9e909d Platform Xcal Install Instruction Sept 2012

8/12/2019 9e909d Platform Xcal Install Instruction Sept 2012

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BouMatic P.O. Box 8050 Madison, WI, 53708-8050 USA Telephone: (608) 222-3484 Fax: (608) 222-9314 www.boumatic.comRemicourt 31, Rue Jules Melotte B 4350 Remicourt Belgium Telephone: +32 (0)19 544 266 Fax: +32 (0)19 545 544

PLATFORMINSTALLATION

INSTRUCTIONS

Xcalibur 360EX Instructions 1 9E-90

External Rotary Milking System

Xcalibur 360EX


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Instructional Content and PurposeThese instructions aim to aid those responsible (out-lined under Responsibilities) for installing, operat-ing, maintaining, troubleshooting, and servicing thisproduct.

ResponsibilitiesProcedures in these instructions are to be performedaccording to applicable codes (state, local, and other)by the person(s) qualied (licensed, if applicable) to

do sothat is:

Welding must be done by a qualied welder; AC power wiring for voltages over 40V (50V in

Europe) must be done by a qualied (licensed)electrician in compliance with the latest editionof the ANSI/NFPA Standard 70, National Electri-cal Code, (USA) or either LVD 73/23/ EEC or EMC89/336/EEC (Europe) and in compliance with thelocal wiring codes as applicable;

Other installation, major maintenance, and servicework must be done by an authorized BouMaticdealer;

Product/system checkout and troubleshootingsteps are to be performed by an authorized Bou-Maticdealer;

Deviation from these instructions could affectproduct performance or create a hazardous situ-ation. Under no circumstances will BouMaticberesponsible for any problems caused in wholeor in part by any deviation from the proceduresspecied in these instructions without prior writtenapproval from BouMatic;

Operation steps may be performed by the owner/operator once the dealer or technician has suc-cessfully nished the product/system checkout

The owner/operator is responsible for properlyoperating, maintaining, and monitoring the prod-uct/system to ensure that it works properly.

Close compliance with the procedures herein is es-sential for the owner to get maximum benet fromthe product/system.

DisclaimersNo warranties are contained in these instructions. Thedivision of responsibilities, stated above, is a generareminder of those provisions in the applicable dealercontract and does not change any agreement be-

tween BouMaticand the dealer. Information in theseinstructions is not all-inclusive and cannot cover alunique situations.

9E-909d 2 Xcalibur 360EX Instructions


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Table of Contents

Xcalibur 360EX Instructions 3 9E-909d

Introduction............................................................................................................ 41. Preparation......................................................................................................... 4 1.1 Part and Tool Requirements....................................................................... 4 1.2 Reviewing Personal Safety Messages.......................................................... 5 1.3 Building Layout........................................................................................ 5

1.4 Equipotential Plane.................................................................................. 5 1.5 Direction of Platform Rotation.................................................................... 6 1.6 Compressed Air Requirements................................................................... 62. Installation......................................................................................................... 7 2.1 Footings ................................................................................................. 7 2.1.1 Center Pivot Footing and Rump Rail Footing.................................... 7 2.2 Utility Stairs, Drains & Conduit................................................................... 7 2.2.1 Utility Passage............................................................................ 7 2.2.2 Drains........................................................................................ 7 2.2.3 Conduit...................................................................................... 7 2.2.3.1 Hydraulic Drive Conduit................................................... 7 2.2.3.2 Management System Conduit........................................... 7 2.2.4 Water Lines................................................................................ 7

2.3 Floor....................................................................................................... 7 2.4. Installation of Components....................................................................... 8 2.4.1 Center Pivot................................................................................ 8 2.4.2 Rump Rail Post............................................................................ 8 2.4.3 Support Posts............................................................................. 8 2.4.4 Installing the Drive Pedestals........................................................ 9 2.4.5 Installing the Rails on the Supports................................................ 10 2.4.5.5 Install Center/Safety Roller............................................... 10 2.4.6 Installing the Preassembled Rollerframes........................................ 10 2.4.7 Installing the I-beam................................................................... 10 2.5 Stall Divider Support Beam Installation....................................................... 10 2.5.1 Mount the Stall Divider Supports and Curbing.................................. 10 2.5.2 Install Utility Bridges.................................................................... 11 2.5.3 Install Drive Ring......................................................................... 11 2.5.4 Install Deck Extension Brackets..................................................... 11 2.5.5 Install Vision Shield Mounting Brackets........................................... 12 2.5.6 Weld Curbing in Place................................................................... 12 2.6 Cow Platform........................................................................................... 12 2.6.1 Cow Deck Corrugated Tin Sheets and Rebar.................................... 12 2.6.2 Deck Extension Corrugated Tin Sheets........................................... 12 2.6.3 Check Radius and Elevation.......................................................... 13 2.6.4 Pouring Concrete........................................................................ 133. Tables and Figures............................................................................................... 14


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9E-909d 4 Xcalibur 360EX Instruction

BouMatics Xcalibur 360EX Exterior Rotary MilkingSystem is an integrated high performance systembuilt around a rotating platform. Cows enter andexit the slowly rotating platform continuously dur-ing milking. This design moves cows through milkingquickly, resulting in a highly productive parlor. All of

its components and systems have been designed towork together to increase productivity, harvest highquality milk, and provide reliable performance.

Rugged rollers support a large steel double I-beam,that is driven by a powerful hydraulic system. A stur-dy steel support structure is bolted to the I-beamand in turn supports a thick concrete deck (rein-forced with steel rebar).

The main airline, milk delivery line, electric power,compressed airline, and communication pivots arelocated at the center of the rotary. The receiver

group, Opti-Flo milk pump, speed control, and me-

ters (if installed) are mounted under the platform toprovide an uncluttered, yet easily accessible, milkingsystem. A stainless steel skirt around the rotarys exterior perimeter shields these components and pro-tects the operators while the rotary is in operation.

Critical components and electronics are convenientlylocated in stainless steel cabinets. The detacherselectronics, valves, cylinders, and CIP jetters areeasily accessible. This integrated design provides op-timal protection.

These instructions are designed to help the installersafely and efciently construct the platform. Reviewthese instructions (especially Section 1) and theconcrete drawings, available through the BouMaticEquipment Catalog, before planning and installingyour parlor. Instructions for the operator are foundin the Xcalibur 360EX Exterior Rotary Milking System

Operating Instructions (9E-910).

1. Preparation

Introduction

N O T I C E

Abbreviations

a/r As required

SS Stainless-steel

Diameter

OD Outside diameter

ID inside diameter or identication, depending on context

D/M Detacher/Meter

D/O Detacher Only

1.1 Part and Tool Requirements

To prepare, be sure you have the following items:

Dealer-Supplied Parts Quantity

Masonry cement (grout) As needed

Concrete See Table 1

Any components normally mounted outside theparlor (in the milk room, utility room, or elsewhere)

a/r

PVC pipe and ttings a/r

Zinc spray paint a/r

Aluminum spray paint a/r

Optional Dealer-Supplied Electrical Parts:

In areas where 120 Volts are not available a transformer will be needed to supply 120VAC to the stall tag

reader.

Important Information on Transits:

The roller support posts must be set properly. If using a laser level you must make sure it is capableof reading within + or - 0.016 in. (0.4mm) at 50 ft(15.25m). Take extra care when setting up the transit or laser level. The transit normally needs to beset up at least twice as errors can be compounded iproper care is not taken. (Marking reference lines onopposite walls of the building on the rst use of thetransit and using them as reference during subse-quent uses will help ensure consistency.) Turn transi180 degrees and then reset measure distances between the lines marked on the wall. They should beequal at every location.

Literature Referenced in these Instructions

Rotary Automation Instructions 9E-920

Rotary Hydraulic Instructions 9E-921


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1.2 Reviewing Personal SafetyMessages

Follow the safety messages below and throughoutthis manual to prevent possible bodily injury. Theowner is responsible for replacing safety labelsshould they become illegible.

Provide positive, lockable disconnects to prevent un-intended application of electrical, hydraulic, or pneu-

matic power to the equipment. Refer to nationalregulations for proper lock-out procedures for equip-ment service or repair. See Figure 1for an illustra-tion of possible methods.

WARNING

Welding of galvanized steel parts may produce fumesand gases hazardous to health. Avoid breathingthese fumes and gases. Use adequate ventilation.

CAUTION

Use proper lifting equipment rated to handle heavyobjects. Each I-beam section weighs approximately800 lbs. (365 kg).

CAUTION

Do not rotate the platform during the pouring or cur-ing phase. The use of a cement pumping system isrecommended. Moving the platform during pouringrisks injury to the installers and damage to the rotary.

CAUTION

Keep ngers away from the roller wheels when theplatform is rotated, or injury could result.

1.3 Building Layout

See Figure 2for the following steps.

Plan the building layout and installation according tothese guidelines:

Establish the parlor wash position. Locatethe wash suction lines as they leave the milk

room and connect to the CIP connections onthe platform. The receiver will be mountedon the inside of the platform. If two receiv-ers are used, the second receiver will beplaced 180 degrees from the rst receiver.

The stall where the receiver is mountedmust have a spoke attached to it for routingthe milk delivery and vacuum lines from thereceiver.

Floor drains should be placed under all re-ceivers at the wash position.

When locating the center of the rotary, allowsufcient room for the bridge (see Figure

2).For optimal cow ow, the cow entrancelane should be a minimum of two cowlengths (15 [4.6m]) long.

Refer to Section 2.2, Utility Stairs, Drains& Conduit to plan the layout of these items.

Establish the distance from the top of thecow platform to the oor of the operators'area (operators platform). This is typically38 to 42 in. (965 to 1067mm).

The cow entrance lane should have a 32 in.(813mm) inside dimension. This will accom-modate the largest cows. If smaller cowsare able to enter the lane simultaneously, a

wall extension can be made to narrow theentrance.

Follow receiver jar location and other layoutdimensions so there are no pinch points inthe basement.

1.4 Equipotential Plane

BouMatic recommends the parlor be constructedwith an equipotential plane.

An equipotential plane is an area where a wire mesh

or other conductive elements are embedded in con-crete, bonded to all adjacent conductive equipment,structures or surfaces and connected to the electricagrounding system to prevent a difference in voltagefrom developing within the plane. Livestock makingcontact between the concrete oor or platform andthe equipment or metal structure will be less likelyto be exposed to a level of voltage that may alteranimal behavior or productivity (Agricultural WiringHandbook, 10th Edition, Published by the NationalFood and Energy Council).


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The cow platform forms its own equipotential planebecause it is an all-steel platform with a concretedeck poured onto it. All of the stall dividers are boltedor welded to the deck (making the entire structureone plane). The plane is grounded by an equipmentgrounding conductor that is routed through the slipring assembly and connected to the milk pump orthe controller frame.

Some states regulate the use of equipotential planes,

so installers should contact local authorities for moreinformation. Details and guidelines for equipotentialplanes can be found in the American Society of Ag-ricultural Engineers (ASAE) EP473-1994, NationalElectrical Code NEC Article 547-8, and WisconsinState Electrical Code Volume 2, Article 547 SectionILHR 16.27.

1.5 Direction of Platform Rotation

The standard rotary parlor is designed to rotatecounterclockwise. This direction provides the most

efcient handling of the milking unit during attach-ment for right-handed operators. If the dairy has or-dered a non-standard rotary that rotates clockwise,the bridge layout must be mirror-imaged so that theentrance will be on the right side of the bridge as youare looking from the center of the parlor towards it.

1.6 Compressed Air Requirements

Refer to Air Supply System literature (9P-595) forinformation on proper sizing of compressors for yoursystem.

Pressurized air, 65 to 70 psi (450-480Kpa), is required at the detacher.

A Refrigerated Air Dryer System should beinstalled immediately after the compressor.This system should be sized to meet the owcapabilities of the compressor and lower thedew point of the output air to 38F.

The air system must include a 3-way lock-out valve that, when closed, will bleed off allsystem pressure to allow for safe mainte-nance of this product. This valve is includedwith the Filter-Regulator assembly.

N O T I C E Review the instructions under the heading

Responsibilities(page 2) and perform onlythe steps which you are responsible for.

Read this entire instruction booklet (payingclose attention to personal safety messagesand installation specications in Section 1)before starting procedures in this section.


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2.1 Footings

Contact BouMatic for a detailed concrete drawingfor your size parlor. Refer to the supplied concretedrawingthroughout section 2.

Concrete drawings can also be found on the BouMaticDealer Portal website in the Technical Manuals section.

W A R N I N G

Welding of galvanized steel parts may produce fumesand gases hazardous to health. Avoid breathing thesefumes and gases. Use adequate ventilation.

N O T I C E

The size and shape of footings is dependent on soil con-ditions. Footings must conform to local building codes.

Refer to the concrete drawingand locate the foot-ings. Using the transit, determine the height of thecow platform at the operator position. Record this asa reference line on two opposite walls of the build-ing. Use this reference line to verify transit settingsduring subsequent use of the transit to insure consis-tency in measurements. Platform heights can be 38"

(965 mm) to 42" (1067 mm).

2.1.1 Center Pivot Footing and RumpRail Footing

Set the height of the footings as shown in Figures 3and 4. Keep footing heights within +/- 1/8 in. (3mm)of each other. The center pivot, roller posts, and rumprail bases will be installed later. The rump rail post po-sition can be moved 12 in. (305mm) along the radiusto avoid interference with doors or other obstacles.

2.2 Utility Stairs, Drains & Conduit

2.2.1 Utility Passage

Stairs are necessary for access to the center of theplatform. The layouts for the various systems used onthe rotary may vary according to the needs of instal-

lation. Figure 2and the concrete drawingindicatesuggested stair locations.

2.2.2 Drains

Place drains at the wash position of the receiver, in the

basement, in the stairwell, and as required by the oorslope (refer to the concrete drawingand Figures 2and 3). When planning the oor slope, be sure to pro-vide a sufcient decline to allow manure to be sprayedtoward a drain from all areas of the parlor.

2.2.3 Conduits

2.2.3.1 Hydraulic Drive Conduit

Refer to Rotary Automation Instructions9E-921 foconduits required for hydraulics.

2.2.3.2 Management System Conduit

Refer toRotary Hydraulic Instruction9E-920 for man-agement system conduits required for components.

2.2.4 Water Lines

1. If desired, place water lines in the center forushing the center concrete oor.

2. Provide water lines along the outer wall forparlor wash down. Do not install water linesunder the platform.

3. Provide for a water line at the entrance andexit sides of the bridge for use in cleaningmilking units and for directing a spray at thecows to move them off the platform aftermilking. The area immediately surrounding thebridge/platform gap switch must be clear ofconduit and piping. Refer to literature 9E-921.

2.3 Floor

N O T I C E

The amount of ll and thickness of the oor will de-termine the distance from the oor to the top of theplatform. To raise the oor, add more ll under theoperators' area.

Establish the elevation of the oor at the operatorsarea. The concrete drawingdetails the remainingoor heights.

2. Installation


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port post threaded mounting rods to thefooting using the supplied adhesive. Allowthe adhesive to set up.

7. Install an M16 nut on each of the mountingrods. Place the support post onto the mount-ing rods so it is resting on the nuts and thewashers.

8. Using a transit, adjust the nuts until the cor-rect height is reached and the support postis level.

9. Place one washer and one nut on each ofthe threaded rods. Tighten the nuts to lockthe support post in place, and verify that itis level and at the correct height. Adjust ifnecessary.

10.Continue the above procedure with theremaining support posts. Ensure the postheights are the same and that the tops arelevel in all directions.

11.Fill the space between the concrete oor andthe support with shrink free mortar. This canbe done at any point in the procedure priorto pouring concrete onto the deck.

N O T I C E

Double-check posts to be vertical and level at 1/32 in. in diameter.

2.4.4 Installing the Drive Pedestals

See fgure 11for setting the hydraulic drive pedestalsand fgure 11afor setting the electric drive pedestals.See fgure 11for Hydraulic Scribe line radius and Fig-ure 11afor Electric drive scribe line radius.

N O T I C E

Steps 2 thru 10 apply only to HYDRAULIC Drives.Steps 11 thru 19 apply only to ELECETRIC Drives.

1. Before setting the drive pedestals, set theradius of the scribe and mark the radius of thedrive ring near the drive access alcoves.

HYDRAULIC Drives Pedestals

2. Place a drive pedestal at each of the driveaccess alcove locations. When looking from

the center of the rotary outward, the drivepedestals will be located to the right of thedrive access alcove on a clockwise rotaryand on the left for a counterclockwise rotary.

3. Orient the drive pedestal with the at faces(drive wheel & motor side) of the supportstoward the drive access alcove in the con-crete. Keep the Drive Support 19.69 in.(500mm) away from the edge of the DriveAccess alcove.

4. Using the two notches on the drive pedes-

tal base and the scribed radius of the drivering, locate the drive pedestal and mark themounting hole locations. See fgure 11foroffset and alignment dimensions.

5. At each mark drill a 3/4 in. (18mm) diam-eter hole, 5 in. (125mm) deep.

6. Clean the holes and bond the seven M16support post threaded mounting rods to thefooting using the supplied adhesive. Allowthe adhesive to set up.

7. Install an M16 nut on each of the mount-ing rods. Place the drive pedestal onto themounting rods so it is resting on the nuts.

8. Place a level on the uprights and level thedrive pedestal using the four nuts under thecorners of the base.

9. Once the pedestal is level, bring the otherthree nuts up under the base and make sureall seven nuts are making contact.

10.Place one washer and one nut on each of thethreaded rods. Tighten the nuts to lock thedrive pedestal in place and verify it is stilllevel. Adjust if necessary.

ELECTRIC Drives Pedestals

11. Place a drill plate and a drive pedestal ateach of the drive access alcove locations.When looking from the center of the rotaryoutward, the drive pedestals will be locatedto the right of the drive access alcove on aclockwise rotary and on the left for a coun-terclockwise rotary. See fgure 11afor elec-tric drive pedestal assembly image.

12. Orient the drill plate as shown in fgure

11b. (Figure 11bshows the drill plateinstallation for counterclockwise rotation.For clockwise rotation the drill plate wouldbe oriented opposite as shown.) Be sure tokeep the drill plate at least 500mm awayfrom the edge of the drive access alcove.

13.Using the two notches on the drill plate andthe scribed radius of the drive ring, locatethe drill plate according to dimension Xand mark the mounting hole locations.

14. At each mark drill a 3/4 in. (18mm) diam-eter hole, 5 in. (125mm) deep.

15. Clean the holes and bond the seven M16

threaded mounting rods to the footing usingthe supplied adhesive. Allow the adhesive toset up.

16. Install an M16 nut on each of the mountingrods. Place the drill plate over the mountingrods so it is resting on the nuts. Then placethe drive pedestal over the mounting rodson top of the drill plate.

17. Place a level on the drive pedestal and makesure it is level in all directions using the fournuts under the corners of the base.


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18.Once the pedestal is level, bring the otherthree nuts up under the base and make sureall seven nuts are making contact with thebottom of the drill plate.

19.Place one washer and one nut on each of thethreaded rods. Tighten the nuts to lock thedrive pedestal and drill plate in place andverify it is still level. Adjust if necessary.

2.4.5 Installing the Rails on the

Supports

See Figure 12for the following steps:

1. Adjust the spacers on the utility bridge so thescribing tool is resting on the support posts.

2. Set the radius of the scribe and mark theinside radius of the lower rail. See Figure 12for dimensions. Double check the rail radiusby scribing a line on the supports on oppositesides of the rotary. Then, check the diameter.Adjust the scribing tool to get the correct di-ameter and then scribe all posts.

3. Place the rail sections on the supports.4. Place the inside edge of the rail on the mark

made in step 1.5. Using the provided clamp plates, tighten the

outside clamp rst, making sure the insideedge of one rail remains on the mark. (SeeFigure 12). Then, tighten the inside clampplate. Clear the ends of the rail from any ex-cess galvanizing.

6. Place another rail on the supports causing it totouch end to end with the rail placed in step 2.

7. Connect the rails with two connection platesand tighten the bolts.

8. Continue to add rails in the same manneraround the circumference of the parlor.

9. The last rail will have to be cut to length. Mea-sure the remaining gap and cut the rail to ft it.

10. Place the last rail, mark the holes with theconnection plate and drill two 3/4 in. (17mm)holes.

11. Tighten the bolts in the last plate and ensureall of the connection plate bolts are tight.

2.4.5.1 Install Center/Safety Roller

1. Mark a line on each safety roller post (17.7

in. (450mm) from the rail mark line.2. Attach the safety roller to the support post

at the mark line using two u-bolts and nuts.3. Repeat steps 1 and 2at every safety roller

support post.

2.4.6 Installing the PreassembledRollerframes

SeeFigure 13for the following steps.

1. Place the roller frames on the rails with thelabels facing the inside.

N O T I C E

All labels on the rollers must face the inside of the

rotary.

2. Connect the roller frames using the M12 X 30bolts and at washers under the lock nuts.

3. Tighten each nut until snug and then loosenslighty. Roller frames should be able to pivot,but should not be loose.

CAUTIONUse proper lifting equipment rated to handle heavyobjects. Each I-beam section weighs approximately800 lbs. (365 kg).

2.4.7 Installing the I-beam

1. lace the I-beam sections onto the rollerwheelswith the notches in the connectionanges (see Figure 14). When placing I-beams ensure that each section is centeredon the roters.

2. Bolt the support plate to the bottom of the I-beam sections using the M10x40 bolts, over-lapping the joints of the I-beam and supportplate by 12 in. (305mm).

3. Connect the I-beams using four M16x60bolts and lock nuts at each connection (SeeFigure 14).

4. When initially putting the beams together, putin only the lower two bolts and use the upperholes to align the plates accurately. Make surethat the worked side of the washer is facingthe head of the bolt and the nut. Place the up-per two bolts, using Loctite, and tighten them

with a 185 bs-ft. (250 Nm) torque. Untightenthe two lower bolts, apply Loctite and tightenthem with a 185 bs-ft. (250 Nm) torque.

N O T I C E

Check for roundness of I-Beam every 45 degrees(See Figure 25.)


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2.5 Stall Divider Support BeamInstallation

2.5.1 Mount the Stall Divider Supportsand Curbing

1. Divide the I-beam into a number of sectionsmatching the size of the rotary. Avoid thejoints of the I-beam as much as possible.

If the nal division is not of an equal size,evenly distribute the difference over the restof the parlor. See Figure 8for dimensions.

2. Using the marks from above, bolt a stall di-vider support beam to the I-beam. (See Fig-ure 15.) Ensure that the rod at the bottomof the stall divider support is touching theinside of the I-beam. Align this stall dividersupport beam with the center pivot. Tightenthe bolts on this stall only.

3. Install the rest of the stall divider supportbeams as indicated in Figure 15. Use thescribe marks to evenly space the beamsaround the parlor. Snug the clamp plate

bolts (rst the inner clamp and then theouter) to the point where the beam can beadjusted by hitting it lightly with a hammer.Align with the outer clamp.

4. Place the inner four spacers in between thesupport beams. Bolt the outermost spacer inplace using M12X20 bolts and nuts. Be surethe outer most spacer is on the outside ofthe bracket. Install the drive ring rst. (Seesection 2.5.3.)

5. Loosely secure the inner and outer curbs inplace by bolting through the curb into thestall divider assembly using a 1/2 in.-13x1.5in. carriage bolt and nut in the upper mount-

ing hole of each curb section. (See Figure16.)

6. Install outer curb section with a cut out forjetter line location. See Figure 16a.

7. Stagger the seams on the curbing so thatthe inner and outer curb joints are not onthe same stall divider support beam.

8. Align the holes in the curb with the holes inthe stall divider support beam using a prybar or pin in the lower mounting hole, andthen tighten the installed carriage bolt.

9. Install a 1/2 in.-13x1.5 in.carriage bolt andnut in the lower mounting hole and tighten.

2.5.2 Install Utility Bridges

1. Bolt the utility bridge sections together onthe ground using M12X30 bolts and locknuts. There will be an end to mount to thecenter pivot, one or two center sections, anda stall divider support mounting bracket.These utility bridges will be located at threelocations equally spaced on the 32, 36, 40,and 44 stall platforms and four locations

equally spaced on the 50, 60, 72, and 80stall platforms as shown in Figure 9.

2. Loosely install one assembly on the centerpivot using two M16X30 bolts and nuts inthe holes farthest from the center of eachassembly.

3. Install two M12x30 galvanized bolts throughthe holes in the mounting bracket and stalldivider support beam. Then install a M12 nuton each bolt and tighten.

4. Lift the outer end of the utility bridge intoplace under a stall divider support beam andattach the mounting bracket to the beamusing two M12 U-bolts and four M12 galva-nized nuts. Tighten the U-bolts until the sup-port bracket and stall divider support beamtouch. See Figure 17.

5. Tighten the u-bolts completely.6. Align the holes in the end of the utility

bridge with the center pivot and tighten thetwo fasteners installed in step 2. Install thetwo remaining bolts and nuts.

7. Repeat for the other utility bridges. Ensure

the bridges are equally spaced and in linewith the stall divider support beam they areconnected to. Tighten all bolts on the centerpivot after they have all been installed.

2.5.3 Install Drive Ring

See Figure 18for basement rotaries and Figure 18afor non-basement rotaries in the following steps.

1. Install each drive ring section onto the sup-port beams using two M12X30 galvanizedbolts and nuts. Stagger the seams so that

they are not located on the same stall di-vider support beam as the inner and outercurb seams.

2. Install joint plates at the bottom of the seamon each of the drive ring sections using twoM12X30 galvanized bolts and nuts.

3. Install the centering guides on the centeringsupport posts using 4 in. (100mm) squareU-bolts. The roller wheel should be 1/8 to3/16 in (3 to 5mm) from the drive ring.

4. A special drive ring section with cut out forjetter line location should be installed (seeFigure 18b).

CAUTION

Keep ngers away from the roller wheels when theplatform is rotated or injury could result.


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2.5.4 Install Deck Extension Brackets

1. Using two M18X35 galvanized bolts andnuts, bolt a stall extension bracket ontothe inner curb adjacent to the stall divider.The stall extension bracket should slope uptoward the center of the rotary with the tabtoward the center. (See Figure 19.)

2. Using a square placed against the bottomof the curb, make sure the side of the stall

extension bracket is square with the bottomof the inner curb, then tighten bolts.3. Repeat steps 1 through 2 for all stall locations.

2.5.5 Install Vision Shield MountingBrackets and Extension Curbing

SeeFigure 19for the following steps.

1. Install the deck extension curbing and a visionshield bracket. Loosely bolt it in place usingM8X20 galvanized bolts and nuts.

2. Repeat step 1for the other vision shieldmounting brackets in the center of the curb.3. Overlap the next section of curb over the rst

and install loosely as in step 1.4. Repeat step 1for the new section of curbing5. Remove the fasteners from the overlap area

and install a vision shield mounting bracket atthat location.

6. Locate the correct radius curved support tubeand mount it on the upper inside area of thevision shield mounting brackets using the pro-vided galvanized M8 U-bolts and nuts.

2.5.6 Weld Curbing in Place

WARNING


1. Weld the outer curb seams.2. Grind the seam ush with the curbing.3. Polish off discoloration caused by welding

with an abrasive pad or bufng wheel.

2.6 Cow Platform

2.6.1 Cow Deck Corrugated Tin Sheetsand Rebar

See Figures 20, 21, 23, and 24for the following steps

1. Install the corrugated sheets forming thebottom of the platform so that they t next

to the stall frame, as shown in Figure 20.Two pieces, one left and one right, will berequired at each stall location. These will beoriented with the ribs facing upward.

N O T I C E

It may be necessary to hammer the sheets to t aroundthe U-Bolts securing the utility bridges in place.

2. Using the provided tape and foam, seal allgaps between the tin sheets, stall dividersupport beam, and curbing.

N O T I C E Avoid standing on the corrugated sheets as it maycause them to buckle. Use planks placed betweenthe inner and outer curbs to access the cow platformbefore it is poured.

WARNING


3. Using 308 or equivalent stainless steel ller,weld the provided 5 in. (125mm) long piecesof stainless steel to the inside and outside curb(see Figure 21).

4. Place the pre-assembled rebar mats at eachstall location. Use the provided standoffs tokeep the rebar off of the corrugated sheets.

5. Tie or weld the rebar mats to each other.6. Using 308 or equivalent stainless steel ller,

weld the rebar mats to the stainless steel stand-offs that were welded to the curbing in step 3.


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2.6.2 Deck Extension Corrugated TinSheets

See Figures 22, 23, and 24for the following steps.

1. Place two stall extension braces between eachstall.

2. Install the corrugated sheets forming the bot-tom of the deck extension so that they t be-tween the inner curbing and the deck extension

curbing. The ends should be on a deck exten-sion support bracket.

3. Fasten corrugated sheets and extension bracesin place using two self drilling screws at eachjoint.

4. Install drains in the platform by drilling holes inthe tin sheets every ve to six stalls, depend-ing on the size of the rotary. Run a drain pipethrough the hole, leaving the mouth of thedrain pipe 2.75 in. (70mm) above the tin sheet.

5. Weld extension rebar to the inside curb of theextension and to the inside curb of the plat-form. These should be evenly spaced.

6. After welding the three rings of rebar (dealer-supplied) weld the deck extension to the exten-sion rebar.

7. Using the provided tape and foam, seal all gapsbetween the tin sheets, stall divider supportbeam, stall extension support, and curbing.

2.6.3 Check Radius and Elevation

The outside curb must maintain the same radius andelevation around the entire perimeter. This consistencymust be maintained so that when the platform is pass-

ing next to the bridge the gap between the bridge andthe platform remains constant at 2in 0.5in (50mm13mm). The height of the platform must remain levelrelative to the bridge within 1in (25mm). Check radiusand elevation around the entire platform to determinewhere adjustments need to be made. This can be doneby marking a stationary point on a measuring stick ortemporary upright placed alongside the top edge of theoutside curb. Rotate the platform past this point, notingwhere the platform moves up or down vertically and inor out horizontally in relation to this point. These are theareas of the platform that will need to be adjusted.

2.6.4 Pouring Concrete

CAUTION

Do not rotate the platform during the pouring or curing

phase. The use of a cement pumping system is recom-mended. Moving the platform during pouring risks in-jury to the installers and damage to the rotary.

Pour the platform using concrete with a minimumstrength of 5000 psi (35MPa). Speciy the concrete sup-plier utilize a minimum shrink formula. Use Novamesh950 at an application rate of 10 lbs./yd. (6kg/m3). Pouto the upper edge of stainless curbs .

Strike off the concrete using the inner and outer curbsfor a guide. This may create a slight skim over the staldivider support beam at the cabinet and fence mountinglocations. This skim can be broken off after the concretehas cured.

Vibrate concrete with a needle vibrator. Float entire sur-face and broom nish. Ensure the surface is sufcientlyrough to prevent the animals from slipping and smoothenough to facilitate cleaning. Also, ensure the height ofthe platform will match the bridge height.

Be sure to include any surface treatments that will beapplied to the rotary deck and bridge (tile or rubbermats) when guring this dimension. Tile thickness mus

be no more than 1/2 in. (12mm) on the cow platform.

N O T I C E

To extend the life of the deck on high usage parlors, itis recommended the entire concrete surface be coatedwith an epoxy nish. This coating should extend overthe concrete and stall divider support beam mountingsurfaces. Keep the epoxy out of the mounting holes forthe cabinet and fence. The large openings in the cabinetmounting face are sized to accept a 2 in. Male NPT x 2in. slip PVC tting and can be used as a dam to keepepoxy out of these openings.

Deck extension: Use 4000 psi concrete with Novo-Mesh 950 added at an application rate of of 10 lbs./yd.(6kg/m3). Hand groove joints every fourth stall. Trowea chamfer into the concrete at the edge where the innerring meets the concrete. Fill in the joints and chamferwith a exible crack ller after the concrete has cured.


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2. Sections 1.3, 2.2.1, and 2.2.2)A typical building layout. Note the relative positions of the reciever group(s), bridge,and CIP connections l909_2

1. (Section 1.2)Lock-out techniques for power,hydraulic and air l909_1

3. Tables and Figures


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4. (Section 2.1.1)Footings l909_3

3.(Sections 2.1.1 and 2.1.2) The Utility Passage. Note the positioning of the various lines and thedrain located at the utility room end of the passage l909_5


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6. (Section 2.4.1)Installing the center pivot l909_8

5. (Section 2.4.1)Roller post footing, rebar layout l909_4


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7a. (Section 2.4.2) Installing the Rump Rail Support Post l909_10

7. (Sections 2.4.1 and 2.4.2) l908_9


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8. (Sections 2.4.2 and 2.4.4)Various Post Dimensions from Pivot Center l909_83

Stalls Dimension A Dimension B Dimension C Dimension D

40 17 ft., 5-3/4 in. (5327.5mm) 17 ft., 7-5/8 in. (5376mm) 17 ft., 9-1/4 in. (5417mm) 24 ft., 2 in. (7367mm)

44 19 ft., 6-5/8 in. (5960.5mm) 19 ft., 8-9/16 in. (6009mm) 19 ft., 10-3/16 in. (6050mm) 26 ft., 3 in. (8000mm)

50 22 ft., 8-7/16 in., (6920.5mm) 22 ft., 10-3/8 in. (6969mm) 23 ft. (7010mm) 29 ft., 4-3/4 in. (1086mm)

60 27 ft., 11-1/16 in. (8510.5mm) 28 ft., 1 in. (8559mm) 28 ft., 2-9/16 in. (8600mm) 34 ft., 7-3/8 in., (10550mm)

72 34 ft., 2-1/4 in. (10420.5mm) 34 ft., 4-3/16 in. (10469 mm) 34 ft., 5-3/4 in. (10510mm) 40 ft., 10-1/2 in. (12460mm)

80 38 ft., 4-5/16 in. (11692.5mm) 38 ft., 6-1/4 in. (11741mm) 38 ft., 7-7/8 in. (11782mm) 45 ft., 5/8 in. (13732mm)


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9. (Sections 2.4.2, 2.4.3, and 2.5.2)Roller Support Post l909_11

10. (Section 2.4.3)Support Post Spacing l909_12

Stalls Dimension A Support Post QTY

32 35-11/16 in. (907mm) 28

36 41-11/32 in. (1050mm) 28

40 41-3/32 in. (1044mm) 32

44 40-29/32 in. (1039mm) 36

50 42-3/4 in. (1086mm) 40

60 40-15/32 in. (1028mm) 52

72 42-15/16 in. (1091mm) 60

80 42-1/2 in. (1080mm) 68


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11. (Section 2.4.4)Installing the Drive Pedestalls l909_70a

11a. (Section 2.4.4) Electric Drive Pedestal Assembly - Single drive with idler wheel shown l909_101

Basement Installation

Stalls Scribe Line DimensionFrom Rotary Center

Offset Dimensions

Stalls Dimension A Dimension B

40 19 ft., 3 in. (5867mm) 40 1.31 in. (33.3mm) 0.14 in. (3.5mm)

44 21 ft., 3-7/8 in. (6500mm) 44 1.19 in. (30.1mm) 0.12 in. (3.1mm)

50 24 ft., 5-3/4 in. (7460mm) 50 1.03 in. (26.2mm) 0.11 in. (2.7mm)

60 29 ft., 8-1/4 in. (9050mm) 60 0.85 in. (21.6mm) 0.09 in. (2.2mm)

72 35 ft., 11-1/2 in. (10960mm) 72 0.70 in. (17.9mm) 0.08 in. (1.9mm)

80 40 ft., 1-1/2 in. (12232mm) 80 0.63 in. (16.0mm) 0.07 in. (1.7mm)

Non-Basement Installation

Stalls Scribe Line DimensionFrom Rotary Center

Offset Dimensions

Stalls Dimension A Dimension B

32 12 ft., 1-1/4 in. (3690mm) 32 2.07 in. (52.7mm) 0.22 in. (5.5mm)

36 14 ft., 2-1/2 in. (4330mm) 36 1.77 in. (45.0mm) 0.18 in. (4.7mm)

40 16 ft., 3-1/2 in. (4967mm) 40 1.55 in. (39.3mm) 0.16 in. (4.1mm)

44 18 ft., 4-1/2 in. (5600mm) 44 1.37 in. (34.9mm) 0.14 in. (3.6mm)


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12. (Section 2.4.5)Installing the Rails on the Supports l909_13

11b. (Section 2.4.4) Electric Drive Drill Plate Location l909_102

Dimension X Table - Basement

Numberof Stalls

Drive Ring CenterlineScribe Radius

Drill PlateDimension X

40 5867 mm [230.98 in.] 19.5 mm [.767 in]

44 6500 mm [255.90 in.] 17.6 mm [.693 in]

50 7460 mm [293.70 in.] 15.3 mm [.602 in]

60 9050 mm [356.30 in.] 12.7 mm [.500 in]

72 10960 mm [431.49 in.] 10.5 mm [.413 in]

80 12232 mm [481.57 in.] 9.4 mm [.370 in]

Dimension X Table - Non-Basement

Numberof Stalls

Drive Ring CenterlineScribe Radius

Drill PlateDimension X

32 3690mm [145.28 in.] 30.9mm [1.22 in.]

36 4330mm [170.47 in.] 26.4mm [1.04 in.]

40 4967mm [195.55 in.] 23.0mm [.91 in.]

44 5600mm [220.47 in.] 20.4mm [.80 in.]

NOTE: Counterclockwise rotation shown. Rotate pedestaland drill plate 180 for clockwise rotation.


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13. (Section 2.4.6) Rollerframe Installation l909_14

14. (Section 2.4.7)I-Beam Installation l909_15


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15.(Section 2.5.1) Mounting the Stall Divider Assembly l909_16

16. (Section 2.5.1)Installing Curbing l909_17


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17. (Section 2.5.2) Installing the Utility Bridge l909_19

16a. (Section 2.5.1) Curb section with cut out for jetter line location l909_32

Stalls Jetter Line Suction Line

40 2 in. (51mm) 2 in. (51mm)

44 2 in. (51mm) 2 in. (51mm)

50 2 in. (51mm) 2 in. (51mm)60 2 in. (51mm) 2-1/2 in. (63mm)

72 2-1/2 in. (63mm) 2-1/2 in. (63mm)

80 2-1/2 in. (63mm) 2-1/2 in. (63mm)


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19. (Sections 2.5.4, 2.5.5) Deck Extension and Vision Shield Mounting l909_21

18b. (Section 2.5.3) Drive ring section with cut out for jetter line location l909_32a


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Table 1: Platform Concrete

(Section 1.1)

Yards Cubic Meters

Size (#Stalls) Platform Extension Platform Extension32 5.5 1.0 4.1 .8

36 6.3 1.2 4.7 .9

40 7.0 1.3 5.3 1.0

44 8.0 1.5 5.9 1.2

50 9.0 2.0 6.8 1.5

60 11.0 2.5 8.3 2.0

72 13.5 3.0 10.2 2.3

80 15 3.5 11.4 2.7

20. (Section 2.6.1) Installing Corrugated Tin Sheets on Platform l909_33


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21. (Section 2.6.1) Installing Rebar for Platform l909_41

22.(Section 2.6.2) Installing Corrugated Tin Sheets for Platform Extension l909_40


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24.(Sections 2.6.1 and 2.6.2) Slopes for Platform and Extension l909_43

23. (Sections 2.6.1 and 2.6.2) Slopes for Platform and Extension l909_42

CONTINUOUS CURB


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25. Section 2.4.7) Installing the I-Beam l909_93

Documents

9e909d Platform Xcal Install Instruction Sept 2012