value, input the new value followed by the E key.

The number of times that chemical pump 2 will pulse each time a wash program using chemical 2 isselected is now set.

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SETTING THE CLOCK TIME

The correct time must be set on the system clock; Aquastar works with a 24 hour clock. To set the timefollow the procedure below :- eg. to set the time to 3.45 pm.

First enter the operators password on the keyboard. When correctly entered the display will show fourdashes, incorrect entry results in an error code.

Press : the current system clock time will be displayed. To change this time press

the display will go blank (or display error code E-20 if the operator or service password has not beenentered correctly). Press the keys corresponding the time (e.g. 3.45 pm is 15:45 in 24 hour clock) thenconfirm the input with the E key.

The system clock time will now be set. The time flashes on the display alternating with r=25.

CHEMICAL CONTAINERS LOW WARNING

The Aquastar system warns the operator when the chemical containers are nearly empty. The amount ofchemical left in the containers is calculated from the initial amount in the container and is reduced by theamount of chemical used for each wash. (This amount is a constant set in the Aquastar control box,Functions N-04, N-07 and N-10). When the amount falls to a level preset in function N-12 (e.g. onlyenough chemical for 5 washes is left in the container), the control box displays a warning. This warningwill appear as a flashing LED above the relevant chemical container on the Aquastar control box whena wash program which uses the relevant chemical is selected. The chemical should be changed when thecontainer is empty.

When the chemical container is changed, the Aquastar control box must be told that a new container hasbeen attached, this is done by inputting the amount of chemical in the new container into the functionN-03, N-06 or N-09.

Example : CHEMICAL CONTAINER 1 RUNS OUT AND IS REPLACED BY A NEW CONTAINEROF 25 LITRE CAPACITY.

First enter the operators password.

Press to access function N-03. The amount of chemical that the Aquastar calculates to beleft in chemical container 1 is displayed alternating with N= 3.

Press the display will go blank. Enter the new amount of chemical (25 litres) by pressing :

The system is now set to 25 litres of chemical in container 1.

7g C

1a

4d

5e E5

e

4d

2b

5e

0 0 EC

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BLANK TABLE FOR DEFAULT SETTINGS AND TIME CODES

The default setting for each A-function is included in the table below. Use column 3 “current setting” tonote the settings as made by your GM dealer. Make sure to do this as this table can be used to reset yoursystem to your specifications should a fault occur. Later setting changes can be noted in columns 4 and5.

NOITCNUFA GNITTESTLUAFED GNITTESTNERRUC EGNAHCGNITTES EGNAHCGNITTES

1 18

2 0

3 0

4 0

5 sdnoces51

6 sdnoces02

7 sdnoces3

8 sdnoces03

9 0

01 0

11 1

21 sdnoces01

31 sdnoces03

41 sdnoces011

51 sdnoces063

61 0tatesA/N

71 sdnoces0

81 sdnoces021

91 sdnoces042

02 sdnoces511

12 sdnoces06

22 sdnoces01

32 sdnoces06

42 sdnoces01

52 0

62 0

72 0tatesA/N

82 0tatesA/N

92 1tatesA/N

03 0

13 sm005

23 sm005

33 0

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NOITCNUFATLUAFED

GNITTESTNERRUC

GNITTESGNITTESEGNAHC

GNITTESEGNAHC

43 0tatesA/N

53 0tatesA/N

63 0tatesA/N

73 0tatesA/N

83 %001

93 sdnoces006

04 setunim084

14 0tatesA/N

24 0tatesA/N

34 5tatesA/N

44 1

54 71

64 1

74 0

84 71

94 1

05 02

15 14

25 84

35 0

45 0

55 0

65 02

75 24

85 84

95 0

06 0

16 0

26 02

36 43

46 84

56 0

66 0

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NOITCNUFATLUAFED

GNITTESTNERRUC

GNITTESGNITTESEGNAHC

GNITTESEGNAHC

76 0

86 76

96 0

07 0

17 0

27 0

37 0

47 0

57 0

67 0

77 0

87 0

97 0

08 01

18 2

28 0

38 0

48 seslup0

58 seslup0

68 seslup0

78 sdnoces0

88 sdnoces0

98 sdnoces0

09 sdnoces0

19 0

29 0

39 sm0

49 sm0052

59 sdnoces021

69 0tatesA/N

79 sdnoces0

89 sdnoces06

99 0

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AQUASTAR WASH PROGRAMS

✰ The Aquastar can have a maximum of 5 preset programs.

✰ Each preset program can have a maximum of 6 stages.

✰ A stage can be one of ✰ a circulating flush✰ a non circulating flush✰ a main wash cycle (long circulation)✰ a sanitizing flush (short circulation)✰ a waiting period

✰ Each of these stages can use either cold, tepid or hot water, as required.

✰ Any one of the three chemicals can be added to any of the stages, if desired.

The following tables can be used to fill in the stages programmed into each preset program of yourAquastar water management system. When initially delivered the Aquastar control box has four programsset up as default, your dealer can change any (or all) of the stages in any (or all) of the preset programs.

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AQUASTAR PRESET PROGRAMS

PRESET 1 The default is a three stage program made up of the following stages :-

EGATS TLUAFED OTDEGNAHC

1 hsulfretawdipetgnitalucricnoN

2 hsawniamilaklatoH

3 hsulfgnitalucricretawdloC4

5

6

EGATS TLUAFED OTDEGNAHC

1 hsulfretawdipetgnitalucricnoN

2 hsawniamdicatoH

3 hsulfgnitalucricretawdloC4

5

6

PRESET 2 The default is a three stage program made up of the following stages :-

PRESET 3 The default is a three stage program made up of the following stages :-

EGATS TLUAFED OTDEGNAHC

1 hsulfretawdipetgnitalucricnoN

2 hsawniamdicadloC

3 hsulfgnitalucricretawdloC4

5

6

PRESET 4 The default is a one stage program as follows :-

EGATS TLUAFED OTDEGNAHC

1 tnatinashtiwhsulfgnitalucricretawdloC

2

3

4

5

6

PRESET 5

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1

2

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4

5

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17

D021004/E 01/99.-3.1

GASCOIGNE MELOTTE

BL

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435-

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A77-

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A27-

A87-

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655-

A16-

A76-

A37-

A97-

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18

01/99.-3.1 D021004/E

GASCOIGNE MELOTTE

EDOC-R EMIT EDOC-R EMIT

10 03:5 31

20 41

30 51

40 61

50 71

60 81

70 91

80 02

90 12

01 22

11 32

21 42

TIME CODE TABLE

STARTING A WASH PROGRAM AUTOMATICALLY

PROGRAMMING AUTO START TIMES INTO THE AQUASTAR

To start awash program automatically it is first necessary to program the system with a number of timesthat you want the Aquastar to automatically start at. To do this follow the procedure below :-

EXAMPLE : To program the times 05:30 and 15:30 into the Aquastar :

1. Enter the service password2. Press the 8 key on the Aquastar keypad the text r=01 flashes alternating with a number.3. Press the C key4. Use the keypad to input the time 05:305. Press the E key. The time 05:30 is now input in r=01.6. Note the programmed time next to the r=01 space in the table in appendix 3.

7. Press the arrow key, r =02 appears on the display alternating with a number8. Press the C key9. Use the keypad to input the time 15:3010. Press the E key. The time 15:30 is now input in r=02.11. Note the programmed time next to the r=02 space in the table in appendix 3.

The above method can be used for programming up to 24 start times in r=01 to r=24.

19

D021004/E 01/99.-3.1

GASCOIGNE MELOTTE

PROGRAMMING THE AQUASTAR TO START A WASH CYCLE AUTOMATICALLY

Clock functions r-27 to r-58 can be used to set automatic program starts. These functions are accessedby pressing key followed by the arrow key.

r-25 This is the current system clock time.r-26 This is the number of the current day. e.g. Sunday =1, Monday =2 etc.r-27 to r-58 First figure - The day you want the program to start

Second figure - (Two digits) The number between 1 and 24 which corresponds tothe time table above setting the time you want the program to start.

Third figure - The preset program number (e.g. Preset program 3). If the number 6is entered here, the system switches to the milking mode.

Example r-27 =2.01.3 could mean : Automatically start on Monday (day 2) at 05.30 (time programmedinto r=01) washing with the program set in preset 3.

Programs which are set to be executed automatically can be cancelled by pressing then

followed by . You can tell that the program has been cancelled because the preceding decimal

point will disappear. A program that is in the cancelled state can be restored by pressing the same keysin the order above (i.e. C, 9, E).

WORKED EXAMPLE : To set the Aquastar to enter the milking mode automatically at 15:30 on aWednesday.

1. Enter the service password

2. Ensure that the time 15:30 is set in one of r=01 to r=24 using the above method. For this example wewill say that it is set in r=02.

3. Press the 7 key, r=25 will be displayed alternating with the clock time. Press the arrow key twiceuntil r=27 is displayed.

4. Press the C key. the display will go blank. Use the keypad to enter the desired code.

5. The code is made up as follows :- Day.Time.Preset Program

In this case the value to input should be 4026. Full stops will automatically be placed on the displaygiving the result 4.02.6.

How did we arrive at the above code?

4 is the day number on which the wash must start. Since Sunday is nominally day 1, Wednesday isnominally day 4.

02 is the r-number corresponding to the time 15:30 which has been programmed in advance.

6 is the code corresponding to the instruction to automatically set the system to milking mode.

7g

C 9j

E

20

01/99.-3.1 D021004/E

GASCOIGNE MELOTTE

MAN

AUT

FIGURE 1

230 V

21

WHAT TO DO IN AN EMERGENCY

If for some reason a breakdown occurs which prevents the Aquastar system from working, it is stillpossible to milk. Normally the pulsation and the vacuum pump is controlled by the wash controller. Ifthe wash programmer fails, then AFTER DISCONNECTING FROM THE MAINS move theemergency switch to the manual position so that pulsation system and the vacuum pump will function.NOTE: All fuses must be intact.

IMPORTANT : Disconnect the control box from the mains before switching theemergency switch.

EMERGENCY WASH PROCEDURE

After disconnecting from the mains, move the switch inside the control box to the manual position.

The pick up and changeover valves cannot be controlled by the solenoids inside the distribution box sothey must be operated by hand. To do this remove the 6mm PVC tube from the vacuum connectionnozzles and connect these nozzles to a source of constant vacuum (nozzle on chemical trap) using the6mm PVC tube with in-line taps and vacuum decay connectors supplied in the emergency kit inside thedistribution box cover. These taps will control the opening and closing of the wash valves.

PROCEDURE

NON CIRCULATING FLUSH

Fill the trough manually with cold (or tepid) water either using buckets or taps which bypass the 24Vwater fill valves.

Turn on the vacuum pump and give it time to build vacuum in the plant. Start the pulsation system.

Open the in-line tap to the pick up valves and suck the water into the plant. This water will be directeddown the drain. Close the in-line tap to shut off the pick up valves as soon as all the water has beensucked out of the trough. DO NOT ALLOW AIR TO ENTER THE PLANT THROUGH THEPICK UP VALVES.

D021004/E 01/99.-3.1

GASCOIGNE MELOTTE

FIGURE 2

22

MAIN WASH

Fill the trough manually with hot water. Manually dose the correct volume of chemical. Take extremecare and wear protective clothing, gloves and goggles.

Turn on the vacuum pump and give it time to build vacuum in the plant. Start the pulsation system.

Main wash water should be circulated, so the changeover valve must direct the water back to the trough.Open the in-line tap to the changeover valve, this prepares it for circulation.

Open the in-line tap to the pick up valves, this sucks the main wash water into the plant. Close the tapas soon as all the water is sucked from the trough. This main wash water should return to the trough.Repeat several times.

Close the in-line tap to the changeover valve to direct the water down the drain.

CIRCULATING FLUSH

Fill the trough manually with cold or tepid water.

Ensure plant is up to vacuum and the pulsation system is on.

The water should be circulated, so open the in-line tap to the changeover valve.

Open the in-line tap to the pick up valves to suck up the water. Close it as soon as all water is sucked outof the trough. The water should return to the trough. Repeat several times. Close the in-line tap to thechangeover valve to direct the water down the drain.

Please refer to the instruction sheet D108802 included in the Aquastar emergency kit.

01/99.-3.1 D021004/E

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1 2 3

STOPE

1a

2b

3c

4d

5e

6f

7g

8h

9j

0

STARWATER MANAGEMENT SYSTEM

C

GASCOIGNE MELOTTE

230 V

1 2 3

STOPE

1a

2b

3c

4d

5e

6f

7g

8h

9j

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STARWATER MANAGEMENT SYSTEM

C

GASCOIGNE MELOTTE

1 2 3

STOPE

1a

2b

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4d

5e

6f

7g

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9j

0

STARWATER MANAGEMENT SYSTEM

C

GASCOIGNE MELOTTE

= MANUALHANDBETRIEBHANDBEDIENINGMANUEL

1 2 3

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4d

5e

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8h

9j

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STARWATER MANAGEMENT SYSTEM

C

GASCOIGNE MELOTTE

1 2

43

23

APPENDIX 6 - EMERGENCY KIT INSTRUCTION SHEET

MANUAL WASH LAVAGE MANUEL HANDBETRIEB WASCHEN HANDBEDIENING WASSEN

D021004/E 01/99.-3.1

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1 342

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EDOCRORRE NOITPIRCSED

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25

ERROR MESSAGES

Definitions of the AQUASTAR control box error codes

D021004/E 01/99.-3.1

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01/99.-3.1 D021004/E

GASCOIGNE MELOTTE

EC - DECLARATION OF INCORPORATION FOR MACHINES

(Machine Directive 89/392/EEC as amended by Directive 91/368/EEC, 93/44/EEC and 93/68/EEC)(EMC directive 89/336/EEC, Annex II, Sub A)

(Low voltage directive 73/23/EEC)

GASCOIGNE MELOTTE HOLDING B.V.Mariastraat 40, NL-4506, AE Cadzand, The Netherlands

declares that

Gascoigne Melotte Aquastar Wash Programmer

complies with the regulations of the above Machine Directives and to the national legislation for theexecution of these Directives.

The above assembly has been manufactured to meet the ISO 5707 Standard for Milking MachineInstallation - Construction and Performance.

It complies with the regulations of the above machine directive (and as amended by 91/368/EEC, 93/44/EEC and 93/68/EEC);

the low voltage directive (directive 73/23/EEC);

The following harmonised standards have been applied:

EN 550022 (1988) Class AEN 50082-1

IEC 801-2 Level 4IEC 801-3 Level 2IEC 801-4 Level 2

This assembly must not be put into service until the machinery into which it is to be incorporated hasbeen declared in conformity with the provisions of the Directives.