the fullwood merlin (mk4) spare parts...

The Fullwood Merlin (MK4) Spare Parts Manual

Technical Manual 006930 Revision 0.03

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Revision: 0.03

Date: 30-Apr-12

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Contents

The Fullwood Merlin (MK4) Spare Parts Manual .................................... 1

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

Important information - read this first .................................................... 5

Icons ......................................................................................................... 5

1. Introduction ................................................................................... 6

2. Revision Control ........................................................................... 6

3. Arm Assembly ............................................................................... 7

3.1 Arm Covers ........................................................................................................ 7

3.2 Attachment Head ................................................................................................ 8

3.3 Jetter Assembly ................................................................................................ 10

3.4 Shells & Liners ................................................................................................. 12

3.5 ACR Cylinders & Ropes ................................................................................... 14

3.6 Arm Cylinders & Arm Assemblies ..................................................................... 15

3.7 Arm Traverse Motors & Rollers ........................................................................ 17

3.8 Eccentric Wheel ............................................................................................... 20

3.9 Foremilk Rejection ............................................................................................ 21 3.9.1 Drain Manifold ........................................................................................................ 22

3.10 Legato Pulstaor ................................................................................................ 23

3.11 S-Lina ............................................................................................................... 24

3.12 Teat Roller ........................................................................................................ 25

3.13 Arm Control Boxes ........................................................................................... 27 3.13.1 Long Box (PCB Box) ........................................................................................... 27

3.14 Valve Box ......................................................................................................... 29

3.15 IFM 6 Way Splitter Box ..................................................................................... 31

4. Crate ............................................................................................ 32

4.1 Entry & Exit Gates ............................................................................................ 32

4.2 Cow Follower .................................................................................................... 34

4.3 Cow Sensor & Antenna .................................................................................... 36

4.4 Gate Cylinders .................................................................................................. 37

4.5 Gate Cylinders Repair Kits ............................................................................... 37

5. Milking Area ................................................................................ 38

5.1 Clamp Valve ..................................................................................................... 38

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5.2 Milk Filter .......................................................................................................... 39

5.3 Milk Flow Sensors ............................................................................................ 40

5.4 Milk Meter ......................................................................................................... 41

5.5 Receiver Vessel ............................................................................................... 42 5.5.1 Milk Sampler Unit .................................................................................................... 43

5.6 Servac .............................................................................................................. 44

5.7 Sanitary Trap .................................................................................................... 45

5.8 4:1 Manifold ...................................................................................................... 46

5.9 CrystaLab ......................................................................................................... 47

5.10 Merlin Control Panel ......................................................................................... 48

5.11 Sampler & Shuttle............................................................................................. 50

5.12 4QCM ............................................................................................................... 51

5.13 Milk Pump ......................................................................................................... 52

5.14 Milk Pump Burkett Valves ................................................................................. 53

6. Main Cabinet ............................................................................... 54

6.1 Phoenix/Fusion Enclosure ................................................................................ 54

6.2 Festo Enclosure ............................................................................................... 55

6.3 Electrical Enclosure (3 Phase) ......................................................................... 57

6.4 Electrical Enclosure (Single Phase).................................................................. 58

6.5 Chemical Dosing Pumps .................................................................................. 59

6.6 Cabin Electronics Enclosure ............................................................................. 61

6.7 Wash Chamber & Burkett Valves ..................................................................... 62

6.8 Water Inlet Fittings............................................................................................ 63

6.9 Main Exhaust .................................................................................................... 64

6.10 APV .................................................................................................................. 65

6.11 APV Butterfly Valve .......................................................................................... 66

7. Feeding ........................................................................................ 67

7.1 Feeder Motors & Hoppers ................................................................................ 67

8. External Equipment .................................................................... 68

8.1 Alarm Unit ......................................................................................................... 68

8.2 Extension Boards & Identification Controllers ................................................... 68

8.3 Delivery Line Parts ........................................................................................... 69

9. Chemicals .................................................................................... 70

10. Miscellaneous ............................................................................. 71

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10.1 Safety/Warning Labels ..................................................................................... 71

10.2 Overlays ........................................................................................................... 72

10.3 Silicon Tubes .................................................................................................... 73

10.4 Air Tubes .......................................................................................................... 74

11. Clamps & Gaskets ...................................................................... 75

11.1 Triclover Clamps............................................................................................... 75

12. Installation Kits ........................................................................... 76

12.1 194716 – Fullwood Merlin Installation Kit ......................................................... 76

12.2 194717 – Fullwood Merlin Site Kit .................................................................... 76

13. Service Kits ................................................................................. 77

13.1 Fullwood Merlin Service 1 Kit - 194690; ........................................................... 77



13.4 Fullwood Merlin Service 4 Kit - 194693; ........................................................... 77 Copyright © 2007, Fullwood Limited reserves the right to change the contents of this manual if necessary, without warning. Fullwood Limited has taken every precaution to avoid errors and omissions on the manual and equipment but does not accept any responsibility or liability for damage of any kind arising from the use of this manual or Fullwood equipment; whether this damage is direct or indirect. If you discover any inaccuracies please inform Fullwood Limited or one of its agents and we will make corrections for the next release.

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Important information - read this first

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

The equipment must be used only for the application described.

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

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

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

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

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

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

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

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

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

Icons

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

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

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

Gives important information to prevent potential problems.

Gives advice or suggestions to make procedures easier or clearer.

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1. Introduction

This manual is a reference for all spares parts available of the Merlin Mk2. In section 10, spare part kits can be found. This manual is divided up into the sections of Merlin as indicated below;

Arm Assembly

Cabinet

Crate

Miscellaneous Shown below are the areas of the Merlin;

If there are any anomalies in this document please contact Fullwood technical services department on; [email protected]

2. Revision Control

Version

Date Pages Writer Checked by

0.01 06/10/2011 All J Tomlin J Tomlin

0.02 12/04/2012 All S Hughes S Hughes

0.03 24/04/2012 All S Hughes S Hughes

mailto:[email protected]

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3. Arm Assembly

3.1 Arm Covers

Ref Pt.No. Description Notes

1 194930 Fullwood Merlin LH Cylinder Arm Cover

194931 Fullwood Merlin RH Cylinder Arm Cover

2 194932 Fullwood Merlin LH Corner Arm Cover

194933 Fullwood Merlin RH Corner Arm Cover

3 194934 Fullwood Merlin LH Cover Drain

194935 Fullwood Merlin RH Cover Drain

4 194828 Standard Head Cover FL7 Liners

194829 Grained Laser Cover Ext SL1 & SL2 Liners

1

2

3

4

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3.2 Attachment Head

3

4

5

6

1

7

2

7 7

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Rubber tubes on Mothership;


1 194937 RH Cleaning Arm

194938 LH Cleaning Arm Shown

2 193368 TDS Kit (Modified)

193365 TDS Cable Assy (Spare)

3 194828 Standard Head Cover

4 194029 Centring Plate Assy(New)

5 194025 Brkt S/Assy-Mothership Cyl

6 194040 Tube Manifold S/Assy

7 194671 MK4 Tube Divider Plate

193404 FTL Plastic Bush

092264 4mm ACR Rope (2mt Long)

194038 Cover - ACR Housing Plates on underside of m/ship


030343 Tube 13.5/20mt/23.8 od Rbr Milk Tube

030341 Tube 9.1nb/20mt/18 od Rbr Pulse Tube

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3.3 Jetter Assembly

7

2

3

4

5

6

1

8

10

10

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1 194844 Fullwood Merlin RH Jetter Bracket

194843 Fullwood Merlin LH Jetter Bracket Shown

2 194300 Jetter Plate Welded Assy(225)

3 091790 Set Nut

4 193685 TDS-Nozzle Brkt S/Assy

193673 Nozzle for Laser

5 194310 Jetter Nipple Assy(225)

6 092447 Jetter Cup

7 007868 Type 200 Mini Solenoid V/v

8 007871 1/8"BSP-4mm SS Male StudElbow>

9 193831 Cable Plug-GB03604(GB2LE)

10 007733 1/8"BSP-6mm SS Male StudElbow>

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3.4 Shells & Liners


1 020227 SL1 CTS [22mm] Liner See chart for compatibility

1 020215 SL1 CTW [25mm] Liner See chart for compatibility

1 020134 SL2 CT Liner See chart for compatibility

1 020146 FL7S Liner See chart for compatibility

1 020167 FL7W Liner See chart for compatibility

1 020184 FL7W(Chlorinated)Liner See chart for compatibility

1 020168 FL7WWT Liner See chart for compatibility

1 020169 FL7SWT See chart for compatibility

2 092675 MK2 SL1 & SL2 White Nylon Shell See chart for compatibility

2 092677 MK2 FL7 White Nylon Shell See chart for compatibility

3 194190 LH Mlk/Vac Chamber S/Assy See chart for compatibility

3 194191 RH Mlk/Vac Chamber S/Assy See chart for compatibility

4 007663 "O" Ring 37.82x1.7 One per shell

5 092259 Rope End Cover One per shell

6 007670 "O" Ring 10id x 2 Section One per shell ( holds rope end cover onto milk chamber)

091369 Liner Gauge 12.5mm Used with FL7

091289 Liner Gauge 11mm Used with SL2 & SL1

1

2

3

5

6

4

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Liner Type

Part No

Milk Tube Min. I.D.

Hood Aperture

Barrel I.D.

Shell Vacuum Milk

Chamber

‘O’ Ring 37.8x1.7

mm

“O” Ring

10.00mm x

2.00mm

Rope End

Cover

Liner Gauge

020227 SLI CTS

15.0 22.5 24.5 092675 194191 194190

007663 007670 092259 091369

020215 SL1 CTW

15.25 25.0 24.5 092675 194191 194190

007663 007670 092259 091369

020134 SL2 CT

12.00 22.0 24.0 092675 194191 194190

007663 007670 092259 091289

020146 FL7 S

13.25 20.75 22.0 092677 194191 194190

007663 007670 092259 091369

020168 FL7W

WT

13.5 22.5 22.0 092677 194191 194190

007663 007670 092259 091369

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3.5 ACR Cylinders & Ropes

When replacing cylinder please see MTB055

1 107749 ACR Cylinder SS Twin Barrel

2 194650 ACR Pulley & Rope Retainer Asy

3 007865 M5x4mm Short Swivel Elbow

1

2

3

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3.6 Arm Cylinders & Arm Assemblies

1

2

3

4

4

5

8

7

6

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1 107816 Serviceable Turn cylinder

2 107815 Serviceable Head Cylinder

3 107817 Serviceable Roller Cylinder

4 194937 RH Cleaning Arm

4 194938 LH Cleaning Arm Version Shown

5 194944 LH Mk4 Lift Arm Version Shown

194945 RH Mk4 Lift Arm

6 194946 LH Mk4 Turn Arm

194947 RH Mk4 Turn Arm

194799 Bronze Bearing 20/28x16-35x4 For 194946 & 194947

7 193404 FTL Plastic Bush

8 194949 LH Mk4 Carrier Arm Version Shown

194950 RH Mk4 Carrier Arm

9 194948 Mk4 Turn Pin

10 194953 MK4 LH Yoke Assy Version Shown

194594 MK4 RH Yoke Assy

100520 M12x65 SS Sckt Cap Screw

194809 Turn Cylinder Pin

194885 RH Cable Plate

194777 E-Type Clip 15id Cylinder Fixings

194814 Pivot Pin S/Assy

194884 LH Cable plate

107820 Serviceable Turn cylinder Seal Kit Turn In Cylinder kit

107819 Serviceable Head Cylinder Seal Kit Attachment Head Cylinder Kit

107821 Serviceable Roller Cylinder Seal Kit Teat Roll Arm Kit

194886 Adjustment Nut

194936 Yoke Support Washer

9 10

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3.7 Arm Traverse Motors & Rollers

5

6

4

3

2

1

8

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Wheel detailed below

10

9

11

13

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1 007954 Ultrasonic Sensor

2 092295 Guide Wheel

3 194940 Fullwood Merlin Arm Pin

4 194782 Univ Short Drag Chain Assy Including Cables

5 194824 100mm Square Cap-Black

6 194939 Roller Wheel Cover

8 194774 Emegy Stop Swtch Red

9 194951 LH Motor Brkt Shown

194952 RH Motor Brkt

10 007337 SGT853 Stepper With Gearbox

11 094217 Sensor(IFC259)

094218 M12 4core Jumper Cable for above

13 194943 Mk4 Parallel Arm

193401 Bronze Bearing 18/25x20/4 For 194943


1 007412 Bearing 61904 ZZ s/steel

2 091667 Top Roller

3 194810 SS Arm Roller Pin

091660 SS Top Roller

1

2

3

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3.8 Eccentric Wheel


1 091665 Small Roller Spindle

2 007412 Bearing 61904 ZZ x 2

3 091792 Nylon Roller

1 3

2

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3.9 Foremilk Rejection


1 194808 Univ Foremilk Drain S/Assy Universal Complete Assembly

2 193749 Rejection Manifold Gasket

3 198840 LH End Plate S/Assy

4 193750 Tie Bolt S/Assy

5 194176 LH Mfld Body(Machined) Used on both LH and RH

6 194188 Clamp Brkt S/Assy(Parker)

7 107685 Pre-Milk Cylinder

8 194841 RH End Plate S/Assy

9 194179 Flexible Collection Manifold

10 194182 Cylinder Bar S/Assy

092898 11mm Polypropylene Ball

194178 Clip-Ball Retainer

7 9

6

5

8

3

1

4

10

2

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3.9.1 Drain Manifold


1 194835 LH Arm Drain Tube S/Assy Shown

194852 RH Arm Drain Tube S/Assy

1

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3.10 Legato Pulstaor

Ref

Pt.No. Description Notes

1 142940 Legato LifePulse 24V 2p+1x10m

2 003512 1/2"BSP-90deg Hose Tail

3 042979 Legato 2 Puls Fltr Silencers

4 042917 Legato Lead Merlin 2cMale 10mt

042918 Legato Lead 2cFemale 0.2mt For testing

5 042916 Legato Pulsation PCB spare Waterproof PCB

042927 24vDC Legato Solenoid.

042923 External Air Filter Housing.

042926 Internal Air Filter

1

4 5

2

3

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3.11 S-Lina


1 107687 S-Lina Kit(Merlin225)

107688 S-Lina Componts Kit(Merlin225)

107322 Repair Kit (80mm Cylinder)

2 107543 Sensor Type ICT100/EM/T/440/01


1 007818 Swivel Rod Eye

2 194858 Lift Pin S/Assy

1

1

2

2

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3.12 Teat Roller


1 092890 LH Teat Roll Complete Complete assembly (Shown)

091071 RH Teat Roll Complete Complete assembly

2 092395 Roller Brush (Full Bristle) Used with sawdust bedding

092492 Roller Brush (Half Bristle) Used with straw bedding

3 091958 C'sk Fabric Cover Retaing Ring

4 091960 Teat Roll Output Shaft

5 091968 Black Foam Rubber Gasket

6 091953 Spray Jet

7 091950 Wash Unit S/Assy

091066 V910 Pneu Motor Pneumatic Motor (Not Shown)

000462 M8x16 Socket C'sk SS S/Scw To secure brush to shaft

091958 C'sk Fabric Cover Retaing Ring

1

2

3 4

5

7

6

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092246 40-S Gear Wheel M/CD

092247 40-D Gear Wheel M/CD

091962 RH Housing-Teat Roll Gearbox

092891 LH Housing-Teat Roll Gearbox

091963 Drive Shaft

091964 Gear Wheel Carrier Bush

091965 Motor Plate

007112 M6 SS Grease Nipple

001946 3Dia x 20 SS Roll Pin

001942 5Dia x 26 SS Roll Pin

091961 Lid-Teat Roll Gearbox

091937 Long Air Motor Adaptor

194836 45mm 1/8 Extension

007461 Set of Bevel Gear Wheel ***

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3.13 Arm Control Boxes

3.13.1 Long Box (PCB Box)


1 194786 SS Encl-Arm Electronics Enclosure Only

2 107544 Electronic Module Type EICT

107545 Voltage Module Type EICTVM PCB Inside Above

1

2

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3 194978 Key (Arm Cntl Box)SM300028

4 094779 Rbt PCB KBDP-2(Spare)

5 094623 Rbt PCB GSD15/CAL-1

6 094770 Rbt PCB CP-10(Spare)

7 094772 Rbt PCB Robot-3 9.1185.0564.1

8 094771 Rbt PCB MELK-3 9.1185.0565.2

9 094984 POS-5 Card (5.1002.9502.0)

10 094986 Canlia-1 Card (5.1002.9501.0)

11 094778 Rbt PCB PM-VD24/F PSU

11 094786 Rbt PCB PM-VDPOW/f

12 094590 PCB (BPI0SD-15/B)

094787 Rbt PCB BP15/C B/Plane

4 5

6 7

8 9

10

11

12

3

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3.14 Valve Box

1

5

2

4

6

11

13

14 10

12

9

8

7

15

16

17

3

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1 194787 LH SS Encl-Arm Pneumatics Empty Enclosure (Shown)

194793 RH SS Encl-Arm Pneumatics

2 107690 GR-QS-4 One-Way Flow Cntl Vlv

107808 4mm Restrictor Nut

3 007954 Ultrasonic Sensor

4 094730 Overlay (Replacement)

5 194243 MPA Valve Block(L3KL7M) Complete assembly

6 194890 40mm M6 Spacer

7 194806 LH Service Plate Model Shown

194807 RH Service Plate

8 107501 Solnd Vlv(CPE10-M1BH-3GLS-M7) 2 of each

107529 2/2 Valve for S-Lina 2 of each

9 194880 S-Lina Supply Manifold

10 107478 Slina Pressure Transducer

11 107624 Solnd VlvCPE10-M1BH-5/3G-M7-B

12 194881 S-Lina Splitter Manifold

13 107355 QSSF-1/8-6-B Bulk Push-In Conn

007179 10mm Bulkhead Conn

14 107823 1/8" Exhaust Restrictor

15 107663 Vlv Type VMPA1-M1H-G-PI

16 107626 Vlv "K" Type VMPA1-M1H-K-PI

17 107627 Vlv "M" Type VMPA1-M1H-M-PI

107488 Non-Return Valve H-QS-4

094242 IP65 Gland Plate

094370 50way shielded arm display cable

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3.15 IFM 6 Way Splitter Box


1 094215 6way Splitter Box

2 194275 Teach Button(E30051) Vacuum sensor calibration tool

3 094212 Re-wirable Socket

4 094213 3core PVC 0.3m Jumper Cable Vacuum Sensor

094218 M12 4core Jumper Turn in Sensor

5 094207 M12 1m Jumper Cable

6 094206 M12 Male Straight Conn (6-8) E Stop Cable

7 094208 M12 Male Straight Conn (4-6) S-Lina, Ultrasonic Sensor, Spray Solenoid

8 094209 M12 Female Straight Conn (4-6) S-Lina sensor

1 2

3 4

5 6

7 6

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4. Crate

4.1 Entry & Exit Gates

B

A

1 2

A

B

4

3

3

4

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1 194082 Merlin225 LH SS Entry Gate

194084 Merlin225 RH SS Entry Gate

194086 Merlin225 LH SS(Jersey)EntGate

194087 Merlin225 RH SS(Jersey)EntGate

2 194083 Merlin225 LH SS Exit Gate

194085 Merlin225 RH SS Exit Gate

A

3 194279 Bearing Block

4 191041 Bottom Bearing Bolting Plate

B

3 194279 Bearing Block (Merlin225)

6 191041 Bottom Bearing Bolting Plate

094964 250mm Earth Bonding Strap

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4.2 Cow Follower

6

5 8

7

1 2

4

3

9

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194206 Merlin225 LH Cow Follower Kit Complete cow follower in kit form

194207 Merlin225 RH Cow Follower Kit Complete cow follower in kit form

1 193390 Cow Bash Bar Assy

2 191278 LH SS Pusher Plate S/Assy Model Shown

191190 RH SS Pusher Plate S/Assy

194073 LH (Jersey)SS Pusher Plt S/Asy

194074 RH (Jersey)SS Pusher Plt S/Asy

3 191279 LH SS Single Rear Pusher S/Asy Model Shown

191204 RH SS Single Rear Pusher S/Assy

4 191275 LH Push Sensor Plate S/Assy Model Shown

191208 RHPush Sensor Plate S/Assy

194073 LH (Jersey)SS Pusher Plt S/Asy

194071 RH(Jersey)Push Sensor Plt S/A

5 094964 250mm Earth Bonding Strap

6 191313 Main Pivot Rod

7 191227 Main Pivot Bush

8 191217 Univ Push Supt S/Assy Universal

191315 Main Pivot Spacer

191221 Univ.Arm Side Push Supt S/Assy Universal

9 091338 Nylon Bush(Pusher)

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4.3 Cow Sensor & Antenna


1 094628 Reflective Photo Sensor

2 193431 Cow Presence Sensor Plate

3 093832 Antenna Pedo Blue(10m cable) Replaces 033573 – the new number has a 10m cable

1

3

2

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4.4 Gate Cylinders

4.5 Gate Cylinders Repair Kits


1 107417 Front Gate Cylinder Exit Gate – With Valve

2 107409 Rear Gate Cylinder Without Valve


1 107426 40mm Cylinder Repair Kit

1

2

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5. Milking Area

5.1 Clamp Valve

VACUUM CLAMP VALVE SERVICE KIT

035497

Contains the following;

ITEM

PART NUMBER

DESCRIPTION QTY

1 035527 Support Disc 2

2 035524 Vac Clamp Valve Diaphragm 1

3 1

2

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5.2 Milk Filter


1 115537 SS nut 2" SMS

2 194818 Milk Filter Filter Body

115615 SS fixation cage

115473 Divided spiral cage L560

191018 O ring (Spare for Filter 092833)

191017 Seal(Spare for Filter 092833)

035571 40mm Flap Valve(FP66 Pump)

035085 Fibr Elmnt-Std Fltr-Box Of100. Filter sock

1

1

2

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5.3 Milk Flow Sensors


1 194797 Milk Detection Valve

194789 Spare Diaphragm

1

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5.4 Milk Meter


1 133706 RH 7/8 Afiflo Upper Cover

133707 LH 7/8 Afiflo Upper Cover

2 s/k Cover gasket (silicone) Change as per Merlin service spec

4 s/k Valve gasket (silicone) Change as per Merlin service spec

5 133517 Milk meter valve

6 133544 Lower cover

7 s/k Valve diaphragm (silicone) Change as per Merlin service spec

9 133547 Retaining clip

10 133523 Milk meter brkt assy

11 133677 Afiflo 2000 Body+Plugs

133678 Cable Electrode Extn+Conn 3.5m

133679 Cable Valve Extn+Conn 3.5m

133560 Service seal kit for Afiflo 2000 milk meter

11

Ref / Pt.No: 006930


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5.5 Receiver Vessel


1 194271 37lt SS Rec Vsl(Merlin225)

2 035144 M10 Handnut

3 070218 Transparent Lid(FP Logo)

4 071314 Lid Seal(For 070218)

6 092382 Sampler Body

7 030437 36nb(Blue Sil)Rbr Elbow

8 092369 Sampler Connection Nipple

10 193966 Capacitive Proximity Switch New one part sensor (Jan 2010)

11 092386 Sampler Brkt

12 092366 Dummy Sampler Connection Nipple Inserted into rubber connector when not using shuttle

2

3

4

1

6

7

12

8

10

11

Ref / Pt.No: 006930


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5.5.1 Milk Sampler Unit


1 092367 Sampling Bottle & Lid 2 002958 SS Pull Spring(95lg/5od/3.4id)

3 092369 Sampler Connection Nipple Inserted into rubber connector when using shuttle

4 007792 Spring Close Pneu Cylinder 5 007793 SS Clevis & Pin> 6 092378 3.18id x 6.35od Silicone Tube

1 2

3

4

5

6

Ref / Pt.No: 006930


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5.6 Servac

SERVAC 3500 SERVICE KIT 045277

Contains the following;

ITEM

PART NUMBER

DESCRIPTION QTY

1 045234 Air Cleaner Element. 1

2 045379 Diaphragm (Pilot Valve) 1

3 045251 Pilot Valve 1

4 007631 25.3 odx22.1 id "O" Ring 1

5 007617 6 odx3 id "O" Ring 1

6 045259 Foam Ring 1

7 045208 Main Diaphragm (Silicone) 1

1

2 3

4

5 6

7

Ref / Pt.No: 006930


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5.7 Sanitary Trap

Generic Image Shown


1 194821 Extnd Merlin San Trap Not handed - Universal

2 070198 Lid Washer

3 070287 Plastic Lid (With Hole)

4 032292 60dia Black Ball(Robot)

1

4

2

3

Ref / Pt.No: 006930


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5.8 4:1 Manifold


1 193754 SS Main Manifold Assy (4:1)

003722 2” Clamp

003721 2” Gasket

1

Ref / Pt.No: 006930


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5.9 CrystaLab


1 133720 Crystalab - Merlin Includes 194329 & 133721

2 194329 Afilab slide brkt

3 099863 15VA 24v Transformer

4 133721 Crystalab Rubber Connector

5 099864 Crysta Lab Level Tool

1

2

4 5

3

Ref / Pt.No: 006930


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5.10 Merlin Control Panel

098362

094715

094344

094343

094335

094342

094347

094346

094345

094349

6 7 9

10 11 12 13

8

14 15 16 17

5

1

2

3 4

Electronic Buttons Air purge Button

Ref / Pt.No: 006930


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1 094732 Robot Overlay

2 107770 Black Button Actuator

107303 SV-3-M5 3/2 Pnl Mntd Vlv

3 005980 Emergency Stop Legend

4 094753 Emegy Stop Swtch Red a02mxb22m

5 099191 Tiny Terminal K/B PCB

6 099192 Tiny Terminal Display 4Line

7 099198 Tiny Term Cntl PCB Assy

8 098362 Spade 4BA/M3.5rec 0.5-1.5sq

9 094715 10W IDC Fem Socket

10 094344 Operator Illum Maintained Vacuum & Pulsation

11 094343 Operator Illum Momentary Reset & Feed

12 094335 White Lamp Holder & Base

13 094342 Screen- Blue

14 094347 Printed Film Legend

15 094346 24v AC/DC White LED

16 094345 1 N/O Switch Block Vacuum, Pulsation & Feed

17 094349 Switch Unit Apen A02503 Reset

094754 Switch Block a02502 n/c

Ref / Pt.No: 006930


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5.11 Sampler & Shuttle


1 092378 3.18id x 6.35od Silicone Tube

2 007792 Spring Close Pneu Cyl+Silencer

3 092369 Sampler Connection Nipple Inserted into rubber connector when using shuttle

4 030206 36nb Strt Rbr Connector

5 092366 Dummy Sampler Connection Nipple Inserted into rubber connector when not using shuttle

6 091078 Milk Sampling Unit

7 092367 Sampling Bottle & Lid

8 092373 31mm Sample Bottle Tray

092372 23mm Sample Bottle Tray

092374 32.5mm Sample Bottle Tray

9 091057 Universal Shuttle

091058 30cc Reservoir(For 091057)

091014 50cc Reservoir(For 091057)

091047 1/4"id Hose Barb PMC 22-04-12

Quick release connector shuttle air supply tube

8 9

3

1

2

4

7

5

6

Ref / Pt.No: 006930


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5.12 4QCM


1 194377 4QC Mounting Plate

2 194991 4QC Conductivity Sensor Flow Cell MK2 4QC

1

2

Ref / Pt.No: 006930


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5.13 Milk Pump

Generic Image Shown

FP66 MILK PUMP SERVICE KIT (NW 40)

135221


1 092436 SS Milk Pump(FP66)1ph

040134 1.5kw 240/400v 3ph Mtr

194864 1.5kw 3ph Milk Pump (Merlin)

040043 1.1kw 220/240v Mtr-Packo 49407 Spare Motor

193291 MK2 Rotor Cover

135221 FP66 Service Kit(NW40) Comprises of rotor seal, back plate seal, casing seal & flap

valve

1

Ref / Pt.No: 006930


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5.14 Milk Pump Burkett Valves


1 194895 1/4"BSP Diaphragm Valve Assy

191362 Diaphragm Kit For 131528N

193283 12mm Gasket

193284 12mm Clamp

003335 1"EPDM Seal (Clamp Fitting)

003336 1"-1 1/2"SS Clamp

1

1

Ref / Pt.No: 006930


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6. Main Cabinet

6.1 Phoenix/Fusion Enclosure


094438 Can Open ILCAN BK-TC

094439 Can Open IB IL 24 PWR IN-PAC

094372 Can DI4 input slice – Phoenix contact

094441 Can Open IB IL 24 DO 16

094442 Can Open FLKM 14-PA-INLINE/OUT

094443 Can Open Cable

094403 Relay & Base 24v HC

094445 Relay PLC-V8L/FLK14/OUT

094446 Relay PLC-BSC-24DC/21 & Base

094427 Relay-PLC-V8/FLK14/Out

094456 Relay Phoenix 2961105

094258 12A Relay HC

094487 2.5 – 4 Way PIT terminal

094488 2.5 – 4 Way Pit Clip Terminal

094489 LED Clip Fuse Holder

Ref / Pt.No: 006930


Revision: 0.03

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6.2 Festo Enclosure

4

2

1

5

6

7

8

9

3

10

Ref / Pt.No: 006930


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1 194770 Air Encl Backplate

2 194771 Air Prep Mount

3 007346 Flow Cntl-PWR-L1466

4 107661 LF-3/8-D-5M-Mini-A Filter

5 107810 Air Prep Manifold

6 107540 Can Open Valve Terminal>

7 107626 Vlv "K" Type VMPA1-M1H-K-PI

8 107627 Vlv "M" Type VMPA1-M1H-M-PI

9 107822 “L” Type VPMA Blank Slice

10 107722 CAN Bus Node CPX-FB14

094242 IP65 Gland Plate

Ref / Pt.No: 006930


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6.3 Electrical Enclosure (3 Phase)


1 094467 Transformer Unit

2 094205 24V Trio PSU – Fullwood Merlin

3 094377 3ph RCB

4 094257 3ph Surge Pro Class 3

5 094374 3ph + neutral Isolator

6 094482 5.5kw Contactor – Fullwood Merlin


8 094313 Toiroidal Transformer-Lintron

9 094255 Pilz Unit (PNOZ)

10 094483 Contactor -24vDC 3P + N 4KW

12 094485 3A-12A Overload

13 094489 LED Clip Fuse Holder

14 094488 2.5-4 way PIT Clip Terminal

15 094487 2.5-4 way PIT Terminal

094490 MCB Mounted in Roof Power Box

16 094484 Combi Surge Suppressor

1

9

4

6

5

3

10

2

8

7

13

15

14

12

16

Ref / Pt.No: 006930


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6.4 Electrical Enclosure (Single Phase)


1 094467 Transformer Unit

2 094205 24V Trio PSU – Fullwood Merlin

3 094294 RCBO Single Phase

4 094260 Plugtab Unit-Surge Suppressor

5 094374 3ph + neutral Isolator

6 094482 5.5kw Contactor – Fullwood Merlin


8 094313 Toiroidal Transformer-Lintron

9 094255 Pilz Unit (PNOZ)

10 094272 Contactor (LC1D09BD)

12 094274 Overload (LRD10)

13 094291 Soft Start Unit (ATS01N125FT)

14 094489 LED Clip Fuse Holder

15 094488 2.5-4 way PIT Clip Terminal

16 094487 2.5-4 way PIT Terminal

17 094484 Combi Surge Suppressor

1

9

4

12

6

5

3

10

8

7

2

13

14

16

15

17

Ref / Pt.No: 006930


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6.5 Chemical Dosing Pumps

003557 003558 003554


1 003557 PVC Braid Tube Blue 8x13.5 Alkali Cleaning

2 003558 PVC Braid Tube Red 8x13.6 Acid Cleaning

3 003554 PVC Braid Tube Clear 6.3x11.5 Teat Roll Cleaning

003559 PVC Braid Tube Black 8x13.7 Teat Spraying systems

003555 PVC Braid Tube Green 6.3x11.5 Acid Injection systems

1

2

3

2a

1

5

6

4

7

8

Ref / Pt.No: 006930


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1 007776 Peristaltic 24vDC Pmp 175rpm 2 193830 Peristaltic 24vDC Pump 2a 079464 24v 51rpm Peristaltic Pump 3 193641 Air Driven Pump(20LPM 6.9BAR) 4 007779 Pump Front Cover For 007776 007781 Housing (Screw On) For 193830 & 079464

5 007780 8mm x 2.4mm Autoprene Tube For 007776 079462 3.2mm Spare Viton Tube For 079464 004797 Tube Spare 4.8mm For 193830 & 079464

6 007777 Rotor/Roller Assy For 007776 007782 Rotor For Autoprene For 193830 & 079464

4 001954 Herbie Clip Size E 7 054088 Backplate For M550 Peristl Pmp 8 007778 Pump Housing 5 091899 10mm Dbl.Ended Chemical Nipple 7 001907 Plstc Hose Clip 9.2-10.8 004780 Footvalve (NON RETURN)


1 193641 Air Driven Pump(20LPM 6.9BAR)

1A 193642 Viton Check Valve

2A 193643 Viton Diaphragm Kit

3A 054112 Shaft/Slide Valve Assy Kit

4 054113 Flange/Housing Kit

5 054114 Endcaps Kit

6 054115 Hardware Kit

7 054116 Grommet Kit 4 of 91004000

1

Ref / Pt.No: 006930


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6.6 Cabin Electronics Enclosure


1 133534 Ideal PCB + Display(Fullwood)

2 099714 FwCC PCB Excl RF Unit

3 193123 4QC Top&Bottom PCB f191c/f192d

4 133539 Afiflo 2000 Cntl PCB

1

3

2

4

Ref / Pt.No: 006930


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6.7 Wash Chamber & Burkett Valves


1 194795 Angle Seat Valve Tri-Burkert

2 003792 3/4" Clamp for Tri-Clover

003791 3/4" Tri-Clover Seal EPDM

3 194820 Merlin Wash Manifold

4 194865 DN15 Tri Angle Seat Vlv

4a 195011 DN15 Seal

4b 195010 DN15 Clamp

4

4

1

4

3 4a

4

4b

2

Ref / Pt.No: 006930


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6.8 Water Inlet Fittings


1 194247 15mm x 1/2" Compression fitting

2 072754 22mm x 15mm Adapter

1 2

Ref / Pt.No: 006930


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6.9 Main Exhaust


1 107813 Manifold 1/2x1/4

2 194882 Midi Manifold Brkt

3 107600 U-1/2 Silencer

4 004789 8mm x 1/4"BSP Swivel Elbow.

5 007339 10R1/4 BSPT Swivel Elbow>

1

4

2

5

3

4

Ref / Pt.No: 006930


Revision: 0.03

Date: 30-Apr-12

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6.10 APV


1 194910 LH Pipework(APV Vlv)Merlin Complete Assembly

1a 194911 RH Pipework(APV Vlv)Merlin Complete Assembly

2 091042 "O" Ring(Spare For Delta S23)

3 091043 Shaft Seal(Spare For Delta S23

4 091044 Shaft Complete(Spare-Delta S23

5 091045 Actuator(Spare For Delta S23)

003335 1"EPDM Seal (Clamp Fitting)

003336 1"-1 1/2"SS Clamp

1 1a

Ref / Pt.No: 006930


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6.11 APV Butterfly Valve


1 092710 LH 1 1/2"Dia SS B/Fly Vlv Asy

092595 RH 1 1/2"Dia SS B/Fly Vlv Asy

091085 1 1/2" Auto Butterfly Valve Without welded pipework

2 107393 6od x 4id PUN-H Blue Tube

3 092578 SS Saddle Short Brkt Assy Back half

091176 SS Saddle Front half

4 091048 EPDM Seal For Series 5 BF Vlv Seal on butterfly valve

1

3

4

2

Ref / Pt.No: 006930


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7. Feeding

7.1 Feeder Motors & Hoppers


1 194870 Merlin Galv Feeder Assy

194871 Merlin SS Feeder Assy

2 061810 Mk2 24vDC Motor Assy

3 007636 V20 Face Seal

4 065236 Washer

5 001938 3/16"dia x2"Lg Sellock Pin

6 066347 Auger & Shaft S/Assy

194440 Feed Chute Replaced 194350 due to clogging up issues

2

1

3 5

4 6

Ref / Pt.No: 006930


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8. External Equipment

8.1 Alarm Unit


1 094646 Alarm Unit Merlin UCC(FwAU)

8.2 Extension Boards & Identification Controllers


1 098918 4 In/Out Board Assy

2 098929 16 Chnl I/P PCB Complete

3 099182 FAM8 Channel PCB


4 099703 FwAC High Power Comp UCC Used with Tiris separation gates not controlled by the Merlin

099803 Fullwood ArchwayCntlr(FwAC)W/F Wireless

1

1 2

3

4

Ref / Pt.No: 006930


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5 099704 Fus Activity Adpt UCC-FwAA Used with pedometer separation gates not controlled by the Merlin

099804 Fullwood Activity Adp(FwAA)W/F

8.3 Delivery Line Parts


1 003360 Din20 SS Expansion Union-22mm

2 003712 22mm SS Equal "T" x 1.5wall

3 003144 22diax1.5 SS Tube(240 Grit)

4 007161 22id x 60od Pipe Insulation

003704 22mm-Expanding Tool

For fitting the 22mm expansion union

193924 22mm Tee+Unions Assy

194904 22mm Bend + Unions Assy

194926 Diversion Valve Assy Valve with unions

1 2

3 4

5

Ref / Pt.No: 006930


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9. Chemicals

DESCRIPTION FULLWOOD PART NO.

25Lt Nightwash 113003

200Lt Nightwash 113004

25Lt AMS Cleaner 113009

200Lt AMS Cleaner 113010

25Lt Prepost Iodine 113014

200Lt Prepost Iodine 113015

IBC Prepost Iodine 113016

Astro Clean Laser Cleaning Solvent 017439

Ref / Pt.No: 006930


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10. Miscellaneous

10.1 Safety/Warning Labels


1 081674 Danger M/C Starts Auto Label

2 093873 Do Not Remove Guard Warng Lbl

3 093874 Restricted Access Warning Lbl

4 093875 Dangerous Chemicals Warng Lbl

5 093877 Hot Surface Warning Label

6 006838 Fullwood "Merlin" Label

7 093869 Crush Hazard Warning Label

1 2

4

5

3

6

7

Ref / Pt.No: 006930


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10.2 Overlays


1 094730 Overlay (Replacement)

2 094732 Robot Overlay

3 094347 Printed Film Legend

1

2

3

Ref / Pt.No: 006930


Revision: 0.03

Date: 30-Apr-12

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10.3 Silicon Tubes


1 030328 Sil Tube 9.1nb/20mt/18 od Rbr. 20 metres, Pulse tube

2 030312 Sil Tube 12nb/20mt/21od 20 metres, Milk tube

3 030333 Sil Tube 19nb/10mt/31.8 od Rbr 5 metres, Pulsator supply

4 030343 Tube 13.5/20mt/23.8 od Rbr

5 030341 Tube 9.1nb/20mt/18 od Rbr

6 030329 Sil Tube 13.5nb/20mt/23.8 od

1

2

3

4

5

6

Ref / Pt.No: 006930


Revision: 0.03

Date: 30-Apr-12

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10.4 Air Tubes


1 107393 6od x 4id PUN-H Blue Tube

2 107405 8mm Blue Tube

3 107403 4mm Blue Tube. /mt. (50mtCoil)

4 107406 10mm Blue PUNH Tube>

1

2

3

4

Ref / Pt.No: 006930


Revision: 0.03

Date: 30-Apr-12

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11. Clamps & Gaskets

11.1 Triclover Clamps

Pt.No. Description

193284 12mm Clamp

193283 12mm Gasket

003722 38mm Clamp

003721 38mm Gasket

003791 3/4" Tri-Clover Seal EPDM

003792 3/4" Clamp for Tri-Clover

195011 DN15 Seal

195010 DN15 Clamp

Ref / Pt.No: 006930


Revision: 0.03

Date: 30-Apr-12

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12. Installation Kits

12.1 194716 – Fullwood Merlin Installation Kit

PART NUMBER

ITEM DESCRIPTION QTY FUNCTION

194926 Diversion Valve Assy 1 Tank Valve

005110 Cable Tie Nylon Black300x4.8mm 100 Various

091304 Sil Trans Tube(2500mm lg) 1 Rinse Drain & Rejection Drain

001894 20mm-32mm Hoseclip SS 2

035085 Fibr Elmnt-Std Fltr-Box Of100. 1 Spare Milk Filter Socks

003706 Adjust C Spanner 3" 1 For Milk Filter and Unions

004780 Footvalve (NON RETURN) 4 For Chemical Lines

107393 6od x 4id PUN-H Blue Tube> 50 Tank Valve / Seg Gate

107714 12mm PUN-H Tube 5 Compressed Air to Robot

100007 M16x125 SS Through Bolt 4 For Bolting Merlin Down

094322 Relay Base DPCO(RS 353-966) 2 Vacuum Pump & Plate Cooler

094329 24vDC Relay DPCO G2R-2-SN 2

030468 50mm Connector(Blue Sil) 1 Vacuum connection

007900 CS6 Brass Wtr Prs Cnt Vlv&Gaug 1 Water pressure regulator

193399 3/4 Male to 15mm Comp Fitting 2

194247 15mm x 1/2"Chrome Comp F/M Con 2 Water inlet fittings

12.2 194717 – Fullwood Merlin Site Kit

PART NUMBER

ITEM DESCRIPTION QTY FUNCTION

045263 Servac 3500 Assy 2 Vacuum regulator

045010 Vacuum Gauge 100mm. 1 Vacuum Display

003181 1"BSP Clamp On Vac Nip(60-80) 2 For Servac

099727 Cable Ethernet CAT5 100m 1 For making Ethernet cable, see instructions 006772 099719 Connector RJ45 Ethernet 10

091896 Jet Removal Tool Assy 1 Replacing Jetters

194237 Cobra Clip Fitting Tool 1 Re fitting Cobra Clips

091289 Liner Gauge 11mm 1 For fitting new Liners See instructions 006716 091369 Liner Gauge 12.5mm 1

091325 Sensor & Laser Adjustment Tool 1 Calibration of Vac Sensor

Ref / Pt.No: 006930


Revision: 0.03

Date: 30-Apr-12

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13. Service Kits

13.1 Fullwood Merlin Service 1 Kit - 194690;

Contains: 4 x 4mm ACR Rope (2mt Long) 1 x FP66 Service Kit(NW40) 4 x Diaphragm (For 194797) 1 x Tube Spare 4.8mm 1 x 40mm Flap Valve (FP66 Pump) 4 x Jetter Cup


Contains: 1 x Tube spare 4.8mm 1 x Servac 3500 service kit 1 x 40mm Flap Valve (FP66 Pump) 1 x FP66 Service Kit(NW40) 0.6m x Tube Spare 8mm


Contains: 1 x Servac 3500 service kit 1 x FP66 Service Kit(NW40) 1 x 40mm Flap Valve (FP66 Pump) 8 x Bronze Bearing 18/25 x 20/4 2 x FTL Plastic Bush 2 x Bronze Bearing 20/28 x 16 - 35 x 4 1 x Tube spare 4.8mm


Contains: 1 x Tube spare 4.8mm 20 x 12mmID 21mmOD milk tube 20 x 9.1mmID 18mm OD milk tube 1 x FP66 Service Kit(NW40) 1 x Servac 3500 Assy 1 x 40mm Flap Valve (FP66 Pump) 1 x Service Seal Kit- MK2 Afiflo 2000 2 x legato 2 Pulsation Filter Silencers 0.6m x Tube Spare 8mm 1 x Milk Filter O-Ring 1 x Milk Filter Seal

the fullwood merlin (mk4) spare parts...

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