MAK 3002 - BARTEC · cate, please refer to the type-examination certificate DE-07-MI005-PTB005, (Section 6) and respectively to the DE-09 MI005-PTB037 (Section 4). Safety precautions

BARTEC BENKE GmbH Schulstraße 30 D-94239 Gotteszell Telefon +49(0)9929)-301-0 Telefax +49(0)9929)-301-112 E-Mail: [email protected] Internet: www.bartec-benke.de

MAK 3002

Operating Manual Software version MAK 1.46/ MAK 2.46

BA 970920

Contents C - 1

MAK 3002 Operating Manual, Software version MAK 1.46/ MAK 2.46 BA 970920 (18.12.07)

Table of contents

Contents Page Date of issue

1 Introduction _____________________________________1-1 2 Safety precautions________________________________2-1 3 Description of the Controller _______________________3-1 3.1 Display__________________________________________3-2 3.2 Keypad__________________________________________3-2 3.3 Softkeys _________________________________________3-2 4 Operation of the controller _________________________4-1 4.1 Selection ________________________________________4-1 4.2 Entries __________________________________________4-2 4.3 Switching a function or a unit on/off____________________4-2 4.4 Menus with several pages ___________________________4-3 4.5 Closing a menu ___________________________________4-3 5 Function overview ________________________________5-1 6 Starting and ending a tour _________________________6-1 6.1 Switching the system on ____________________________6-1 6.2 Manual start of a tour_______________________________6-1 6.3 Starting a tour with schedule data _____________________6-2 6.4 Ending a tour _____________________________________6-3 7 Entering the supplier code _________________________7-1 7.1 Entry on the keypad________________________________7-1 7.2 Entry with the reader station _________________________7-1 7.3 Entry with thebarcode reader_________________________7-2 7.4 Entry with the TAG reader ___________________________7-2 7.5 Entry with the barcode scanner _______________________7-2 7.6 Automatic entry of the supplier code with GPS ___________7-3 7.7 Schedule data ____________________________________7-4 8 Tour schedule ___________________________________8-1 8.1 Unscheduled collections ____________________________8-2 8.2 Changing the tour schedule__________________________8-3 8.2.1 New supplier _____________________________________8-4 8.2.2 Change sequence _________________________________8-4 9 Milk collection ___________________________________9-1 10 Sampling_______________________________________10-1 10.1 Branch sampling _________________________________10-1 10.1.1 Manual branch selection ___________________________10-1 10.1.2 Automatic branch preset ___________________________10-2 10.2 ULTRASAMPLER®-sampling________________________10-3 10.3 Sample bottle identification _________________________10-5 10.4 Tank sampling ___________________________________10-5 10.5 Repeat sampling _________________________________10-6 10.6 Hand sampling___________________________________10-6 11 Tank compartment monitoring_____________________11-1 12 Milk separation__________________________________12-1 12.1 Passive selection of milk compartments _______________12-2 12.2 Active selection of milk compartments_________________12-3 12.3 Possible messages during milk separation _____________12-5 13 Data transfer to the office _________________________13-1 13.1 TDL-format______________________________________13-1 13.2 PRF-format _____________________________________13-4 14 Whey-tour (V 2000) ______________________________14-1 14.1 Loading ________________________________________14-1 14.2 Whey delivery ___________________________________14-2

Contents C - 2


Contents Page Date of issue

15 Special functions during the tour __________________ 15-1 15.1 Sampling on/off __________________________________ 15-3 15.2 Tank sampling on/off______________________________ 15-4 15.3 Delivery ________________________________________ 15-4 15.3.1 Measured delivery________________________________ 15-4 15.3.2 Unmeasured delivery _____________________________ 15-6 15.4 Transferring milk _________________________________ 15-7 15.4.1 Measured pump over _____________________________ 15-7 15.4.2 Unmeasured pump over __________________________ 15-10 15.5 Cleaning ______________________________________ 15-11 15.6 Cleaning the sampler ____________________________ 15-13 15.7 Clearing the air eliminator _________________________ 15-15 15.8 Adding the air eliminator volume____________________ 15-16 15.9 Vat intake _____________________________________ 15-16 15.10 Ticket copy ____________________________________ 15-17 15.11 Long-term storage_______________________________ 15-17 15.12 Supplier selection _______________________________ 15-18 15.13 Schedule data hand _____________________________ 15-18 15.14 Reset counter __________________________________ 15-19 15.15 Compartment levels _____________________________ 15-20 15.16 Actual tour data_________________________________ 15-20 15.17 Show GPS ____________________________________ 15-21 15.18 Compartment overpump __________________________ 15-21 15.19 Activate pre sample______________________________ 15-24 15.20 Activate hand sample ____________________________ 15-25 15.21 Filling an additional sample bottle ___________________ 15-25 15.22 Print journal____________________________________ 15-26 15.23 Special codes __________________________________ 15-27 16 Functions when no tour is active __________________ 16-1 16.1 Configuration____________________________________ 16-2 16.2 Print journal_____________________________________ 16-3 16.3 Delivery ________________________________________ 16-6 16.4 CIP ___________________________________________ 16-7 16.5 Data transfer ____________________________________ 16-8 16.6 Sampling bottle transport __________________________ 16-8 16.7 Long-term storage________________________________ 16-9 16.8 Internal storage _________________________________ 16-11 16.9 Storage cassette ________________________________ 16-11 16.10 Vacuum test ___________________________________ 16-12 16.11 Adjusting the reading device for sample bottle feeding___ 16-12 16.12 Print out spooler ________________________________ 16-13 16.13 Reset total quantity counter _______________________ 16-13 16.14 Show GPS ____________________________________ 16-14 16.15 Repeat sampling ________________________________ 16-14 16.16 Extract backup _________________________________ 16-15 16.17 Data bases ____________________________________ 16-16 16.17.1 Quantity memory________________________________ 16-16 16.17.2 Customer data__________________________________ 16-20 17 System monitoring ______________________________ 17-1 17.1 Pictograms _____________________________________ 17-1 17.2 Messages ______________________________________ 17-2 17.3 Help system ____________________________________ 17-4 17.4 Deactivating a device _____________________________ 17-4 17.5 Emergency mode ________________________________ 17-5

Contents C - 3


Contents C - 4


All rights reservd. Subject to change without prior notice. No part of this document may be reproduced, processed or distributed in any form or by any means without the prior written permission of BARTEC.

Copyright © 2007 by BARTEC BENKE Schulstraße 30 D-94239 Gotteszell

Document: BA 970920 valid from: 02.07 Revision: Software version MAK 1.46/ MAK 2.46 18.12.07 Authors: W. Klingseis, G. Rothe Translation: Mark Shortland, EXACT! Mannheim /G. Rothe

Introduction 1-1


1 Introduction The MAK 3002 system consists of a number of separate components which communicate with each other over a serial field bus (P-NET).

This document describes how to operate the controller on principle and dur-ing a collection tour. Various functions resulting from different configuration settings, are described separately. Several functions can be used in combi-nation. This causes corresponding combinations in operation process.

This document is based on Software version MAK 1.46/ MAK 2.46.

Several program options are not available with the 1-MB-version of the MAK 3002-software (MAK 1.xx), but exclusively with the 2-MB-version (MAK 2.xx). In the according text you are hinted to that by this symbol.

The configuration of the system is described in a separate document (MAK 3002, Configuration Software version MAK 1.46/ MAK 2.46).

Components of a MAK 3002 System (Example)

Controller Cartridge-Station Printer Truck-Interface Temperature sensor

MID ULTRASAMPLER ®-Controller GPS receiver

Cable type reader

ULTRASAMPLER ®

P-NET

Reader station

Introduction 1-2


Measuring systems put into circulation according to directive 2004/22/EC, Appendix I, Number 7.6 must describe the testing method in the operating instructions. Since the testing method is already described in the type-examination certifi-cate, please refer to the type-examination certificate DE-07-MI005-PTB005, (Section 6) and respectively to the DE-09 MI005-PTB037 (Section 4).

Safety precautions 2-1


2 Safety precautions The operator of the system is responsible for compliance with all the regula-tions that apply to the storage, transportation and transshipment (load-ing/unloading) of milk. Regulations and requirements lose none of their validity when the system is operated using MAK units. MAK units are built with due consideration to the regulations currently in force and have left the factory in perfect condition. These units must be in-stalled and maintained by qualified technical personnel.

• Make sure that the data and operating conditions specified by the manufacturer (BARTEC) are observed.

• Following the instructions for operating and servicing the units.

• If you discover any signs of damage or destruction to any parts of the system or if safe operation of the system cannot be guaranteed for any other reason, do not start up the system or, if already in operation, shut down the system immediately. Notify your local BARTEC service representative.

• You should also contact our service specialists if you discover any faults or defects during operation or if you have cause to doubt whether the units are working properly.

BARTEC GmbH and its vicarious agents only assume liability in the case of deliberate acts or gross negligence. The extent of liability in such a case is limited to the value of the order placed with BARTEC GmbH. BARTEC accepts no liability for any damage resulting from non-observance of the safety regulations or from non-compliance with the operating instruc-tions or operating conditions. Secondary damage is excluded from the liabil-ity.

Disclaimer of liability

Safety precautions 2-2


Description of the Controller 3-1


3 Description of the Controller The key component of the MAK 3002 system is the controller, which acts as the central control and information unit for the entire system. Communication between the controller and the other components within the system takes place over a serial field bus (P-NET). Two different controller models are available: Controller, Type 6731-10 (version with numerical keypad) Controller, Type 6741-10 (version with alphanumerical keypad) The layout of the two controllers is identical except for the number of keys and the case dimensions.

Controller Type 6731-10 Controller Type 6741-10

Models

Description of the Controller 3-2


3.1 Display The LC display is the controller's graphic user interface. All the menus used for the system's configuration and operation are displayed here. The display can be heated and its contrast is adjustable. For operation in the dark it is possible to illuminate the display with the help of LEDs. The illumination con-trol function can be configured in the BIOS setup.

3.2 Keypad Entries are made via the keypad. The keys are luminescent. The differences between the two system models are described in section 4.2.

3.3 Softkeys To the right of the display are four additional keys that are activated by the controller software and assigned various functions according to the current operating status. The meanings of the active keys are indicated in the right-hand margin of the display; which function is assigned to which key is unmis-takeable. These software-controlled keys are called softkeys.

Softkeys

Operation of the controller 4-1


4 Operation of the controller The controller is operated via the softkeys and the alphanumerical keypad with menu-assisted prompting. When the system is started up, the main menu appears on the display.

Displays On the left-hand side you will see: - Number of the collection, - Total quantity counter (total quantity collected during a tour), - Date and time Change the displays If you press the F2 key (at the controller with numerical keypad the keys ^ + F1/F2 ), will be displayed the total quantity of the day instead of the to-tal quantity of the tour. Submenus can be selected via the softkeys on the right-hand side. The various interactive control options possible within the menus are de-scribed below.

4.1 Selection available for selection are presented line by line in bright letters on a dark background. When a function is selected, its presentation is inverted (dark letters on a bright background). You can open a submenu in two ways: 1. By pressing the corresponding numerical key, 2. By marking the submenu with the select field softkey (the bright cursor

bar is moved down one line with each press of the key). Press the OK softkey to execute the selected function or open the marked submenu.



4.2 Entries Some menus require you to make numerical entries. These entries can be made via the appropriately marked keys on the keypad. The controller keys have dual meanings. The meanings are printed on the keys. To change between the two sets of meanings on the controller with an alphanumerical keypad, use the ALT key. This key has an integrated LED. When the LED is on, the lower line of characters marked on the keys is ac-tive. When the LED is off, the upper line of characters is active instead. When you press a key on the controller with a numerical keypad, the charac-ter in the lower line is typed in. To enter the characters in the upper line, you must press the ^ key simultaneously. Press the ready softkey to confirm your entry.

4.3 Switching a function or a unit on/off In some menus you can switch functions or units on or off. In these cases, press the 1 key on the keypad to switch the function or unit on. The word ON will then appear in the field next to the respective function. To switch a function or unit off, type 0. The word OFF will then appear in the field instead.



4.4 Menus with several pages The select page softkey appears if it is not possible to show all the functions or values available within a menu on the display at once. Press this key to display the next page of the menu and view the information which will not fit on the first page.

4.5 Closing a menu Menus which have no further submenus can be closed by pressing the ready softkey. It makes no difference which menu page is currently visible. You will always be returned to the next menu up in the hierarchy. To close a selection menu, select the 0:END field and confirm. In menus designed for making entries you will find an Abort softkey. Press this key to exit an input line without saving the changes you have made in it. The Abort softkey can also be used to close a menu and return to the previ-ous menu (providing select field and ready softkeys are also displayed). All entries which have been confirmed with the OK softkey will be saved.



Function overview 5-1


5 Function overview The sequence and scope of operations during a collection tour depend on your particular equipment and on the software configuration. Several functions can be used in combination. This causes corresponding combinations in operation process. All functions which are available in principle are described in this manual. Several functions can be used in combination. This causes corresponding combinations in operation process. For this reason may the following figures differ from that in the display of your controller.

Starting and ending a tour To do collection- or delivery procedures must a tour be startet. For a tour can schedule data be provided. This data can contain al required information (supplier data, correct supplier order etc. A tour can also be started without schedule data. In this case all required data must be entered manually (Chapter 6).

Register the supplier code Data of all collection- or delivery procedures will be captured an can be as-signed to each supplier. Therefore must a supplier code be registered before starting any procedure. The supplier code can be registered on different ways (Chapter 7).

Schedule data Tour planning is performed by using the software in the office. The created data can be transferred to the vehicle software on different ways. The driver has to execute the orders corresponding to the schedule data. However there is also the possibility of modifying a tour if necessary (Chapter 8).

Milk collection At the suppliers will the actual milk collection take place if all required data are entered and captured (Chapter 9).

Sampling From the collected milk can different samples be taken and botteled (Chap-ter 10).

Tank compartment monitoring The level in the tank compartments can be monitored at any time (Chapter 11).

Milk saparation During collecting the milk can be filled into different compartments separated according to different quality levels (Chapter 12).

Data transfer The captured tour data can be transferred to the office on different ways (Chapter 13).

Function overview 5-2


Whey tour With a special equipped truck of the type „V 2000“ you can do a „whey-tour“. The truck must be charged with whey (Chapter 14).

Special functions during the Tour Some functions are available as „special functions“ during a tour (e.g. acti-vating or deactivating of functions, delivery- and pump over procedures, cleaning, print functions) (Chapter 15).

Functions when no tour is active Special functions for checking, configuration, trouble shooting and mainte-nance of the system are available out of a tour (Chapter 16).

System monitoring To guarantee a save and trouble-free operation the system is monitored permanent (Chapter 17).

Starting and ending a tour 6-1


6 Starting and ending a tour 6.1 Switching the system on

When the MAK system is switched on (with the truck ignition switch, the con-trol gear or a separate switch), the controller first runs a setup program. Any prompts have to be acknowledged. If „data capturing“ is enabled (configuration /system config./ data capt.: ON), a disk symbol in the basic menu appears when there are data for transfer-ring available. This symbol flashes while the internal memory is being ac-cessed.

6.2 Manual start of a tour Press the Begin Tour softkey. Either enter the data for the current tour in the window which then appears or check the data that is already displayed there and change it if necessary. The required information depends on your particular configuration.

tour Tour code driver Driver code vehicle Vehicle code tank Tank semitrailer code trailer Trailer code dairy Dairy code site Site code odometer Distance travelled so far in kilometers tour capac. (Only if tank sampling with the sampler is configured). Sum of

the volumes of the configured tank compartments. The preset quantity for the tank sample must be entered here (see sec-tion 10.4).

num bottle Number of sample bottles to be filled (only available with UL-TRASAMPLER® vario). The entered number will overwrite a configured number (param. config./ sequence cntrl./ truck pa-rameter: num. bottle).

low. tmp. l. lower temperature limit



up. tmp. l. upper temperature limit teach in Switches the „teach tour schedule“ function on or off milk separ. Switches the „milk separation“ function on or off Then press the ready softkey. The „Begin Tour“ block will printed, providing the printer is configured.

6.3 Starting a tour with schedule data The tours can be planned in the office. This schedule data can be trans-ferred to the controller by data cassette, short distance radio or GPRS. The shedule data function The „tour sched.“ function can remain deactivated. If data is to transfer by cassette, the schedule data cassette must be in-serted in the cassette slot at the beginning of the tour. The data is either read directly from the cassette or copied to the RAM of the controller first, depending on the configuratio.

When using short distance radio the tour data is transferred automatically when a tour is finnished and another is started. The vehicle must be located within the reception area of the radio station. If there are several tours saved in the schedule data, select a tour from the list and press OK . The „Begin Tour“ menu appears with the schedule data. You can overwrite the data if necessary.



6.4 Ending a tour To end the current tour, press the end tour softkey. Then enter the data re-quired depending on configuration (code of the site, code of destination dairy, odometer)

Press ready to print out the „end tour“ ticket.



Entering the supplier code 7-1


7 Entering the supplier code To be able to make a collection, you must enter a supplier code. It is possi-ble for the supplier code to be entered in various ways, depending on your particular equipment and configuration. The collection starts after the sup-plier code has been entered. If a printer is configured, the code will be printed out.

7.1 Entry on the keypad To enter a supplier code manual, Press the hand input softkey.

Enter the supplier code on the keypad and press the OK softkey.

7.2 Entry with the reader station If a reader station is connected and configured, you can enter the supplier code using either a Wiegand card reader or the radio or cable-type reading head. The icon for the configured device appears on the display. If you are using the reading head, move it smoothly over the code block in the direction of the arrow. If you are using a Wiegand card reader, pull the card smoothly through the reading slot. Please heed the instructions sup-plied with the reading device connected to your system.



7.3 Entry with thebarcode reader If a barcode reader is configured, the barcode icon appears on the display to indicate that it is ready for reading. Move the reading wand over the barcode label.

7.4 Entry with the TAG reader The same symbol as at the barcode reader indicates that the TAG reader is ready for reading. Point the TAG reading head to the TAG. The collection starts after the supplier code has been read in.

7.5 Entry with the barcode scanner To enter the supplier code with the barcode scanner, first press the Scanner on softkey, then position the scanner on the barcode label. If the scanner is fasten mounted you must bring the barcode label to the scanner.



7.6 Automatic entry of the supplier code with GPS If the supplier code entry function is configured with a GPS receiver, the supplier code is displayed as soon as the vehicle stops at the supplier loca-tion. Precondition: A collection must already have taken place at this location with the same supplier code (collection quantity > 0). The supplier code must be entered once manually. It is then saved automatically and assigned to the appropriate location. When the supplier code and the associated supplier data (if any) are dis-played, press hand input .

Then confirm the supplier code and start the collection.

If several different suppliers have been saved for the same location, you can use the select softkey to choose the one you need.



7.7 Schedule data The sequencing of the suppliers can be fixed in the tour schedule data (see section 8). The supplier code is displayed in the controller´s display. After finnishing a milk collection is the next supplier code automatically displayed. If other supplier data is saved it will additionally be displayed.

Tour schedule 8-1


8 Tour schedule If the tour schedule function is active (system config/ data capture/ tour sched.: ON) and schedule data for this truck are available, the schedule data will also specify the sequence in which the suppliers are to be visited during the selected tour. After you have selected and confirmed a tour, the menu containing the pre-set tour data is opened. You can change this data if necessary

When you confirm the data, the code for the first supplier on the tour is dis-played.

If you are using a controller with an alphanumerical keypad, you can scroll up and down in the list of supplier codes using the ↑ and ↓ keys. When using a controller with a numerical keypad the supplier selection can be done by the special function suppl. selection . Press the menu softkey and select this function (see section 15.12). The collection starts as soon as you have confirmed the supplier code.

Tour schedule 8-2


If external start of the intake is configured (param.config/ sequence cntrl./ truck parameter/ ext. Int. st. ∏ ON) you can start the collection by a start key or a similar device. If the entered supplier code is found in the schedule data, the preset quantity will be determined - providing it either has also been saved or can be de-rived from the quantity memory - and the collection is started. If milk separa-tion is active and there´s missing one of the data (quantity, quality), the sys-tem stops. The collection then starts after you have entered the missing data.

8.1 Unscheduled collections During a scheduled tour it is also possible to make unscheduled collections. If you enter a supplier code that is not preset for the selected tour, a mes-sage to this effect will appear on the display.

If you would like to go ahead with the collection from this supplier, confirm the message.

Proceed with the collection by performing the steps required for your particu-lar configuration.

Tour schedule 8-3


8.2 Changing the tour schedule It is possible to change the preset tour. You can add new suppliers to the tour or change the sequence of the preset suppliers. After selecting a tour in the „Begin Tour“ menu, activate the „teach in“ option.

Begin the tour. If you enter or read in a supplier code that is not preset (either a new sup-plier or a new sequence), a message to this effect will appear.

Confirm this message and enter a preset quantity and quality if this is re-quired by your configuration.

Tour schedule 8-4


8.2.1 New supplier After confirming these entries, you can specify whether the supplier should be added to the tour at this point.

8.2.2 Change sequence If you enter a supplier code that is already included in the tour at a different point, you can specify whether the supplier should be rearranged within the tour. If you confirm this change with YES , the supplier will be moved to the new position within the current tour and deleted from the old position

If your MAK system is configured so that the schedule data is stored in the RAM drive of the controller, there must be no schedule data cassette in the cassette slot when you next begin a tour. Otherwise, the new tour schedule will be overwritten with the schedule data on the cassette.

Milk collection 9-1


9 Milk collection The collection starts after the supplier code has been entered and the tour-start record is printed (depending on configuration). The current collection quantity, the temperature and the operating state of the pump are shown on the display. At trucks type V2000 is aditionally the level of the air eliminator displayed (percentage).

When the collection has finished, press the End Intake softkey or the ready softkey if the configuration defines to finnish by key. If the configuration de-fines automatically finnishing you need not press a key. The collection ticket will be printed when the counter stops.

If you want to do a further collection you must enter the supplier code again. Repeat the collection process as described above. If the pump switches off before the collection has finished (temporary no milk flow), you must re-enter or confirm the supplier code in order to start again.

Pump on Pump on, flow present

Pump off

Milk collection 9-2


Sampling 10-1


10 Sampling 10.1 Branch sampling

The variously sized branches ensure that the sample tank is filled to practi-cally the same level even with different collection quantities. The number of the currently selected branch is shown on the display next to the sample bot-tle icon.

10.1.1 Manual branch selection If the branch is to select manual you must select the branch (0, 1 or 2) be-fore you capture the supplier number.

Branch selection on the vehicle Depending on the configuration, the branch is selected with the branch se-lector on the vehicle. An answering signal ensures that the selectet branch is displayed (param. config/sampling/smp. branch/ext. brnch: ON)

Branch selection at the controller When the branch is to select via controller, key in the number of the branch which corresponds to the anticipated (estimated) collection quantity (key 0 , 1 or 2 ).

Radio or cable-type reading head If you are using the radio or cable-type reading head, you can change the branch number by pressing the reading head button.

Sampling 10-2


10.1.2 Automatic branch preset If automatic branch preset is configured (param. config/ sampling/ branch. pr. → ON), you must specify a preset quantity after entering the supplier code. The branch is then selected automatically on the basis of this quantity.

If the „quantity memory“ function is active (system config./ data capture/ qty.-memry. → ON and param. config/ qty.-memry./ teach in >0%), there is no need to enter a preset quantity for the automatic branch preset function. In this case, the current preset quantity is calculated from the previous preset quantity, the last collection from the same supplier and the configured teach-in factor. If the system fails to obtain a preset quantity from the quantity memory (e.g. because the supplier is new), it will stop and you will have to enter a preset quantity manually. However this preset quantity can also be transferred by the schedule data.

Quantity memory

Sampling 10-3


10.2 ULTRASAMPLER®-sampling If you are using the ULTRASAMPLER®, you must specify a preset quantity after entering the supplier code. The controller calculates the pumping rate of the ULTRASAMPLER® pump (needed to guarantee the configured sam-ple volume despite varying collection quantities) from the preset quantity and the configured pump power. Enter the anticipated collection quantity as the preset quantity press OK and then ready .

If the „quantity memory“ function is active (system config./ data capture/ qty.-memry. → ON and param. config/ qty.-memry./ teach in >0%), there is no need to enter a preset quantity. In this case, the current preset quantity is calculated from the previous preset quantity, the last collection from the same supplier and the configured teach-in factor. If the system fails to obtain a preset quantity from the quantity memory (e.g. because the supplier is new), it will stop and you will have to enter a preset quantity manually. However this preset quantity can also be transferred by the schedule data.

Quantity memory

Sampling 10-4


If automatic sample bottle handling is not configured, or if saple bottle detec-tion by proximity switch is configured, the sampling icon will flash, prompting you to position the sample bottle. Place the sample bottle in the filling position. Press contin .

The collection is started. The milk flow is signalled either by the flow level meter or by the temperature sensor, which has a conductivity probe. To indi-cate that the ULTRASAMPLER® is working, the field containing the sample bottle icon and the letter „S“ (= sampler mode) are highlighted.

To end the collection, press the End Intake softkey. The sample volume will be printed on the collection ticket. • If you receive a „filling error“ message when collecting small quantities,

this may be because the pump power is too high. In this case, the maxi-mum pumping rate of the sampler pump will not be high enough to fill the configured sampling volume. If necessary, change the pump configura-tion.

• The „filling lvl. reached“ message appears if the permissible overfilling level of the sample bottles (configured in per cent) is reached before the end of the collection. The sampler is stopped. In this case, the actual col-lection quantity may have been greater than the preset quantity or the configured pump power may be too high.

• If the sensor is already wet prior to the collection, the sampler will not start. When the collection has finished, the following message appears: „Ultrasampler 1, no sample decanted“.

Sampling 10-5


10.3 Sample bottle identification If you are using the automatic sample bottle handling function, the sample bottles will be moved into the filling position automatically. With the right con-figuration it is possible for the sample bottle number to be read automatically at the same time. If you receive the „sample bottle not ready for filling“ message, it could be that no sample bottle has yet been transported to the filling position. If the message does not disappear again within a short time, check the bottle han-dling system and try to rectify the fault. If the message appears even when there is a bottle in the filling position, clean the window of the barcode reader. It could be that the sample bottle number cannot be identified be-cause of dirt. If the configuration permits the „sample bottle identification“ function to be switched off (param. config/ smpl.b.id./ Em.Read Off ∏ ON), you can do so by pressing a softkey. Sample bottle identification is switched on again when you begin a new tour. Risk of accident! Disconnect the power supply and/or the compressed air supply to the sam-pler and the bottle handling system before you clean the reading window!

10.4 Tank sampling If tank sampling is configured, one sample is filled during the course of the complete tour. The tank sample icon appears on the display. If a tank sampler is configured, the „tour capac.“ field appears at the bottom of the tour data. Here is the last value displayed as a proposal. If 0 is dis-played or if you change the entry to 0 the sum of the volumes of all the con-figured tank compartments will be supposed. Correct this quantity to the total collection quantity anticipated during the tour (e.g. including the volume of the trailer).

Sampling 10-6


After confirming the tour data, you will be prompted by the flashing tank sample icon to position the tank sample bottle. Following press the contin softkey and continue the tour as described above.

10.5 Repeat sampling If repeat sampling is configured (param.config/ sampling/ Rep.sampl.→ ON), you can decide at the beginning of a tour whether a general sample should be taken for this tour or whether repeat samples should be taken. In the lat-ter case, a sample is taken automatically for the suppliers who have been marked for repeat sampling (see section 16.15).

10.6 Hand sampling If hand sampling is configured (param. config./ sampling/ hand-sampl → ON), a sample bottle must be filled by hand, either at the time of the first collection after switching on the sampling function or if the last sample was taken more than one hour previously. A sample bottle is read and carried back to the entrance magazine. In the display you will be demanded to remove and fill the bottle. Re-move the bottle (last bottle in the entrance magazine) and fill it by hand. Put the bottle back to its position and press the ready softkey

Tank compartment monitoring 11-1


11 Tank compartment monitor-ing The level in the tank compartments can be monitored (configuration: system config/ sequence cntrl/ monitoring → ON). If this function is active, the cur-rent volumes of the compartments are calculated. a message is output and the collection interrupted when the configured maximum compartment level is reached.

Change over to the next available tank compartment. The collection is then continued. You can check the level in the tank compartments when no collection is in progress (see section 15.15).

Tank compartment monitoring 11-2


Milk separation 12-1


12 Milk separation When the milk is collected, it can be filled into separate tank compartments according to its quality. Qualities from 1 (good) to 9 (poor) are possible. You can configure all tank compartments. The quality is derived either from the quantity memory or is transferred by the tour schedule data or the driver will have to enter the quality of the milk in accordance with the available supplier data. The appropriate compartment can be selected passively or actively, depending on the configuration After beginning the tour, you can either confirm the configured assignment of qualities to tank compartments or change it for the duration of the current tour..

Confirm the default quality assignment with ready . If you would like to change it, press change . You can then change the quality of each compart-ment individually.

Confirm your changes with ready . Confirm the complete new assignment with OK .



12.1 Passive selection of milk compart-ments If no quality is transferred by schedule data or cannot be derived from the quantity memory, specify the quality of milk to be collected after you have entered the supplier code. The system will check whether the activated compartment matches to the quality. If it does not, you will be prompted by the system to change over to this compartment.

Meanings of the icons: S Compartments 1...n (in the example 1...4) Q The milk quality assigned to the compartment;

„—“ means that the compartment is unavailable (not configured, not enabled or full)

τ The compartment requested by the system in accordance with the milk quality

X The currently active compartment

Change over to the requested compartment. The collection starts as soon as you have changed over to the appropriate compartment, providing it is actu-ally available.

If the milk that is collected is of a different quality to that of the previous col-lection, you will be prompted after collecting a configured change-over quan-tity to change over to the compartment actually intended for this quality.

In this example, milk of quality 1 is being collected. The milk collected with the previous collection procedure was quality 2. The compartment for this quality, i.e. compartment 3, is still active. After a configured change-over quantity of 20 l has been collected, the collection is interrupted. You must now change over to compartment 1.

If the configuration permits, the quality of the milk being collected can be changed by the driver to be „poorer“ or „better“. The system then suggests that this milk be pumped into the compartment with the corresponding qual-ity. It is also possible to add milk of one quality to a compartment with a dif-ferent quality without making it „better“ or „poorer“ first. This may be neces-sary, for example, if there is no longer sufficient capacity in the normal tank compartment. If milk of poorer quality is added to a compartment containing higher quality milk, the quality of this compartment will be reduced to the quality of the cur-rent collection for the rest of the tour.

Example



12.2 Active selection of milk compart-ments If no quality is transferred by schedule data or is not be derived from the quantity memory, you will have to enter a quality manually. After you have entered the milk quality, the system will suggest the tank compartment that is configured for this quality. It is possible to change the default compart-ment. If milk is added to a compartment whose quality is different from that of the current collection, the quality of that compartment will be reduced ac-cordingly (see „Passive selection of milk compartments”).

Press the ready softkey to select the compartment and start the collection. If a tour schedule is active, the quality can be preset. Providing a compart-ment is available for the preset quality, it will be selected automatically with the active compartment selection method and the collection then starts.. At the beginning of a collection, the system always changes over to the last selected compartment. If the milk being collected is of a different quality from that collected previously, the system will change over to the new compart-ment automatically, and without stopping the pump, after reaching the con-figured change-over quantity. If the configured maximum level of a compartment is reached, the collection will be interrupted and a warning displayed.

After confirming the „compartment full“ warning, you can press the compart level softkey in active milk separation mode to call up a display of the compartment levels. If any compartments of the required quality are free, the system will suggest the next available one.

Quality change

Compartment full



Confirm the compartment selection to continue the collection.

If there is no free compartment available in the tank for the quality of milk you want to collect, the system will output an error message. After confirming this message, you will be prompted to enter a compartment number.

Enter a compartment number. A message appears depending on the quality of the selected compartment.

If a collection is interrupted shortly before the end because the compartment is full, you can choose to keep this compartment active. A reserve capacity of 100 l is then released for the full compartment, enabling the collection to be completed. It is possible for an additional 100 l to be released when the reserve capacity is already exhausted. Caution: Risk of compartment overflow!

No compartment available with demanded quality

Reserve capacity

You can change the milk quality if the pump stops because the limits con-figured for the temperature or the pH value (upper or lower) exceeded.



12.3 Possible messages during milk se-paration An attempt to change the preset quality is not allowed by the configuration. The preset quality is not changed. No compartment has been configured with this quality or the corresponding compartment is full. An attempt has been made to select a compartment that either has not been configured or is not allowed due to the parameter settings. You have selected a compartment with a quality that is better than that of the current collection. When you change over compartments, this selection will cause the quality of the new compartment to be reduced to the quality of the current collection for the rest of the tour. You have selected a compartment with a quality that is poorer than that of the current collection. The configured maximum level of the selected tank compartment has been reached.

Increasing of quality not allowedDecreasing of quality not allowed

No compartment available withdemanded quality

Compartment not configurated

Comp. quallity better than demanded, selection effects devaluation

Comp. quality not as goodas demanded

Comp. capcty. reached



Data transfer to the office 13-1


13 Data transfer to the office The scheduled data function enables a tour’s scheduled data and feedback data to be processed on a PC (configuration: system config. / data capture → ON). Data is transferred on data storage cassettes or via long-distance data transmission.

13.1 TDL-format The data which is collected during the tour is saved in TDL format, either on the RAM drive or on the data storage cassette (HLK in German = SSM car-tridge) depending on the configuration. The data on the RAM drive can be transferred to the office in various ways. The data transfer method can be configured in the param. config/ data cap-ture/ Configuration/ dat. transf. menu. The following settings are permitted there for the „data transfer“ parameter: 0 = OFF Data transfer to data storage cassette 1 = PNET Data transfer per cable via P-NET 2 = Radio Data transfer via short-distance radio link 3 = WLAN Data transfer via wireless network 4 = 0-MODM Data transfer per cable via V24 interface. 5 = Markerbyte Data transfer per cable in Markerbyte-format 6 = GSM Data transfer via radio modem The required transfer conditions must be ensured before the start of each data transfer: if the data is to be transferred per cable, the appropriate cable connection must be established (either P-NET or V24), while if it is to be transferred via radio, the vehicle must be located within the reception area of the radio station.

The data transfer is started in the office. The floppy disk icon and the data transfer icon both flash for the duration of the transfer. The data transfer is finished when both icons disappear and the main menu with the two Softkeys is displayed. You must wait until this menu appears before disconnecting the cable or leaving the radio reception area.



The data can also be transferred to a data storage cassette if your system is configured accordingly (see above). If the data is transferred to a data storage cassette and a second TDL cas-sette is configured (param. config/ data capture/ Configuration/PRF-Format → OFF; 2 TDL-cass → ON), the tour data can be transferred to a tour cas-sette and to a sampling cassette too.

If there is no cassette in the cassette slot at the end of a tour, you will be prompted to insert a tour cassette. The data size is displayed (required free memory in bytes).

When a tour cassette is inserted, the available memory capacity (number of bytes that can still be recorded) may be displayed as well, depending on the configuration.

If there is already saved data no capacity will be displayed. Change the cassette in that case. If the capacity indicated here is not sufficient you must also change the cassette



If the storage capacity is adequate, the data recording can be continued by pressing the start softkey.

Press the Abort key if you do not want to transfer any tour data to the tour cassette. If samples have been taken during the tour, you will now be prompted to insert a sampling cassette. The available storage capacity is displayed when you insert the sampling cassette. You can now transfer the sampling data to this cassette independently of the tour data recording. Data will stay in memory till data is written in succession to both cassettes once.



13.2 PRF-format If the software at the office end requires the data to be transferred in PRF format, you can do so using a cassette. Switch on the PRF format in the configuration menu for this purpose (param. config/ data capture/ Configuration/PRF-format → ON). At the end of the tour the data is transferred to a data storage cassette, which must be formatted as a tour cassette.

If there is no tour cassette in the cassette slot at the end of a tour, you will be prompted to load one.



When a tour cassette is inserted, the available storage capacity (number of data records that can still be recorded) may be displayed, depending on the configuration. If the capacity indicated here is not sufficient you must change the cassette. If the storage capacity is adequate, the data recording can be continued by pressing the start softkey.

Press the Abort key if you do not want to transfer any tour data to the tour cassette. If samples have been taken during the tour, you will now be prompted to insert a sampling cassette. The available storage capacity is displayed when you insert the sampling cassette. You can now transfer the sampling data to this cassette independently of the tour data recording. Data will stay in memory till data is written in succession to both cassettes once.



Whey-tour (V 2000) 14-1


14 Whey-tour (V 2000) With a special equipped truck of the type „V 2000“ you can do a „whey-tour“. The truck must be charged with whey. When starting a tour you must answer the question for whey-tour by press-ing the YES softkey.

14.1 Loading To load the truck with whey select the menu „load site“ in the special func-tions menu.

After entering a load number (e. g. the dairy number) you can start loading.

Whey-tour (V 2000) 14-2


14.2 Whey delivery set qu.) and the maximal pump power for this delivery (pump power ap-proximately 200...300 l/min; with a fast connected hose > 300 l/min possi-ble).

Then you can start delivering the whey. The delivery stops when reaching the preset quantity.

Special functions during the tour 15-1


15 Special functions during the tour It is possible to call up a number of special functions during the tour. De-pending on the current working mode of the system is the menu softkey dis-played if there are special functions are available.

Which special functions are available depends also on the the current work-ing mode, on your particular truck type and on the system configuration All the possible special functions are summarized below.

Function

Section Section if also available when no tour is active

sampling on/off 15.1 ves.smp. on/off 15.2 delivery 15.3 16.3 pump over 15.4 CIP 15.5 16.4 Samp. clean 15.6 clear air.elim. 15.7 add a.e.volume 15.8 intake from vat 15.9 ticket copy 15.10 lngtrm.st. 15.11 16.7 suppl. selection 15.12 sched. data hand 15.13 reset counter 15.14 Compartm. level 15.15 actual tourdata 15.16 show GPS 15.17 16.14 comp overpump 15.18 pre sample 15.19 hand-sampl 15.20 extra bttl 15.21 print journal 15.22 16.2



Special functions are called up with the menu softkey.



15.1 Sampling on/off If the logical input „sampling on” (input no. 8) is not configured, this menu item allows you to activate or deactivate the sampling function, depending on its current status. The sample bottle icon appears on the display to indi-cate that the sampling function is switched on.

If „pre sampling“ is configured (configuration: param.config./ sampling/ pre sample: >0), you will be asked for pre sampling after activating the sampling function.

If sampling is activated automatically when a tour starts (configuration: pa-ram.config./ sampling/aut.smp.on: ON) will this questioning happen when the tout is started.



15.2 Tank sampling on/off This menu item allows you to activate or deactivate the tank (vessel) sam-pling function, depending on its current status. The tank sampling icon ap-pears on the display to indicate that the tank sampling function is switched on.

15.3 Delivery You can make deliveries to a dairy during a tour. To do so, select the „deliv-ery“ item in the „special function“ menu. Deliveries can be made in measu-red or unmeasured mode.

15.3.1 Measured delivery If the delivery shall be done via a measuring device, select „measured“ and press OK .



Then enter the code of the dairy to which you want to deliver. The dairy code can be entered in the same way as the supplier code. There´s no need of entering the code if there is no entry of a code demanded by configuration or a if code for delivery is configured (param.config/ sequence contrl./ truck pa-rameter/ delivery). If the truck equipment and the configuration make possible (param.config/ sequence contrl./ truck parameter/del.quant: ON), you can enter a preset quantity. The delivery will automatcally stop when reaching this quantity. As preset quantity will be proposed the total collected quantity. You can change this value. If the „milk separation“ function is active, after entering the code of the diary you must select the quality of milk to deliver. Depending on configuration you can determine that samples are taken dur-ing a delivery. If a delivery is made with a preset quantity (see above) and the function „quantity memory“ is also active, you can decide to register the quantity in the quantity memory.

If there are several compartments for this quality you must select the com-partment from which the delivery is to be made. Select the compartment by using the select field softkey and then press select . Behind the displayed volume will a check mark appear. By repeated pressing the select softkey you can cancel the selection.

Confirm the compartment and and start the delivery. The delivered quantity is measured and displayed.

Milk separation

Preset quantity

Sampling

Quantity memory

Compartment selection



When the counter has stopped and the configured stop delay is expired the delivery will be finnished and the delivery ticket is printed. You can finnish the delivery before the stop delay is expired by pressing the ready softkey.

15.3.2 Unmeasured delivery The unmeasured delivery will take place by using gravity. Select „unmeas-ured“ in the delivery menu and press OK .

Then enter or read in the dairy code. There´s no need of entering the code if there is no entry of a code demanded by configuration or a if code for deliv-ery is configured (param.config/ sequence contrl./ truck parameter/ delivery). If the „milk separation“ function is active, you must select the quality of milk to deliver and the compartment from which the delivery is to be made. Confirm the compartment and and start the delivery. The delivered quantity is not measured. Unmeasured deliveries can also be done when no tour is active (see section 16.3).

Milk separation



15.4 Transferring milk During a tour it may become necessary to transfer milk, e.g. into a trailer, in order to make room in the tank for further collections. If the configuration and the type of collection truck permit, select „pump over“ in the „special function“ menu. Transferring milk can be done measured or unmeasured.

15.4.1 Measured pump over If the transferred quantity shall be measured, select „measured“ and press OK .

Then enter or read in the code (e.g. of the trailer) and transfer the milk. The-re´s no need of entering the code if there is no entry of a code demanded by configuration or a if code for delivery is configured (param.config/ sequence contrl./ truck parameter/ delivery). If milk separation is performed, after entering the code you must select the quality of the milk to be transferred. Depending on configuration you can activate sampling during pump over. If pump over is performed with a preset quantity (see above) and the func-tion „quantity memory“ is active you can decide to capture the quantity the-re.

Milk separation

Sampling

Quantity memory



If there are several compartments for this quality you must select the com-partment from which the transfer is to be made. Select the compartment by using the select field softkey and then press select . Behind the displayed volume will a check mark appear. By repeated pressing the select softkey you can cancel the selection.

Confirm the compartment and and start the transfer. The transferred quantity is measured and displayed

When the counter has stopped and the configured stop delay is expired the transfer will be finnished and the transfer ticket is printed. You can finnish the transfer before the stop delay is expired by pressing the ready softkey.

Compartment selection



At the „V 2000“ truck you can throttle the pump power before stopping it. Press the low speed softkey for it.

Doe to the automatic hose emptying at the truck type „V 2000“ (pa-ram.config/ sequence contrl./ truck parameter/ clear hose) the measuring u-nit has to be refilled. To do so press the pump start softkey.

V 2000



15.4.2 Unmeasured pump over If you don´t want to measure the quantity select „unmeasured“ and press OK .

Then enter or read in the code (e.g. of the trailer) and transfer the milk. The-re´s no need of entering the code if there is no entry of a code demanded by configuration or a if code for delivery is configured (param.config/ sequence contrl./ truck parameter/ delivery). If the „milk separation“ function is active, you must select the quality of milk to deliver and the compartment from which the delivery is to be made. Confirm the compartment and and start the delivery. The transferred quantity is not measured.

Milk separation



15.5 Cleaning At the end of a tour, the collection truck has to be cleaned in accordance with the regulations in force at the dairy in question. The menu for truck cleaning is available in a tour and if configurated out of a tour too (param.config./ sequence cntrl./ cleaning/ out of tour: ON). Confirm „CIP“ to open the menu for collection truck cleaning.

You can now enter or read in a code (e.g. the code for the cleaning station). There is no code to enter if a CIP code is entered in the configuration (param config/ sequence cntrl./ truck parameter/ CIP). If there is no code to be entered, press contin .

The cleaning process is started. The CIP data will be recorded.



To end the cleaning, press the CIP end softkey. The cleaning process is re-corded. If a printer is connected and configured, a cleaning ticket is printed. It contains the following information about the cleaning fluid: • The maximum temperature, • How long the temperature has exceeded a certain (configured) level, • The measured quantity.

If the ULTRASAMPLER has been used to take samples during the tour, the sampling system will also be activated during the cleaning process. You can switch off the sampling system with the sampling OFF softkey.

If the sampler is active, you can stop it and re-start it during the cleaning process. If the cleaning process is running longer than 30 minutes the sampler will au-tomatically stop.



In the case of the Schwarte „Mega 700“ and „V 2000“ vehicle types, there are a few options that must be selected before you start the cleaning opera-tion.

automatic : The air eliminator is cleared (emptied) automatically (by compressed air signal) during the cleaning process when the fluid is changed.

by hand : The air eliminator must be cleared manually during the cleaning process when the fluid is changed. A softkey is provided on the controller for this purpose.

by hand/slow : Same as „by hand“, but with reduced pump power

15.6 Cleaning the sampler The sampler can be cleaned independently of the collection truck. As when the collection truck is cleaned, a tour has to be active in order to clean the sampler. Press the menu softkey to open the „special function“ menu. Select „Samp. clean“. You can cancel the cleaning process in the menu which is displayed next by pressing the sampling OFF softkey.

V 2000 Mega 700



To start cleaning the sampler, press contin . The sampler is started. with the Sampler stop / Sampler start softkey you can stop and re-start the sampler.

To end the sampler cleaning process, press the ready softkey. The sampler stops and the tour menu appears.

If the cleaning process is running longer than 30 minutes the sampler will au-tomatically stop.



15.7 Clearing the air eliminator The air eliminator is generally cleared (emptied) after the last collection of a tour. Press the menu softkey to open the „special function“ menu. Select „clear air. elim“. If two air eliminators are installed, you must now de-cide which one to clear.

Depending on the truck type either the collection truck pump starts and emp-ties the contents of the air eliminator into the milk tank or the air eliminator is cleared by compressed air. The pump runs for a specific (configured) time. You can stop the pump be-fore the end of this time by pressing the ready softkey. The pump must al-ways be stopped in this way if no time is configured. After the air eliminator has been cleared, the „add air eliminator volume“ function is activated automatically, i.e. the air eliminator volume is added to the next collection quantity.



15.8 Adding the air eliminator volume This function is only available before making the first collection or after clear-ing the air eliminator. You can activate or deactivate the „add air eliminator volume“ function, depending on its current status. If the „add air eliminator volume“ function is active, the air eliminator volume is added to the quantity delivered by the first supplier. The „add air eliminator volume“ function can be activated in the configuration. After the air eliminator has been cleared, the „add air eliminator volume“ function is activated automatically.

15.9 Vat intake When milk is collected from cooling vats, there is a risk that air will be drawn in as well. The „VAT intake“ function has to be activated in this case to pre-vent the collection from being interrupted. Press the menu softkey to open the „special function“ menu. Select „VAT intake”.

The vat intake function only remains active for the duration of the subse-quent collection. It must be re-activated for each further collection from a cooling vat.



15.10 Ticket copy The „ticket copy“ function is only available if a collection (or a delivery) is made during the course of a tour. A copy of the last ticket is printed. You can print as many copies as required. The word „copy“ is printed on each copy of the ticket together with the num-ber of the copy.

15.11 Long-term storage The data stored in the long-term memory can be viewed, printed or moved. Select the „lngtrm. st.“ item in the „special function“ menu. Long-term memory operations are also possible when no tour is active. They are described in section 16.7.



15.12 Supplier selection It is possible to change the preset sequence of suppliers in a tour schedule. To do so, select the „suppl. selection“ item in the „special function“ menu. In the next menu that is displayed you can scroll up and down in the tour schedule using the next and previous softkeys, in order to select suppliers. If customer data has been saved under a selected supplier code, it is dis-played as well. At the controller with alphanumeric keyboard you can use the ↑ and ↓ keys to browse the supplieres.

Select a supplier and press OK . The collection starts after the supplier code has been entered.

15.13 Schedule data hand If you confirm the „sched. data hand“ function, the next collection will not start immediately after the supplier code is entered. The program remains in the collection dialog, giving you an opportunity to enter or change schedule data manually. A number sign (sharp sign, #) appears on the display next to the icon for the entry mode to indicate that the „sched. data hand“ function is active.

If a reader station is installed you must read in a supplier code and confirm it by the reading head button. After activating the hand input is this icon displayed if the supplier code was not captured neigther via GPS nor via barcode or TAG.



At the controller with alphanumerical keyboard you can activate and deacti-vate this function with the F6 key too.

15.14 Reset counter The internal counter in the MID or the volume counter is reset automatically to zero at the end of a collection. You can trigger this reset manually with the „reset counter“ function. Counting errors, such as can arise due to rolling movements between collec-tions or owing to a leak, are thus ruled out. Any unintentionally measured flow is ignored after the counter has been reset, and the recording of the flow rate starts at 0 again with the next collection. You can check the current counter total by selecting the „actual tourdata“ item in the „special function“ menu (see section 15.16).



15.15 Compartment levels If no collection is active you can check the fill level of the compartments. If there are more than 5 compartments configured, the levels of the following compartments are displayed when pressing any key.

Press any key to close the compartment level display..

15.16 Actual tour data This function allows you to view the actual data for the tour depending on the configuration (count in the MID or in the volume counter, total quantity, col-lected quantity during the day, sampling box temperature, distance travelled so far during the tour in kilometers).



15.17 Show GPS When you confirm this function, the GPS data is displayed (longitude, lati-tude, number of received satellites, GPS quality). This function is also available when no tour is started (see section 16.14).

When receiving more than 5 satellites the receiving quality is sufficient. Quality: 1 : GPS (Standard GPS) 2 : DGPS (Differencial GPS) NFIX : no reception

15.18 Compartment overpump (Only available with active milk separation.) The contents of one tank compartment can be transferred to another com-partment if necessary.

Compartment overpump can be done measured or unmeasured. The handling is identical.



If required, you can enter a code number before starting the transfer proce-dure (job number, driver code, etc.). To do so, press the hand input softkey and enter the number.

If you do not need to enter a number, press contin .



Select the first line indicated „compart. no” and enter the number of that compartment whose volume is to transfer. The current volume will be pro-posed for the preset quantity. If you don’t want to transfer the complete vol-ume enter the desired volume.

Use the next line to enter the number of the destination compartment. If the quality level of the destination compartment doesn’t match the quality level of the source compartment a message appears. Repeat the compart-ment selection if necessary. The destination compartment is designated for milk with a lower quality level than in the source compartment. The transferred milk will be devaluated to the quality of the destination compartment in this case. The destination compartment is designated for milk with a higher quality level than in the source compartment. Transferring will devalu-ate the quality level of the destination com-partment. Depending on the configuration you can activate sampling during overpump capturing the quantity in the quantity memory.



The transfer operation begins after you confirm your entries. The transferred quantity of milk is measured and the action is recorded.

If the transferred milk devaluates the quality level of the destination com-partment because of the current compartment selection another message appears. You can start overpumping only after having confirmed this mes-sage.

15.19 Activate pre sample If „pre sample“ is configured (configuration: param. config/ sampling/pre sample >0), you can activate the pre sample function if sample mode is acti-vated.



15.20 Activate hand sample If „hand-sample“ is configured (configuration: param. config/ sampling/hand-sampl: ON), you can activate the hand sample function if sample mode is activated.

15.21 Filling an additional sample bottle (only available with ULTRASAMPLER ® vario)

The message as shown will be displayed for 2 seconds after confirming this menu item.

At the next collection a sample bottle will be filled additional to the configu-rated number or the number set at tour start.



15.22 Print journal

In this menu you can print data of the current tour at the printer. First specify which data you want to print.

The following data is printed depending on your selection: Standard

data Quantities Actions Errors

total data quantity + actions quantity data

Standard data Tour data, such as tour code, beginning of tour, end of tour, dairy code, driver code, vehicle code, magazine code, km count.

Quantities All the data measured during collections, deliveries or clean-ing operations (collection and delivery quantities, tempera-tures).

Actions All the actions performed during the tour (e.g. activating or deactivating the sampling function, activating or deactivating the „add air eliminator volume“ function, activating emer-gency mode).

Errors All errors and faults reported by the controller (e.g. filling er-rors, configured limits exceeded, faults in individual devices).

The menu „print journal“ is outside of a tour available also to print further data (see section 16.2).



15.23 Special codes Various functions can be triggered by special codes. Like the supplier codes, the special codes can be input via the reader station, the barcode reader or the barcode scanner. The respective functions are then activated immediately after the code has been read in. There is no need to open any menus. The special codes that are available are listed in the following table. Special code Function F1 Measured delivery F2 Transfer milk (pump over) F3XXX0 Sampling on F4XXX0 Sampling off F3XXX5 Tank sampling on / off F5 Add air eliminator volume F6 Unmeasured delivery F7 Driver code (Benelux) F8 Vat intake F9 Clear air eliminator



Functions when no tour is active 16-1


16 Functions when no tour is ac-tive Various functions can be called up with the menu softkey when no tour is active. The number of functions available depends on the current configuration. If there are more than 9 functions, the remainder are displayed on a second menu page. Some of the functions are also available during a tour (see sec-tion 15).

Function

Section Section if also available when a tour is active

configuration 16.1 print journal 16.2 15.22 delivery 16.3 15.3 CIP 16.4 15.5 dat. transf 16.5 smp.bttl transp 16.6 lngtrm.st. 16.7 15.11 intern. st. 16.8 storage cass. 16.9 vakuum test 16.10 s. b. handl 16.11 print out spool 16.12 abs. cntr. reset 16.13 show GPS 16.14 15.17 Rep. sampl 16.15 extract backup 16.16 databases 16.17



16.1 Configuration The configuration menus can be used to adapt the software to the specific working conditions, to the system's hardware components and to the type of collection truck. Most of the configuration functions are protected by pass-words. The configuration menus are described in a separate document (MAK 3002 - Configuration Software version MAK 1.46/ MAK 2.46). The col-lection truck driver can change the contrast of the controller display without entering a password; in order to change the time and the language however, the driver password must be entered first.



16.2 Print journal Use the menu „print journal“ to select several data for printing. During a tour ist his function available to print data of the current tour (see section 15.22).

Further selections are possible in the „print journal“ sub-menu. The „manual selection“ item allows you to select the tours whose data you want to print manually. First specify which data you want printed in addition to the standard data.

The following data is printed depending on your selection: Standard

data Quantities Actions Errors

total data quantity + actions quantity data

Standard data Tour data, such as tour code, beginning of tour, end of tour, dairy code, driver code, vehicle code, magazine code, km count.

Quantities All the data measured during collections, deliveries or clean-ing operations (collection and delivery quantities, tempera-tures).

Actions All the actions performed during the tour (e.g. activating or deactivating the sampling function, activating or deactivating the „add air eliminator volume“ function, activating emer-gency mode).

Manual selection



Errors All errors and faults reported by the controller (e.g. filling er-rors, configured limits exceeded, faults in individual devices).

After confirming the data selection, you are presented with the details of the last tour. If several tours are stored, you can scroll up and down in the list using the back and contin. softkeys in order to select the required tour.

Press the print softkey to start printing the data for the selected tour.

When you have specified which data you want printed (total data, quantities and actions or quantity data) as described in the section on manual selection, the journal is printed with the selected data for all the tours. Specify which data you want to print, i.e. total data, quantities and actions or quantity data. The data for all tours which have not yet been printed is printed now.

Total journal

Not printed tours



After selecting the „sched. data jou.“ option, you can choose one of the stored tours.

Then press the print softkey. The schedule data for the selected tour is printed (serial number, supplier code, preset quantity, time up to which a quantity still remaining is valid) . Press the OK softkey to close the menu. You can use this option to print out the current data in the quantity memory (supplier code, quantity, data and time the data was saved, quantity still re-maining).

If data backup is configured (param. config./data capture/ configuration/ ba-ckupdata: ON), are tourdata saved for max. 10 days. The information of the last tour is displayed. You can use the back and contin. keys to select another tour.

Backupdata

Schedule data journal

Quantity memory



Start printing the data of the selected tour by pressing the print softkey.

The printout of the current tour joural will be automatically proposed if this is set in the configuration (param. config/ print pack/ ticket config./ journal TE: ON).

16.3 Delivery Apart from the measured and unmeasured deliveries during a tour (see sec-tion 15.3) you can unmeasured deliveries also do out of a tour.

First enter the quality of the milk to deliver. Then use the select field softkey to select the compartment to be emptied.



Use the select softkey to confirm the compartment. A tick is displayed be-hind the volume. Repeated pressing of the select softkey reverses the se-lection. You can select several compartments.

Confirm your selection with the OK softkey and do the delivery.

Press the ready softkey when the delivery is finnished.

16.4 CIP The menu for truck cleaning is available out of a tour only if configurated (pa-ram.config./ sequence cntrl./ cleaning/ out of tour: ON).

When cleaning out of a tour no CIP data will be recorded! Cleaning of the collection truck during a tour is described in section 15.5.



16.5 Data transfer

When confirming the menu item „dat. transf“ data is transferred in marker-byte format. This menu item is available only if data transfer in markerbyte format is con-figured (param.config./ data capture/ configuration/ dat. transf.: 5) or if data transfer takes place via radio modem (param.config./ data capture/ configu-ration/ dat. transf.: 6). A manual call for data transfer is to start then.

16.6 Sampling bottle transport When automatical sample bottle feeding is configured (param. con-fig/smpl.b.id./ s.b.handl.: ON ), you can manual trigger a sample bottle trans-port by confirming this menu item.



16.7 Long-term storage The data stored in the long-term memory can be viewed, printed or moved. Select the „lngtrm. st.“ function in the „special function“ menu.

Then you can demarcate surching by entering a supplier code and (or) a tour number as well as a period in the format DD.MM.YY.

To search without restrictions press the ready softkey.

If you enter just a supplier code all data concerning this supplier will be searched.

If you define a period by entering a start date and an end date, will only data be searched recorded during this period.

You can use the contin softkey to scroll up and down in the list of data re-cords.



Press the issue softkey to issue the selected record or press total issue , to issue all found records.

Then choose to print or to transfer data to a data storage cassette.

Print data

Transfer data to cassette



The contents of the long-term memory are checked when you switch on the controller. If the memory contains more than 1000 obsolete data records (i.e. records marked as erased), they are deleted permanently and the long-term memory is re-organized. This process may take several minutes. Do not under any circumstances interrupt the power supply until it has finished. If you do, you may lose all your data!

16.8 Internal storage When you confirm this function, the contents of the configured RAM drive are displayed.

16.9 Storage cassette When you confirm this function, the contents of the data storage cassette are displayed.



16.10 Vacuum test The menu item „vacuum test“ is available for the truck type V 2000-2 only.

The measuring system is pressure-tight closed. Then ejector 2 runs for 60 seconds to exhaust the system. The produced vacuum is displayed. After the ejector has stopped you can monitor the pressure drop. After testing the ejector 2 the ejector 1 is testet in the same way.

16.11 Adjusting the reading device for sample bottle feeding The menu is used to adjust the reading device for sample bottle feeding that is present.

Barcode reader If a barcode reader is present you start reading with this function. The read-ing procedure will be permanent repeated. If necessary change the reading position until the barcode is read and displayed dependably. The best read-ing distance is approximately 4 mm between the case of the reader and the barcode label.

TAG-reader If a sample box rack ARS 300 is used, you can use this menu item to adjust the TAG-reader station. The reading procedure will be permanent repeated. If necessary change the position of the TAG-reader until the TAG is read dependably and the code is displayed.

The ready softkey will finnish this function.



16.12 Print out spooler This menu item will only appear if there was a malfunction during printing. The print jobs stay saved in the spooler and can be printed after eliminating the malfunction.

16.13 Reset total quantity counter (Only available when seal switch is actuated!)

When you confirm this function the contents of the total quantity counter will be deleted from seal RAM.



16.14 Show GPS When you confirm this function, the GPS data is displayed (longitude, lati-tude, number of received satellites, GPS quality). This function is also avail-able during a tour (see section 15.17).

When receiving more than 5 satellites the receiving quality is sufficient. Quality: 1 : GPS (Standard GPS) 2 : DGPS (Differencial GPS) NFIX : no reception

16.15 Repeat sampling When no tour is active you can mark the supplier codes for repeat sampling (see section 10.5).

First select a tour with the select field softkey and press OK . The supplier codes of the selected tour will be displayed.



Select the supplier code with the select field softkey. Then press the select softkey. A mark appears behind the supplier code. The supplier is marked for a repeat sample (retest). By repeated pressing the select softkey you can undo the mark. If there are more than 12 suppliers in the tour you can use the contin. soft-key to switch to the following pages with more supplier numbers.

Mark all suppliers intended for repeat sampling this way.

16.16 Extract backup Backup data can be transferred to the data storage cassette.

By entering a tour number and / or a period you can demarcate the data to transfer (data format: dd.mm.yy). If you don’t enter any demarcation will all data be transferred.



16.17 Data bases The data bases „quantity memory“ and „supplier data“ can be inspected and edited. After confirming this menu item you can select a data base.

16.17.1 Quantity memory

You can inspect and edit or reorganize the stored data in the quantity mem-ory.



Inspect Quantity memory

Confirm the menu item „einsehen“. Then you are asked to enter the pass-word. Enter the valid user password. When level 2 user-pw is displayed press the ready softkey. The first record of the quantity memory will be displayed.

Meaning of the data fields U000 Supplier code U001 Preset quantity (= expected quantity) U002 Quantity still remaining (difference to preset quantity) U003 Date U004 Time U005 Quality (0...9) U006 GPS coordinates U007 GPS coordinates U009 last used compartment for the supplier U010 sequence no. (continuous number of procedures during the tour) U011 Number of the tour, in which at the position of the supplier was

stopped last. U012 process ID (kind of procedure: collection, delivery, pump over)

You can scroll up and down in the list of data records using the ← and → softkeys. If you have not entered a valid password, the softkey new search is dis-played instead of the menu softkey. If you press this softkey, you can enter a supplier code to search and display the appropriate data. Without entering a valid password data can only be inspected!



If you have entered a valid password a menu is available.

Edit data records You can edit each entry in a data field independent. Before closing the editing screen you must decide to store the modifications.

Delete data record By confirming the menu item „delete“ will all data of this record be deleted without a query.



Search data record To find a record fast you can enter a supplier code.

The first record of this supplier will be displayed. Use the softkeys ← and → to continue searching.

When you close the „special function“ menu, you can decide whether or not the data records should be re-sorted.

It is a good idea to re-sort the data records whenever a new schedule has been learned. The data records are sorted in ascending order of the supplier codes. The system also searches for data records in ascending order while the program is running. The search is faster if the records have been prop-erly sorted.



Reorganize Quantity memory

If you realize that the quantity function doesn’t work properly anymore, you can repair the data base with this function. Never switch off the system during reorganizing. It would cause data loss!

16.17.2 Customer data

After confirming the menu item „custo. data” you are asked to enter to enter the password. Enter the valid user password. When level 2 user-pw is displayed press the ready softkey. The first record of the customer database (supplier data-base) will be displayed.



Meaning of the data fields

C004 supplier code C008 name 1 C009 name 2 C010 street, No. C012 post code, place

Use the softkeys ← and → to browse the records. If you have not entered a valid password, the softkey new search is dis-played instead of the menu softkey. If you press this softkey, you can enter a supplier code to search and display the appropriate data. Without entering a valid password data can only be inspected! If you have entered a valid password a menu is available.

Edit data records You can edit each entry in a data field independent. Before closing the editing screen you must decide to store the modifications.



Delete data record By confirming the menu item „delete“ will all data of this record be deleted without a query.

Search data record To find a record fast you can enter a supplier code.

The stored data record of this supplier is displayed.



When you close the „special function“ menu, you can decide whether or not the data records should be re-sorted.

Never switch off the system during reorganizing. It would cause data loss!



System monitoring 17-1


17 System monitoring The MAK 3002 system is monitored permanently to ensure reliable opera-tion. All events that occur while the system is in operation are reported on the display, either in plain text or in pictogram form.

17.1 Pictograms The following pictograms are used to indicate the various operating states that can occur during work with the MAK 3002 system.

System busy Tour feedback

data available, flashes during access to RAM drive

Seal switch activated (flashes)

Printer busy Tour started Pump off Pump on Pump on, flow present (rotates)

Branch sam-pling on, branch no. 2

Filling branch sample

Sampler sam-pling on

Filling sam-pler sample

Tank sam-pling on

Filling tank sample

Barcode reader ready

Radio or cable-type reading head ready

Card reader ready

Supplier identified according to GPS data

No supplier identified (vehicle mov-ing, no sup-plier stored at this position); flashes if position can-not be deter-mined

Without pump stop: tempera-ture too high With pump stop: warning limit ex-ceeded (flashes)

Without pump stop: tempera-ture too low With pump stop: warning limit under-shot (flashes)

Without pump stop: pH value too high With pump stop: warning limit ex-ceeded (flashes)

Without pump stop: pH value too low With pump stop: warning limit under-shot (flashes)

Emergency mode (flashes)

Transferring data (flashes)

Press F1 to display help text

Correction signal not received for DGPS, fixed search toler-ance: 200 m.

Air eliminator empty

Air eliminator full

Manual enter-ing of sched-ule data func-tion is active.



17.2 Messages Messages are displayed in plain text. They serve to inform you about: • Operating states or changes to the operating regime, • Failure to observe the configured limits (upper or lower), • Errors and faults during operation. Messages are headed „Information“, „Warning“ or „Interruption“, depending on their contents. Messages usually have to be confirmed. Only then will the program con-tinue. In the case of messages which draw attention to a fault or an error, you should rectify the cause. The device which originated the fault can be deactivated temporarily in order to continue the tour (see section (see section 17.4). The system distinguishes between several types of error:

Communication errors

Communication errors are errors which occur when data is transferred be-tween the controller and individual hardware modules. The display shows: • The designation of the device whose response led to the error (in this ex-

ample the Temperature sensor 1), • The type of error (No Response), • The error code for P-NET devices (0 10). Possible causes • Loose terminal wires on the functional unit in question • Internal device fault • Incorrect wiring • Defective insulation of the connecting cables • short power failure Remedy • Switch off and on the system • Check the connecting cables and if necessary tighten the screws • During a tour: deactivate the functional unit (see section 17.4) • In the depot: replace defective device



Peripheral device messages

The respective P-NET device identifies the error itself and reports it to the controller. The display shows: • The designation of the device whose response led to the error (in this ex-

ample Ultrasampler 1) • The type of error (filling level reached) • The error code (2f 1)

Possible causes: • Defective peripheral device • Power failure • Illegal parameters reported by device Remedy: If the message remains displayed even after it has been confirmed several times, switch off the MAK system briefly, then switch it back on again. If the error still persists, deactivate the faulty device temporarily (see section 17.4) and have it repaired or replaced later.

System messages

System errors can occur within the MAK system during normal operation and are identified by the controller. Possible causes: • Incorrect configuration • Configured limits exceeded • Essential operating conditions not fulfilled (in this example the configured

temperature limit has been reached) Remedy: • Check the operating conditions and if necessary take steps to ensure that

they are fulfilled • Confirm the error message (several times if necessary; in this example

abort the current collection).



Contact your nearest Service Center if you are unable to rectify an error or fault. If a printer is configured, you can document the error by printing out the current display contents. To do so, press F2 .

17.3 Help system You can display help texts in certain situations. If a help text is available, a question mark appears on the display. You can then call up the help infor-mation by pressing F1 .

17.4 Deactivating a device If a message remains displayed even after it has been confirmed several times, you can deactivate the device that is causing the trouble. To do so, press the Abort softkey first of all. You can then decide whether or not you really do want to deactivate the device.

F1



Press disable . You can now either abort your action or continue without the deactivated device.

If you abort the action, you can then decide whether to abort or continue the current tour.

17.5 Emergency mode After you have aborted a tour, you can activate emergency mode.



Working in emergency mode is the same as working without sequence con-trol. Ending emergency mode Emergency mode can only be ended by re-starting the controller. When the cause of the fault that led to emergency mode being activated has been rectified, switch off the system and then switch it back on again. Emer-gency mode is ended when you re-start the system

Switch the system off only when no tour is active!


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Documents

MAK 3002 - BARTEC · cate, please refer to the type-examination certificate DE-07-MI005-PTB005, (Section 6) and respectively to the DE-09 MI005-PTB037 (Section 4). Safety precautions