Merlin Spare Parts Manualtestpacko.businesscatalyst.com/assets/006720-merlin-2-pièces... · Ref / Pt.No: 006720 Merlin Spare Parts Manual Revision: 12 July 2013 006720 Page 11 Ref

Merlin Spare Parts Manual

006720 Revision 12

Ref / Pt.No: 006720


Revision: 12

July 2013

006720 Page 2

Contents

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

Important information - read this first .................................................... 6

Icons ......................................................................................................... 6

1. Introduction ................................................................................... 7

2. Arm Assembly ............................................................................... 8

2.1 Mothership .......................................................................................................... 8

2.2 Jetter Assembly ................................................................................................ 12

2.3 Laser ................................................................................................................ 13

2.4 Shells & Liners ................................................................................................. 14

2.5 ACR Cylinders & Ropes ................................................................................... 17

2.6 Arm Cylinders ................................................................................................... 18

2.7 Arm Traverse Motors & Rollers ........................................................................ 20

2.8 Eccentric Wheel ............................................................................................... 23

2.9 Foremilk Rejection, Pre February 2009 ............................................................ 24

2.10 Foremilk Rejection, Post February 2009 .......................................................... 25

2.11 Tube Clamps .................................................................................................... 26

2.12 Legato Pulstaor ................................................................................................ 27

2.13 S-Lina ............................................................................................................... 28

2.14 Teat Roller ........................................................................................................ 30

2.15 Arm Control Box ............................................................................................... 32

2.16 CPV Enclosure ................................................................................................. 35

2.17 Long Box (pre April 2009) ................................................................................. 37

2.18 Long Box (post April 2009) ............................................................................... 37

3. Crate ............................................................................................ 38

3.1 Entry & Exit Gates ............................................................................................ 38

3.2 Cow Follower .................................................................................................... 39

3.3 Cow Sensor & Antenna .................................................................................... 41

3.4 Gate Cylinders .................................................................................................. 42

4. Milking Area ................................................................................ 43

4.1 Clamp Valve ..................................................................................................... 43

4.2 Milk Filter .......................................................................................................... 44

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4.3 Milk Sensors ..................................................................................................... 45

4.4 Milk Meter ......................................................................................................... 46

4.5 Receiver Vessel ............................................................................................... 47

4.6 Servac .............................................................................................................. 48

4.7 Sanitary Trap .................................................................................................... 49

4.8 Blood Sensor .................................................................................................... 50

4.9 Merlin Control Box ............................................................................................ 51

4.10 Sampler & Shuttle............................................................................................. 53

4.11 Digital Vacuum Gauge ...................................................................................... 54

4.12 4QCM ............................................................................................................... 55

4.13 Milk Pump ......................................................................................................... 56

4.14 Milk Pump Burkett Valves ................................................................................. 57

5. Main Cabinet ............................................................................... 59

5.1 Phoenix Enclosure............................................................................................ 59

SECTION 1 ................................................................................................................. 60

SECTION 2 ................................................................................................................. 60

SECTION 3 ................................................................................................................. 60

5.2 Festo Enclosure ............................................................................................... 63

5.3 Electrical Enclosure .......................................................................................... 64

5.4 Chemical Dosing Pumps .................................................................................. 66

5.5 Teat Spray Motor .............................................................................................. 68

5.6 Fusion Enclosure .............................................................................................. 69

5.7 Wash Chamber & Burkett Valves ..................................................................... 71

5.8 Burkett Valves on Side Panel ........................................................................... 72

5.9 Re-classifier ...................................................................................................... 74

5.10 Flow Control ..................................................................................................... 75

5.11 Tyco Valves ...................................................................................................... 76

5.12 APV Butterfly Valve .......................................................................................... 77

5.13 Compressed Air Filter ....................................................................................... 78

6. Feeding ........................................................................................ 79

6.1 Feeder Assembly.............................................................................................. 79

6.2 Feeder Motors & Hoppers ................................................................................ 80

7. External Equipment .................................................................... 81

7.1 Alarm Unit ......................................................................................................... 81

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7.2 Extension Boards & Identification Controllers ................................................... 82

7.3 Delivery Line Parts ........................................................................................... 84

7.4 Bulk Tank Connections ..................................................................................... 85

7.5 Tube Coolers & Plate Coolers .......................................................................... 86

8. Milk Rejection Unit ...................................................................... 88

8.1 Milk Separation Control Box 193723 ................................................................ 91

9. Chemicals .................................................................................... 92

10. Miscellaneous ............................................................................. 93

10.1 Safety/Warning Labels ..................................................................................... 93

10.2 Overlays ........................................................................................................... 94

10.3 Sensors ............................................................................................................ 95

10.4 Silicon Tubes .................................................................................................... 96

10.5 Air Tubes .......................................................................................................... 97

11. Spares Kits .................................................................................. 98

11.1 116359, Merlin Spares; liners & shells ............................................................. 98

11.2 116360, Merlin Spares; silicon tubes ................................................................ 98

11.3 116361, Merlin Spares; air fittings .................................................................... 98

11.4 116362, Merlin Spares; bolts ............................................................................ 99

11.5 116363, Merlin Spares; nuts ............................................................................. 99

11.6 116364, Merlin Spares; washers .................................................................... 100

11.7 116365, Merlin Spares; roll pins ..................................................................... 100

11.8 116366, Merlin Spares; split pins ................................................................... 100

11.9 116367, Merlin Spares; circlips ...................................................................... 100

11.10 116368, Merlin Spares; jetters .................................................................... 100

11.11 116369, Merlin Spares; jubilee clips ............................................................ 100

11.12 116370, Merlin Spares; sensors .................................................................. 101

11.13 116371, Merlin Spares; pulsator ................................................................. 101

11.14 116372, Merlin Spares; bearings ................................................................ 101

11.15 116373, Merlin Spares; springs ................................................................... 101

11.16 116374, Merlin Spares; milk pump .............................................................. 101

11.17 116375, Merlin Spares; arm electrical ......................................................... 102

11.18 116376, Merlin Spares; pneumatic vlvs....................................................... 102

11.19 116377, Merlin Spares; teat rollers ............................................................. 102

11.20 116378, Merlin Spares; overlays ................................................................. 103

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11.21 116379, Merlin Spares; miscellaneous........................................................ 103

11.22 116380, Merlin Spares; roof box ................................................................. 103

11.23 116381, Merlin Spares; large pump ............................................................ 103

11.24 116382, Merlin Spares; small pump ............................................................ 104

11.25 116383, Merlin Spares; teat spray pump..................................................... 104

11.26 116385, Merlin Spares; foremilk manifold ................................................... 104

11.27 116386, Merlin Spares; Arm PCBs ............................................................. 104

11.28 116387, Merlin Spares; Fusion PCBs ......................................................... 105

11.29 116388, Merlin Spares; Festo cylinders ...................................................... 105

11.30 116389, Merlin Spares; Festo air ctrl .......................................................... 105

11.31 116390, Merlin Spares; Festo tube ............................................................. 105

11.32 116391, Merlin Spares; Festo CAN Block ................................................... 105

11.33 116392, Merlin Spares; Festo arm Block .................................................... 106

11.34 116393, Merlin Spares; Festo arm solnd..................................................... 106

11.35 116394, Merlin Spares; Festo S-lina ........................................................... 106

11.36 116395, Merlin Spares; Phoenix ................................................................. 106

11.37 116396, Merlin Spares; Electrical cabt ........................................................ 107

11.38 116397, Merlin Spares; Wash box .............................................................. 107

11.39 116398, Merlin Spares; External ................................................................. 107

11.40 116399, Merlin Spares; Festo Cylinder repair kit ........................................ 107 Copyright © 2007, Fullwood Limited reserves the right to change the contents of this manual if necessary, without warning. Fullwood Limited has taken every precaution to avoid errors and omissions on the manual and equipment but does not accept any responsibility or liability for damage of any kind arising from the use of this manual or Fullwood equipment; whether this damage is direct or indirect. If you discover any inaccuracies please inform Fullwood Limited or one of its agents and we will make corrections for the next release.

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Important information - read this first

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

The equipment must be used only for the application described.

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

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

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

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

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

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

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

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

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

Icons

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

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

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

Gives important information to prevent potential problems.

Gives advice or suggestions to make procedures easier or clearer.

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1. Introduction

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

Arm Assembly

Cabinet

Feeder

Milking Area

Crate

External Equipment

Miscellaneous Shown below are the areas of the Merlin;

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

mailto:[email protected]

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2. Arm Assembly

2.1 Mothership

2

1

3

4

13

Ref / Pt.No: 006720


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6

7

8

9 10

11

5

Ref / Pt.No: 006720


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12

Ref / Pt.No: 006720


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Ref Pt.No. Description Notes

1 194000 Mothership(Welded)S/Assy

2 194013 Laser Cover Assy(15mm Higher) SL1 CTF liners (Germany)

193404 FTL Plastic Bush

3 194029 Centring Plate Assy(New)

4 092264 4mm ACR Rope (2mt Long)

5 194014 Tube Divider-Mothership

6 194023 Tube Divider-Inside

7 194028 Tube Divider-Outside

8 194032 Roller Shaft

9 194033 Tube Retainer Shaft

10 091793 Small Nylon Roller

11 194039 Cord Pulley S/Assy

12 194025 Brkt S/Assy-Mothership Cyl

13 091791 SS Bush

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

194015 Clamp Spacer S/Assy-Tube Divdr

194040 Tube Manifold S/Assy

194034 Rope Separator S/Assy

007865 M5x4mm Short Swivel Elbow>

007182 4mm Bulkhead Conn(RS 3272359)

107404 4mm Black Tube

030343 Tube 13.5/20mt/23.8 od Rbr

030341 Tube 9.1nb/20mt/18 od Rbr

030328 Sil Tube 9.1nb/20mt/18 od Rbr

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

005110 Lk2a Plastic Cable Tie-Black

001631 M8 SS Washer Form C

001159 M8 SS Nyloc Nut

000519 M5x10 SS Hex Hd Setscrew

000424 M6x20 Hex Hd SS Screw

000520 M6x12 SS Setscrew Hex Hd

000464 M6x10 Socket Cap SS Screw

001635 M5 Plain Washer SS (Type C)

001622 M6 SS Washer Form C

000074 M16x55 Hex Hd SS Bolt


001632 M16 SS Washer Form A

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2.2 Jetter Assembly


1 070290 16x25 Hose Clip S.S

2 053000 Jetter Claw

3 001895 12-20x9 Wide SS Jub Clip

4 030328 Sil Tube 9.1nb/20mt/18 od Rbr.

5 092448 Jetter Rubber

6 092447 Jetter Cup

7 092445 Sltd Jetter Nipple Assy

8 030312 Sil Tube 12nb/20mt/21od

9 194031 Jetter Plate-Wide Shell Crs

10 091790 Set Nut

193685 TDS-Nozzle Brkt S/Assy

193673 Nozzle for Laser

007773 Spray Nozzle Alternate Spray Nozzle

007739 1/8"-6mm SS straight Connctor>

1

4

5

6

2

3

7

8

9

10

Ref / Pt.No: 006720


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2.3 Laser


1 193368 TDS Kit (Modified)

2 193365 TDS Cable Assy (Spare)

1

2

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2.4 Shells & Liners


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

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

1 020134 SL2 CT Liner See chart for compatibility

1 020146 FL7S Liner See chart for compatibility

1 020167 FL7W Liner See chart for compatibility

1 020184 FL7W(Chlorinated)Liner See chart for compatibility

1 020168 FL7WWT Liner See chart for compatibility

1 020169 FL7SWT See chart for compatibility

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

2 092677 MK2 FL7 White Nylon Shell See chart for compatibility

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

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

3 092801 USA MK3 Vac/Mlk Chamb-12.5Cone See chart for compatibility

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

5 092259 Rope End Cover One per shell

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

091369 Liner Gauge 12.5mm

091289 Liner Gauge 11mm Used with SL2

Robots post 2003 leave the factory with: 092677 MK2 FL7 White Nylon Shells , 020146 FL7S

Liners and 092804 MK3 Vac/Milk Chambers(15.5Cone) UNLESS OTHERWISE SPECIFIED. July 2009

With effect from 01/07/2009, Merlins will be equipped with revised Milk/Vac Chambers;

194191 RH Mlk/Vac Chamber S/Assy 194190 LH Mlk/Vac Chamber S/Assy

See MTB039 (Merlin Technical Bulletin) on the online catalogue or Fullwood Bulletin board.

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Pt.No. Description Notes

1 092677 FL7 White Nylon Shell X4

092675 SL1 & SL2 White Nylon Shell

2 092259 Rope End Cover X4

3 194191 RH Mlk/Vac Chamber S/Assy X2 required per Merlin

194190 LH Mlk/Vac Chamber S/Assy X2 required per Merlin

4 See page 16 X4 in a pack

Other items not illustrated


007663 O Ring 37.82x1.7 1 required per shell

007670 O Ring 10id x 2 Section *** 1 required per rope cover

091289 Liner Gauge 11mm Only for SL2 liners!

091369 Liner Gauge 12.5mm For any other liner!

4

3 1 2

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Liner Type

Part No

Milk Tube Min. I.D.

Hood Aperture

Barrel I.D.

Shell Vacuum Milk

Chamber

„O‟ Ring 37.8x1.7

mm

“O” Ring

10.00mm x

2.00mm

Rope End

Cover

Liner Gauge

Complete Kit i.e.

4x Shells Etc.

Part No

020227 SLI CTS

15.0 22.5 24.5 092675 092804

007663 007670 092259 091369 092940

020215 SL1 CTW

15.25 25.0 24.5 092675 092804

007663 007670 092259 091369 092941

020134 SL2 CT

12.00 22.0 24.0 092675 092678

007663 007670 092259 091289 092942

020146 FL7 S

13.25 20.75 22.0 092677 092804

007663 007670 092259 091369 092943

020168 FL7W

WT

13.5 22.5 22.0 092677 092804

007663 007670 092259 091369 092946

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2.5 ACR Cylinders & Ropes

The range of seal kits available for the Festo ACR cylinders has now been expanded to include the last generation cylinder that has the nylon end caps.

There is no seal kit for the latest cylinder used on the RT mothership.


1 092264 4mm ACR Rope (2mt Long)

2 000365 M6x10 Socket Csk SS Screw

3 007940 Nylon Washer

4 107418 ACR Cylinder Later Type

5 007417 ACR Rope Guide

6 194039 Cord Pulley S/Assy

193957 Seal Kit-ACR Cyl-Alum End Caps Early Type

193958 Seal Kit-ACR Cyl-Nyln End Caps Later Type

107532 Scraper Seal for ACR cylinder Nylon end caps

107555 Seal(667827) Nylon end caps

107610 Cylinder DZF-25-100-A-P-A

194039 Cord Pulley S/Assy

2

3

1

4 5 6

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2.6 Arm Cylinders

107524 - Mothership Seal Kit


1 107414 Turn cylinder 50/270

2 107410 Mothership cylinder 40/20

3 107412 Teat motor turn cyl 32/160

107524 Mothership Seal Kit

107547 Scraper(372312) Added into BOM 107524

107546 Lip Seal(235663) Added into BOM 107524

107609 Polymer Slide Bearing

107518 Repair Kit- 32mm CRHD cylinder Teat roll arm

107532 Scraper Seal for ACR cylinder Use with 107518

107555 Seal(667827) Use with 107518

107454 CRHD 50/270 Arm turn in seal kit

107556 Seal(12219862) Use with 107454

107557 Scraper(372313) Use with 107454

1

2

3

Ref / Pt.No: 006720


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107518 - 32mm CRHD Cyl Repair Kit-Festo

107454 - 50mm Cylinder Repair Kit-Festo

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2.7 Arm Traverse Motors & Rollers


1 005922 Drag Chain ass'y

1 000357 M6x16 SS Butn/Hd Sckt Scw 2 off to mount drag chain

1 001630 M6 SS Washer Form A 2 off to mount drag chain

1 001158 M6 SS Nyloc Nut 2 off to mount drag chain

2 007295 Double Clamp

2 007294 Stacker Saddle Clamp

2 007298 Bottom Saddle Clamp (spare)

3 007287 Channel For Igus Clamps

3 000357 M6x16 SS Butn/Hd Sckt Scw 2 of to mount channel

3 001630 M6 SS Washer Form A 2 of to mount channel

3 001158 M6 SS Nyloc Nut 2 of to mount channel

4 193394 RH SS Carriage End Plate Assy

5 193393 LH SS Carriage End Plate Assy

6 191090 SS Drag Chain Platform Assy

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1 000362 M5x12 SS Butn/Hd Sckt Scw 2 off

1 001635 M5 Plain Washer SS (Type C) 2 off

2 000343 M8x25 Hex Hd SS Setscrew 2 off

2 001631 M8 SS Washer Form C 4 off

2 001159 M8 SS Nyloc Nut 2 off

1

2

3

7

8

5

4

9

6

5

Wheel detailed below

15 10

12

11 13

14

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3 007465 Drive Roller

4 091659 Plstc Cap(80x80x5 Box)

5 002950 Pressure Spring

5 000286 M20x55 SS Hex Hd Screw 1 off

6 193393 LH SS Carriage End Plate Assy

6 193394 RH SS Carriage End Plate Assy

7 007337 SGT853 Stepper With Gearbox

8 094802 PG11 Cable Gland for 5-10

9 094975 5core 1mm Cable

10 007412 Bearing 61904 ZZ s/steel 2 per roller

11 001631 M8 SS Washer Form C

12 000359 M8x10 SS Hex Hd Screw

13 091668 Top Roller Spindle

14 091669 Ring

15 091667 Top Roller 2 of plastic roller

15 091660 SS Top Roller 2 of SS roller


1 092295 Guide Wheel

1 001949 6 Dia SS Clevis Pin

1 001905 1/16"x3/8" Cotter Pin SS

2 007954 Ultrasonic Sensor

3 007437 Sensor & Cable-NRS4 P12PA370

3 091676 Sensor Holder

3 007455 20mm Pipe Clip

3 000371 M6x40 SS Socket Capscrew 2 off

3 001158 M6 SS Nyloc Nut 2 off

2 1

3

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2.8 Eccentric Wheel


1 000448 M16x25 Hex Hd SS Setscrew

2 001632 M16 SS Washer Form A

3 091665 Small Roller Spindle

4 007412 Bearing 61904 ZZ x 2

5 091792 Nylon Roller Custom made for each robot (will need machining to size)

6 001782 20mm External Circlip

1

2

3 4 5

6

Ref / Pt.No: 006720


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2.9 Foremilk Rejection, Pre February 2009


1 092898 11mm Polypropylene Ball

2 092899 18mm 55 shore Natl Sil Ball

3 092209 Retaining Clip

4 193745 LH End Plate S/Assy

5 193746 RH End Plate S/Assy

6 193742 LH Manifold Body

193743 RH Mainifold Body

7 193749 Rejection Manifold Gasket

8 193739 Ball Chamber-Spare(Coarse)

9 193777 Spare-LH Mfld Body&Chamber Kit

9 193778 Spare-RH Mfld Body&Chamber Kit

9 193744 Ball Chamber-Reject Manifold Integral on 193777/78

10 091678 Long Pin

4

6

8 3

7

2

1

9

10

Ref / Pt.No: 006720


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2.10 Foremilk Rejection, Post February 2009


1 193775 LH Mfld Body&Chamber Assy Slice

193776 RH Mfld Body&Chamber Assy Slice

2 092898 11mm Polypropylene Ball

3 092899 18mm 55 Shore Natl Sil Ball

4 193734 End Cap-Ball Chamber

5 193749 Rejection Manifold Gasket

6 193746 RH End Plate S/Assy

7 193745 LH End Plate S/Assy

8 193750 Tie Bolt S/Assy

9 193752 90deg Rubber Bend

10 021186 Milk Tube Connector

11 001158 M6 SS Nyloc Nut

193777 Spare-LH Mfld Body&Chamber Kit

193778 Spare-RH Mfld Body&Chamber Kit

070290 16x25 Hose Clip S.S

9

10

2

3

11

4

1

8

6

7

Ref / Pt.No: 006720


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2.11 Tube Clamps


1 107413 Shut off cylinder 25/15

Seal kit not available Cylinder is a bonded assembly

and should be serviced/repaired at Festo agency only

2 007409 3/4"BSP Maclow Clip

3 030348 Tube 11nb/10mt/21od Rbr

1

2

3

Ref / Pt.No: 006720


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2.12 Legato Pulstaor

Ref


1 142940 Legato LifePulse 24V 2p+1x10m

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

3 042979 Legato 2 Puls Fltr Silencers

4 042917 Legato Lead Merlin 2cMale 10mt

5 042916 Legato Pulsation PCB spare Waterproof PCB

6 191309 LH Brkt-Legato Pulsator

191316 RH Brkt-Legato Pulsator

7 001894 20mm-32mm Hoseclip SS

1

6

3

4 5

2

7

Ref / Pt.No: 006720


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2.13 S-Lina

107469 Festo MK3 S-Lina

107322 - Repair Kit [80mm Cylinder]


1 107465 Valve HA-1/8-QS-6

1 107464 QSF-1/8-6-B Push In Fitting

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

2a 107529 2/2 Valve for S-lina

3 107512 Sckt Conn Cable-KMYZ-9-24-2.5

4 107544 Electronic Module Type EICT Blue Box

4a 107545 Voltage Module Type EICTVM PCB inside 107544

5 107530 S-Lina Main PCB

6 107469 Festo MK3 S-Lina>

7 107322 Repair Kit (80mm Cylinder)

107543 Sensor Type ICT100/EM/T/440/01 Sensor for 107544

4 4a

2

3 5

1

6

Ref / Pt.No: 006720


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107322 Seal kit individual parts;

107525 Lip Seal

107526 End Cap Seal

107527 Nose Seal

107528 Piston Seal


1 007818 M20x1.5 RVS Ball End Eye

2 001941 6 Dia x 45mm SS Roll Pin

3 091672 Long Pin(Hole One End)

1

2

3

Ref / Pt.No: 006720


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2.14 Teat Roller


1 092890 LH Teat Roll Complete Complete assembly

091071 RH Teat Roll Complete Complete assembly

2 091066 V910 Pneu Motor

3 007733 1/8” BSP -6mm SS Male Stud Elbow

4 000462 M8x16 Socket C'sk SS S/Scw

5 091958 C'sk Fabric Cover Retaing Ring

6 092395 Roller Brush (Full Bristle) Used with sawdust bedding

6 092492 Roller Brush (Half Bristle) Used with straw bedding

7 091960 Teat Roll Output Shaft

8 091968 Black Foam Rubber Gasket

007459 Bearing W61804-2RSI

007460 20x30x7 CC NBR Oil Seal

007668 "O" Ring 146id x 2 Section

092246 40-S Gear Wheel M/CD

092247 40-D Gear Wheel M/CD

2 3

4 5

6

7

8

Ref / Pt.No: 006720


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091962 RH Housing-Teat Roll Gearbox

092891 LH Housing-Teat Roll Gearbox

091963 Drive Shaft

091964 Gear Wheel Carrier Bush

091965 Motor Plate

000373 M3x3 SS Socket Grubscrew

000355 M4x10 Socket Cap SS Screw 14 off

000356 M6x35 Csk Hd SS M/C Screw 8 off

007112 M6 SS Grease Nipple

000279 M4x16 SS Sckt Cap Screw 4 off

001946 3Dia x 20 SS Roll Pin

001942 5Dia x 26 SS Roll Pin

091961 Lid-Teat Roll Gearbox

091937 Long Air Motor Adaptor

000484 M4x6 SS Socket Cap Screw 4 off

007733 1/8"BSP-6mm SS Male Stud Elbow

Ref / Pt.No: 006720


Revision: 12

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006720 Page 32

2.15 Arm Control Box

1 2

3

4

9

5

10 6

11

8

7

Ref / Pt.No: 006720


Revision: 12

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006720 Page 33

4 5

6 7

8 9

10

11

13

12

Ref / Pt.No: 006720


Revision: 12

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1 094648 Robot Arm SS Cntl Box Only Box only

2 094730 Overlay (Replacement)

3 092663 Key (Arm Cntl Box)SM300028

4 094779 Rbt PCB KBDP-2(Spare)

5 094623 Rbt PCB GSD15/CAL-1

6 094770 Rbt PCB CP-10(Spare)

7 094772 Rbt PCB Robot-3 9.1185.0564.1

8 094771 Rbt PCB MELK-3 9.1185.0565.2

9 094984 POS-5 Card (5.1002.9502.0)

10 094986 Canlia-1 Card (5.1002.9501.0)

11 094778 Rbt PCB PM-VD24/F PSU

11 094786 Rbt PCB PM-VDPOW/f

12 094590 PCB (BPI0SD-15/B)

13 094638 19" Racking + PCB's Complete inner rack assembly

Ref / Pt.No: 006720


Revision: 12

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2.16 CPV Enclosure

1

2

3

4

5

6

7

8

9

10 11

12

14

13

Ref / Pt.No: 006720


Revision: 12

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193963 Valve Block(LH)Retro Fit Kit Complete retro fit kit

193964 Valve Block(RH)Retro Fit Kit Complete retro fit kit

1 097682 Plycabon Enclosure C/Lid ME918

2 107483 CPV Valve Terminal

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

4 107625 UC-QS-4H Silencer

5 107515 M7-4mm Elbow QSML-M7-4


7 107403 4mm Blue Tube. /mt.(50mtCoil)

8 007349 6mm Equal"Y"(YJPMK6)

9 100503 M5x25mm Chs Hd M/C Screw SS

10 001292 M5 Nyloc Nut SS

11 094712 Crimp Terminals 4809 P914L

12 000532 M3x30mm Pan Hd M/C Screw SS

13 001222 M3 SS Hex Nut

14 007936 Nylon Spacer 3.1x6x7.5

15 107477 Valve CPE10-M1H-3GL-M7

16 007314 4mm Equal Union Connector

17 107622 Flow Cntl Vlv(GRLA-M5-QS-4-D)

18 107626 Vlv "K" Type VMPA1-M1H-K-PI Double valve slice

19 107627 Vlv "M" Type VMPA1-M1H-M-PI Single valve slice

005057 8-3/8"BSPT Male Swivel Elbow

007769 1/8"-6mm Push In Elbow

107623 Reducer (DM5I-M7A-ISK)

107549 M7-6mm Elbow QSML-M7-6

094724 14core Cable Unitronic FD CY

000560 Z8 x3/8" Pan Hd S/Tap-Ab SS

107620 Plug-SD-SUB-D-BU25

107512 Sckt Conn Cable-KMYZ-9-24-2.5

107572 QSM-M7-6-I Push In Fitting

193760 Grommet 4id x 6.4od x 3.2

193761 Grommet 5.6id x 8od x 3.2

096871 PG9 Cable Gland for 4-8

15 16

17

Ref / Pt.No: 006720


Revision: 12

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2.17 Long Box (pre April 2009)

2.18 Long Box (post April 2009)


1 091916 Box M/CD (Lid+Box)

2 094783 Rbt PCB CDAP2 5.1002.2917 MK3

3 007768 Roxspur Vacuum Sensor+"O"Ring

4 092169 Sealing Sleeve spare


194075 LH Vac Sensor Cntl Box Assy

194076 RH Vac Sensor Cntl Box Assy

1 096871 PG9 Cable Gland for 4-8

2 194053 Box M/CD (Lid+Box)

3 194058 Symetric Top Nat Din Rail

4 194052 End Stop

5 096872 PG7 Cable Gland for 3-6.5

6 194051 MiniBlk 2spring Term 2.5mm Gry

7 095768 100mf 63v Axial Elec Capacitor

194055 End Section

194056 Jumper Bar

094480 Insulate Bootlace Ferrule-0.34

2

1 4

1

2

3

4

6

5

3

7

Ref / Pt.No: 006720


Revision: 12

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3. Crate

3.1 Entry & Exit Gates

A

B


1 193224 SS Entry Gate L/H Robot

193228 SS Entry Gate For R/H Robot

2 193225 SS Exit Gate L/H Robot

193229 SS Exit Gate For R/H Robot

3 191042 Top Split Bearing Block

4 191040 Top Bearing Bolting Plate

5 191043 Bottom Bearing Block

6 191041 Bottom Bearing Bolting Plate

1 2

B

A

6

5 3

4

Ref / Pt.No: 006720


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3.2 Cow Follower

2

3

4

1

6

5 8

7

9

Ref / Pt.No: 006720


Revision: 12

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1 191278 LH SS Pusher Plate S/Assy Left hand Merlin

191190 SS Pusher Plate S/Assy Right hand Merlin

2 191279 LH SS Single Rear Pusher S/Asy Left hand Merlin

191204 SS Single Rear Pusher S/Assy Right hand Merlin

3

4 191275 LH Push Sensor Plate S/Assy Left hand Merlin

191208 Push Sensor Plate S/Assy Right hand Merlin

5 094964 250mm Earth Bonding Strap

6 191228 Main Pivot Rod

7 191227 Main Pivot Bush

8 191281 LH Push Supt S/Assy Left hand Merlin

191221 Univ.Arm Side Push Supt S/Assy Right hand Merlin

9 191212 SS Shock Absorber S/Assy

Ref / Pt.No: 006720


Revision: 12

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3.3 Cow Sensor & Antenna


1 094628 Reflective Photo Sensor EQ-501

2 193431 Cow Presence Sensor Plate

3 033573 Antenna (Low Frequency) + Spacer

1 2

3

Ref / Pt.No: 006720


Revision: 12

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3.4 Gate Cylinders

View from above Merlin


1 107417 Front Gate Cylinder Exit Gate

2 107416 Rear Gate Cylinder Entry Gate - 400mm stroke

107409 Rear Gate Cylinder Entry Gate - 500mm Stroke

3 007843 Ball Shut-Off Valve

107426 40mm Cylinder Repair Kit

1

2

3

Ref / Pt.No: 006720


Revision: 12

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4. Milking Area

4.1 Clamp Valve


1 035515 Vac Clamp Valve

2 035526 Tube Support Bracket

3 035520 Valve Body RH

4 035523 Shut Off Tube

5 035517 Shut Off Bar

6 035527 Support Disc

7 035524 Vac Clamp Black Diaphragm

8 035519 Valve Body LH

9 035534 Main Vacuum Nipple

10 030328 Sil Tube 9.1nb/20mt/18 od Rbr. 2 metres

5

6 6 6 6 6 6

7

8

9

2

3

4

1

10

Ref / Pt.No: 006720


Revision: 12

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4.2 Milk Filter


1 115537 SS nut 2" SMS

2 231/207037 Filter Body Packo part Number

3 115615 SS fixation cage

4 115473 Divided spiral cage L560

5 191018 O ring (Spare for Filter 092833)

6 191017 Seal(Spare for Filter 092833)

2

1

3

4

1

5

6

Ref / Pt.No: 006720


Revision: 12

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4.3 Milk Sensors


193070 Conductivity Sensor Box Assy

1 193073 Sensor Mounting Plate

2 193306 Sensor Box M/CD (Drilled)

3 193071 Flow Sensor Assy

4 007293 Rubber Grommet

1

2

3

4

Ref / Pt.No: 006720


Revision: 12

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4.4 Milk Meter


1 133541 Upper cover

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

3 133543 AfiFlo Mid-Section with 10m cable

133542 AfiFlo Mid-Section with 20m cable

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

5 133517 Milk meter valve

6 133544 Lower cover

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

8 133546 Solenoid valve (integral) 10m cable

9 133547 Retaining clip

10 091146 Milk meter brkt assy

11 033891 Milk Meter Body Assy (Robot)

133560 Service seal kit for Afiflo 2000 milk meter

11

Ref / Pt.No: 006720


Revision: 12

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4.5 Receiver Vessel


1 092435 LH 37lt SS Rec Vsl For Enclos

092421 37lt SS Rec Vsl For Enclos-RH

2 035144 M10 Handnut

3 070218 Transparent Lid(FP Logo)

4 071314 Lid Seal(For 070218)

5 003245 1 1/4"SS Clamped Coupling

6 092382 Sampler Body

7 030437 36nb(Blue Sil)Rbr Elbow

8 030206 36nb Strt Rbr Connector

9 193971 Sensor Cable 5m + Skt 90deg

10 193970 Capactive Liquid Level Sensor

11 092369 Sampler Connection Nipple

1

2

5

6

7 8

9

10

11

Ref / Pt.No: 006720


Revision: 12

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4.6 Servac


1 045263 Servac 3500 Assy

2 045234 Air Cleaner Element

3 045223 Diaphragm

4 045251 Pilot Valve

5 007631 25.3 odx22.1 id "O" Ring

6 007617 6 odx3 id "O" Ring

7 045208 Main Diaphragm(Silicone)

045277 Servac Regulator Service Kit Contains items 2-6

1

2

3

4

5

6

7

Ref / Pt.No: 006720


Revision: 12

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4.7 Sanitary Trap


1 092434 LH San Trap For Enclosure For left hand Merlin

1 092420 San Trap For Enclosure-RH For right hand Merlin

2 092472 Long SS Vac Conn Tube Assembly

3 003245 1 1/4"SS Clamped Coupling

4 092474 Short SS Vac Conn Tube Assembly

5 070198 Lid Washer

6 070287 Plastic Lid (With Hole)

7 032132 50mm OD (2") White Ball

8 033471 Mlk Mtr/Mlk Ln Connecting Tube

9 194170 PVC Tube S/A-S/Trap to Vac Ln

10 007339 10R1/4 BSPT Swivel Elbow

1

3

5

6

7

4

8

2

9

10

Ref / Pt.No: 006720


Revision: 12

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4.8 Blood Sensor


1 094203 Blood Sensor

2 193983 Brkt-Mlk Mtr to Blood Sensor

3 193754 SS Main Manifold Assy (4:1)

4 191355 38mm Clamp

5 193988 RH Brkt Assy-Blood Sensor

6 133557 Silicone Rbr Reducing Elbow Cut to size

1

3

4

5 2

6

Ref / Pt.No: 006720


Revision: 12

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4.9 Merlin Control Box

193863

094461

094464

096086

094715

094344

094343

094335

094342

094347

094346

094345

094349

098362

2

3

1 3a

4 5 6 7

8 9 10 11

12 13 14 15

20

16 17 18 19

Ref / Pt.No: 006720


Revision: 12

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1 094417 M/C Base (094420) Rear box

2 094418 M/C Keypad Lid Flat (094421) Face panel

3 094419 M/C CLOSED LID FLAT (094422) Button panel

3a 094732 Robot Overlay

4 193863 "Z" Brkt-Back Of Display Box

5 094461 Panel Socket

6 094464 Contact Socket Solder

7 099191 Tiny Terminal K/B PCB

8 099192 Tiny Terminal Display 4Line

9 099198 Tiny Term Cntl PCB Assy

10 096086 14w Ribbon Cable

11 094715 10W IDC Fem Socket

12 094344 Operator Illum Maintained

13 094343 Operator Illum Momentary

14 094335 White Lamp Holder & Base

15 094342 Screen- Blue

16 094347 Printed Film Legend

17 094346 24v AC/DC White LED

18 094345 1 N/O Switch Block

19 094349 Switch Unit Apen A02503

20 098362 Spade 4BA/M3.5rec 0.5-1.5sq

193895 Display Box Seal To stop water ingress on the tiny terminal

Ref / Pt.No: 006720


Revision: 12

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4.10 Sampler & Shuttle


1 092378 3.18id x 6.35od Silicone Tube

2 007792 Spring Close Pneu Cyl+Silencer

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


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

6 091078 Milk Sampling Unit

7 092367 Sampling Bottle & Lid

8 092373 31mm Sample Bottle Tray

092372 23mm Sample Bottle Tray

092374 32.5mm Sample Bottle Tray

9 091057 Universal Shuttle

091058 30cc Reservoir(For 091057)

091014 50cc Reservoir(For 091057)

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

Quick release connector shuttle air supply tube

8 9

3

1

2

4

7

6

5

Ref / Pt.No: 006720


Revision: 12

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4.11 Digital Vacuum Gauge


1 045011 Digital Vacuum Gauge Not Fitted to Merlin after 04/09

006684 Digital Vacuum Gauge Manual

Ref / Pt.No: 006720


Revision: 12

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4.12 4QCM


1 092607 LH SS Tube Guide Brkt Assy

193867 RH SS Tube Guide Brkt Assy

2 193093 4QC Conductivity Sensor Flow Cell

1

2

Ref / Pt.No: 006720


Revision: 12

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4.13 Milk Pump


1 092436 SS Milk Pump(FP66)1ph

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

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

valve

092407 Rotor Seal(For FP66 Pump).

007671 FP66 Back Plate Seal.

038004 Pump Casing Seal Oring EPDM.

035571 40mm Flap Valve(FP66 Pump)

037044 150x200x75 Micron Bag

Ref / Pt.No: 006720


Revision: 12

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4.14 Milk Pump Burkett Valves

1

2

3

4

5

6

Ref / Pt.No: 006720


Revision: 12

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193310 LH Burket Valve Kit

193311 RH Burket Valve Kit

1 092900 LH Mlk Pmp Outlet+Burkert Vlv

092910 RH Mlk Pmp Outlet+Burkert Vlv

2 191355 38mm Clamp

3 091275 Diaphragm Valve 2/2 Assy(8mm)

4 091180 Diaphragm Valve Assy(Small)

5 193284 12mm Clamp

6 007310 8mm od Push In Non Return Vlv

035571 40mm Flap Valve(FP66 Pump)

193283 12mm Gasket

004819 6-6-6 Push In Tee

004843 6mm x 1/4"BSP Swivel Elbow

001893 Plstc Hose Clip 18.6-22.1

007837 1/8"-6mm Swivel Elbow

007734 1/8"BSPT-8mm SS Swivel Elbow

007878 Plastc "Y" Piece 6mm x 8mm

005056 8mm-6mm Reducer-Comp Air Tube

191352 38mm Gasket For 191355

Ref / Pt.No: 006720


Revision: 12

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5. Main Cabinet

5.1 Phoenix Enclosure

SECTION 1

SECTION 2

SECTION 3

Ref / Pt.No: 006720


Revision: 12

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SECTION 1

SECTION 2

SECTION 3

1

2

6

5

4 3

7

10

9

8

12

13

14

15

16 17

Ref / Pt.No: 006720


Revision: 12

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1 094438 Can Open ILCAN BK-TC

2 094439 Can Open IB IL 24 PWR IN-PAC

3 094440 Can Open IB IL 24 DI2-PAC

4 094441 Can Open IB IL 24 DO 16

5 094442 Can Open FLKM 14-PA-INLINE/OUT

6 094443 Can Open Cable

7 094444 Relay PLC-BSC-24DC/21HC & Base

8 094445 Relay PLC-V8L/FLK14/OUT

9 094446 Relay PLC-BSC-24DC/21 & Base

10 094427 Relay-PLC-V8/FLK14/Out

11 094430 Relay-PLC-ATP B

Ref / Pt.No: 006720


Revision: 12

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12 094456 Relay Phoenix 2961105

13 094459 12A Relay

14 094447 Input PLC-VT/LA

15 094448 Fuse Holder ST4-FSI/C-LED24

16 094449 3a Fuse (RS493-6969)

17 094450 5a Fuse

Ref / Pt.No: 006720


Revision: 12

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5.2 Festo Enclosure


1 107420 Air Prep/Dump Vlv (One gauge)

2 107422 Distribution (6) M/Fold

3 094435 Mounting Plate OMP4060

4 107419 Air Prep M/Fold (Two gauges)

4a 107684 Pressure Switch Connector Plastic cap for 107419

4b 107683 Pressure Switch

5 107540 Can Open Valve Terminal

6 007878 Plastc "Y" Piece 6mm x 8mm

7 004767 10-8mm pipe reducer, TRPB10-8

8 094435 Mounting Plate OMP4060

107406 10mm Blue PUNH Tube>

107405 8mm Blue Tube>

094434 600x400x132 Encls CPCF406013T

1

2

4

5

3

7

6

4a

8

4b

Ref / Pt.No: 006720


Revision: 12

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5.3 Electrical Enclosure

INSIDE ENCLOSURE

Section 1

Section 2

Ref / Pt.No: 006720


Revision: 12

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SECTION 1

SECTION 2


1 094260 Plugtrab Unit-Surge Suppressor

2 094286 24V Relay(6012.9024.0040)

3 094428 Contact-QUINT-PS-100-240AC

4 094291 Soft Start Unit(ATS01N125FT)

5 094274 Overload (LRD10)

6 094272 Contactor (LC1D09BD)

7 094294 RCCB's(C60HC16R30)

8 094270 Safety Relay(ESM-BA303) Check which one fitted prior to ordering 8a 094255 Safety Relay Pilz Unit (PNOZ)

9 094313 Toiroidal Transformer-Lintron

10 094265 Fuse Terminal

11 094266 Link Terminal

12 094267 25A Fuse Terminal

13 094452 Transformer 1ph 240/24vAC 50va

14 098109 Transformer 75va 26v 50/60HZ

097702 Fuse 6.3at 20x5 A/S Glass

063748 Fuse 10a Qb Glass 1 1/4x1/4

094666 Fuse HRC Ceramic 5x20 4A F

094665 Fuse HRC Ceramic 5x20 2A F

10

9

11

12

13

14

1 8/8a

5

6

7

4

2

3

Ref / Pt.No: 006720


Revision: 12

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5.4 Chemical Dosing Pumps

Large pump Small pump

003570 003571 071696

8 13 12 11 9

14

10

1 2

3

4

5

6

7

Ref / Pt.No: 006720


Revision: 12

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1 007776 Peristaltic 24vDC Pmp 175rpm

2 193830 Peristaltic 24vDC Pump

3 007780 8mm x 2.4mm Autoprene Tube

4 001954 Herbie Clip Size E

5 091899 10mm Dbl.Ended Chemical Nipple

6 004797 Tube Spare 4.8mm

7 001907 Plstc Hose Clip 9.2-10.8

8 007779 Pump Front Cover

9 007777 Rotor/Roller Assy

10 007778 Pump Housing

11 007781 Housing (Screw On)

12 007782 Rotor For Autoprene

13 054088 Backplate For M550 Peristl Pmp

14 004780 Footvalve (NON RETURN)

Ref / Pt.No: 006720


Revision: 12

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5.5 Teat Spray Motor


193641 Air Driven Pump(20LPM 6.9BAR)

1A 193642 Viton Check Valve

2A 193643 Viton Diaphragm Kit

3A 054112 Shaft/Slide Valve Assy Kit

4 054113 Flange/Housing Kit

5 054114 Endcaps Kit

6 054115 Hardware Kit

7 054116 Grommet Kit 4 of 91004000


A 193651 Flojet Inlet Strainer To prevent foreign particles being drawn up into the Pump

A

Ref / Pt.No: 006720


Revision: 12

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5.6 Fusion Enclosure

IDEAL

UCC

4QC

Ref / Pt.No: 006720


Revision: 12

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1 133534 Ideal PCB + Display(Fullwood)


2 099714 FwCC PCB Excl RF Unit


3 193123 4QC Top&Bottom PCB f191c/f192d

193124 4QC Bottom Analog PCB f192d

1

3

2

Ref / Pt.No: 006720


Revision: 12

July 2013

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5.7 Wash Chamber & Burkett Valves


1 193911 RH Chemical Mixer Box Assy

193910 LH Chemical Mixer Box Assy

2 003327 1/2"BSP SS 316 End Cap

3 091088 2002 Compact Piston Vlv 2/2

091049 Seal Kit (643438D)

091050 Pnu Service Kit For Actuator

4 092614 Dia Vlv(Con To Btm Mix Chamb)

5 003329 1/2"BSP SS 316 Locknut

6 003568 16id/23od Reinfd Poly Hose Clr

7 070290 16x25 Hose Clip S.S

8 003336 1"-1 1/2"SS Clamp

003335 1"EPDM Seal (Clamp Fitting)

9 091258 Diaphragm Valve 2/2 Assy(15mm)

1 2

5 6

7

8

9

3

4

Ref / Pt.No: 006720


Revision: 12

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5.8 Burkett Valves on Side Panel


1 091122 2031Compact Dia(15)Vlv 2/2 Way

091053 Diaphragm Service Kit


2 091119 2031Compact Dia(8)Vlv 2/2 Way


091052 Diaphragm Service Kit


4 007837 1/8"-6mm Swivel Elbow on all 3 valves

1

2

3

4

1

Ref / Pt.No: 006720


Revision: 12

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1 091088 2002 Compact Piston Vlv 2/2

091049 Seal Kit (643438D)


2 092411 T3P 15mm x 1/2"BSP Male Conntr

3 055641 15mm Copper Tube

4 003568 16id/23od Reinfd Poly Hose Clr

5 070290 16x25 Hose Clip S.S

1

2

3

4

5

Ref / Pt.No: 006720


Revision: 12

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5.9 Re-classifier


1 107423 Re-Classifier Complete assembly

2 107439 Cartridge FFPU-1/2 for 107423

1

2

Ref / Pt.No: 006720


Revision: 12

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5.10 Flow Control


1 092757 Flow Control Valve Bracket

2 007903 Flow Cntl (3250X)

3 107421 Collection(4) M/Fold

4 007970 1/8"-6mm Push In Elbow

1

2

4

3

Ref / Pt.No: 006720


Revision: 12

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5.11 Tyco Valves

1.091018


1 193940 Bearing

2 193941 O-ring

3 193942 O-ring

4 193943 Valve Seat

5 193944 O-ring

6 193945 Distance Sleeve

7 038069 "O"Ring 21,82x3,53NBR 90 Shore

8 193947 Connecting Piece

193948 O-Ring Sevice Kit Contains items: 2 x items 3,7,5,2 & 1 off item 8

1

1 2

3

4

5

6

7 8

Ref / Pt.No: 006720


Revision: 12

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5.12 APV Butterfly Valve


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

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

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

3 092578 SS Saddle Short Brkt Assy Back half

091176 SS Saddle Front half

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

5 070290 16x25 Hose Clip S.S


1

3

4

2

5 6

TO MILK PUMP

Ref / Pt.No: 006720


Revision: 12

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5.13 Compressed Air Filter


1 107661 LF-3/8-D-5M-Mini-A Filter

2 107658 QSL-3/8-10 Swivel Elbow

3 004840 10mmx3/8BSP Male Connector.

4 107379 Mntg Brkt HFOE-D-MINI

000355 M4x10 Socket Cap SS Screw


001519 M4 Washer SS (Form A)

1

2

3

4

Ref / Pt.No: 006720


Revision: 12

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6. Feeding

6.1 Feeder Assembly


1 092363 Feeding Module Surround(Pedo) Pedometer

1 092338 I.D. Surround Assy Tiris

2 091840 SS Manger Pan Assy

1

2

Ref / Pt.No: 006720


Revision: 12

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6.2 Feeder Motors & Hoppers


1 191170 SS Small Hopper Assy

1 193900 Robot Large Hopper Assy

2 191057 SS Funnel Assy

3 191079 SS Food Chute Assy

4 003532 3"id Colex Tube (Ref GVH300)

5 040041 High Powered 24v DC Motor

6 007636 V20 Face Seal

7 065236 Washer

8 001938 3/16"dia x2"Lg Sellock Pin

9 066347 Auger & Shaft S/Assy

1 2

3

4

5

9

6

7

8

Ref / Pt.No: 006720


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7. External Equipment

7.1 Alarm Unit


1 094646 Robot FIC Alarm 861515

1

Ref / Pt.No: 006720


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7.2 Extension Boards & Identification Controllers


1 098918 4 In/Out Board Assy

2 098929 16 Chnl I/P PCB Complete

3 099182 FAM8 Channel PCB


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

099803 Fullwood ArchwayCntlr(FwAC)W/F Wireless

1 2

3

4

Ref / Pt.No: 006720


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

099804 Fullwood Activity Adp(FwAA)W/F

5

Ref / Pt.No: 006720


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7.3 Delivery Line Parts


1 003360 Din20 SS Expansion Union-22mm

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

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

4 007161 22id x 60od Pipe Insulation

003704 22mm-Expanding Tool

For fitting the 22mm expansion union

1 2

3 4

Ref / Pt.No: 006720


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7.4 Bulk Tank Connections


1 138161 NW50 (50mm Ø thread on tank outlet) The part numbered set consists of; milk inlet piece and adapter elbows (rubber Ø 50) for the cleaning pump suction line.

138162 NW65 (65mm Ø thread on tank outlet)


2 138159 NW50 (50mm Ø thread on tank outlet)



3 091089 20mm APV Delta S23 C/O Valve

130014 Set of gaskets APV valve

20944 Seal NW50

20945 Seal NW65

20946 Seal NW80

NOTE: Every Merlin installation requires a connection piece to allow the milk supply from the Merlin to enter through the bottom of the Bulk tank. This connection is placed between the butterfly valve and the Bulk tank. A 22mm tube is welded onto the connection to allow the fitting of a three way APV valve. (An APV valve is provided with each new Merlin).

The NW size should be the same as the butterfly valve on the tank. Older tanks will mainly have NW50 while new tanks are equipped with NW65 or NW80. Other connections have to be produced on demand. (SMS, RJT, DS)

The part numbers relate to Packo tanks, but the outlet thread type on most manufactures bulk tanks are the same.

NOTE: When ordering always specify milk cooling tank type AND serial number.

Ref / Pt.No: 006720


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7.5 Tube Coolers & Plate Coolers


1 0/207727 Single stage cooler with straight tube connection

25mm milk line

0/200928 Single stage cooler with straight tube connection

32mm milk line


38mm milk line


40mm milk line


40mm milk line with bypass for quick draining

0/210634 Single stage cooler with NW connection 20 NW (Din 11851)




0/207353 Single stage cooler with SMS connection 25mm SMS connection

0/200697 Double stage cooler with straight tube connection

40mm milk line

0/200167 Double stage cooler with straight tube connection

40mm milk line with bypass for quick draining

239/220047

NW (Din 11851) Connection kit

239/220048


239/220049


239/220050


1

Ref / Pt.No: 006720


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2 074460 Single stage plate cooler 1200 Litres/hour Model G.28ZT.16

074461 Single stage plate cooler 1800 Litres/hour Model G.28ZT.22




074465 Two stage plate cooler 1200 Litres/hour Model G.28ZT.16/12





NOTE: A singe stage cooler uses mains or well water to reduce the temperature of the milk, a two stage or double cooler uses mains/well water and iced water to reduce the temperature of the milk.

2

Ref / Pt.No: 006720


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8. Milk Rejection Unit


1 193723 Mlk Seperation Cntl Box Assy

2 007733 1/8"BSP-6mm SS Male StudElbow

3 193691 Support Frame Assy

107512 , Sckt Conn Cable-KMYZ-9-24-2.5

3

2

1

Ref / Pt.No: 006720


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1 193720 Clamp Bush/Pivot Arm Assy

2 007933 6-4 Reducer


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

5 107477 Valve CPE10-M1H-3GL-M7

6 107517 UC-M7 Silencer

7 005004 4mm equal tee JP B

8 107552 Pneu. Service Unit

9 107550 Non-Return Valve

10 107503 One-Way Flow Cntl Vlv

1

2 3

4

5 6

7

8

9

10

Ref / Pt.No: 006720


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1 107496 Prox Sensor(SME-8-K-LED-24)

2 005868 20mm Flexible Conduit

3 107494 DNC-32-160-PPV-A Cylinder

1

2

3

Ref / Pt.No: 006720


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8.1 Milk Separation Control Box 193723


1 005813 Enc.Plstc 289x239x107 IP65

2 094438 Can Open ILCAN BK-TC

3 064488 Lamp Holder Red,6.35mm Tab Con

4 005179 Push Switch Black SPDT

098042 Bulb Mes 24v 1.2w For above item

5 094425 4 Input Slices

6 094426 4 Output Slice

7 094662 Din Feed Thro Term Red

8 094439 Can Open IB IL 24 PWR IN-PAC

9 005704 Hex Nut 20mm Conduit

10 003519 20mm Flex Cond/Gland For 05176

11 094425 4 Input Slices

12 094426 4 Output Slice

13 005871 Blue Term. Block

005164 Yellow Ferrule(1.0mmSQ)

005163 Orange Ferrule(0.5mmSQ)

2

1

3

4

7

8

9

11

12

13 10

Ref / Pt.No: 006720


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9. Chemicals


1 114060 20lt ABW Cleaner

2 092166 20Lt Drum MIP AC (Supajet)

3 114010 25lts F/C RTU Teat Dip

4 114014 Farmcare Dairy Hypochlorite

Ref / Pt.No: 006720


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10. Miscellaneous

10.1 Safety/Warning Labels


1 093870 M/C Starts Without Warng Label

2 093871 Dangerous M/C Warning Label

3 093872 Do Not Reach Over M/C Warn Lbl

4 093873 Do Not Remove Guard Warng Lbl

5 093874 Restricted Access Warning Lbl

6 093875 Dangerous Chemicals Warng Lbl

7 093877 Hot Surface Warning Label

8 006460 Merlin Label (PVC)

1 2

4 3

6

7

5

8

Ref / Pt.No: 006720


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10.2 Overlays


1 094730 Overlay (Replacement)

2 094732 Robot Overlay

3 094347 Printed Film Legend

1

2

3

Ref / Pt.No: 006720


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10.3 Sensors


1 007954 Ultrasonic Sensor

2 007466 Double block sensor

3 007437 Sensor & Cable-NRS4 P12PA370

4 194274 Pressure Switch(PX7009) 007768 - no longer available as a spare part – for fitting please refer to 006855

5 094628 Reflective Photo Sensor EQ-501

6 193071 Flow Sensor Assy

7 193970 Capactive Liquid Level Sensor

8 193971 Sensor Cable 5m + Skt 90deg

1 2 3

4 5 6

7 8

Ref / Pt.No: 006720


Revision: 12

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10.4 Silicon Tubes


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

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

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

4 030343 Tube 13.5/20mt/23.8 od Rbr

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

1

2

3

4

5

Ref / Pt.No: 006720


Revision: 12

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10.5 Air Tubes



2 107405 8mm Blue Tube

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

4 107406 10mm Blue PUNH Tube>

1

2

3

4

Ref / Pt.No: 006720


Revision: 12

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11. Spares Kits

All kits in this section can be purchased under the codes provided.

11.1 116359, Merlin Spares; liners & shells

Part No Description Qty

092264 4mm ACR Rope (2mt Long) 24

007663 "O" Ring 37.82x1.7 24

092804 MK3 Vac/Milk Chamber(15.5Cone) 4

007670 "O" Ring 10id x 2 Section 24

092259 Rope End Cover 4

007417 ACR Rope Guide 4

091289 Liner Gauge 11mm 1

091369 Liner Gauge 12.5mm 1

092677 MK2 FL7 White Nylon Shell 8

11.2 116360, Merlin Spares; silicon tubes


030328 Sil Tube 9.1nb/20mt/18 od Rbr 20

030312 Sil Tube 12nb/20mt/21od 20

030333 Sil Tube 19nb/10mt/31.8 od Rbr 5

11.3 116361, Merlin Spares; air fittings


007839 1/4"-6mm Short Elbow 2

007314 4mm Equal Union Connector 2



007964 M5x6mm Push In Strt Conn 2

007837 1/8"-6mm Swivel Elbow *** 2

005036 R1/8"-4mm Straight Connec *** 2

007871 1/8"x4mm SS Male Elbow *** 2

005003 4mm x M5 Male Connector *** 2

007869 G1/8"x4mm SS Straight Conn *** 2

005027 4mm x 1/4"BSP Swivel Elbow 2

005066 6mm Bulkhead Union(3116 06 00) 2

004819 6-6-6 Push In Tee.*** 2

007310 8mm od Push In Non Return Vlv 2

004828 1/8"BSP-6mm Straight Connector 2

Ref / Pt.No: 006720


Revision: 12

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11.4 116362, Merlin Spares; bolts


000590 M5x12 SS Hex Hd Setscrew 4

000389 1/4"BSW x 1/2" Skt Grubscrew 4

000452 M16x40 Socket Cap SS Screw 4

000447 M6x16 Hex Hd SS Setscrew 4

000460 M6x16 Socket Csk Hd SS Scw 4








000370 M5x16 Chs Hd SS M/C Screw 4


000472 M4x8 Csk Slot SS M/C Scw 4



000365 M6x10 Socket Csk SS Screw 4




000357 M6x16 SS Butn/Hd Sckt Scw 4

000356 M6x35 Csk Hd SS M/C Screw 4


000423 M6x25 Hex Hd SS Screw 4

000074 M16x55 Hex Hd SS Bolt 4


000462 M8x16 Socket Csk SS S/Scw 4

000473 M3x12 C/Hd Slot SS M/C Scw 4

000470 M4x6 Csk Slot SS M/C Scw 4

000455 M4x20 CH Hd SS M/C Screw 4

000073 M10x120 Hex Hd SS Bolt 4

11.5 116363, Merlin Spares; nuts


001151 M12 Nyloc Nut-SS 4

001292 M5 Nyloc Nut SS 4

001160 M12 SS Full Nut 4

001162 M14 SS Full Nut 4

001159 M8 SS Nyloc Nut 4




001154 M4 SS Hex Nut 4

Ref / Pt.No: 006720


Revision: 12

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11.6 116364, Merlin Spares; washers


001628 M12 SS Penny Washer 4

007112 M6 SS Grease Nipple 4

001629 M5 SS Washer Form A 4



001627 M8 SS Locking Washer (Pair) 4

007940 Nylon Washer 4

001691 M8 Nylon Washer 17od 1.6t 4

11.7 116365, Merlin Spares; roll pins


001941 6Dia x 45 SS Roll Pin 4

001945 6Dia x 30 SS Roll Pin 4

11.8 116366, Merlin Spares; split pins


001947 2Dia x 16 SS Split Pin 4

11.9 116367, Merlin Spares; circlips


001769 M6x0.7 SS Circlip 4

11.10 116368, Merlin Spares; jetters


092447 Jetter Cup 4

092445 Sltd Jetter Nipple Assy 4

092448 Jetter Rubber 4

053000 Jetter Claw 1

11.11 116369, Merlin Spares; jubilee clips


001895 12-20x9 Wide SS Jubilee Clip 12

070290 16x25 Hose Clip S.S *** 12

Ref / Pt.No: 006720


Revision: 12

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11.12 116370, Merlin Spares; sensors


007954 Ultrasonic Sensor 1

007466 Double block sensor 1

007437 Sensor & Cable-NRS4 P12PA370 * 1

007768 Roxspur Vacuum Sensor+"O"Ring 2

094628 Reflective Photo Sensor EQ-501 1

193071 Flow Sensor Assy 2

094848 Level Sensor LL103101-2 2

193970 Capactive Liquid Level Sensor 2

193971 Sensor Cable 5m + Skt 90deg 2

11.13 116371, Merlin Spares; pulsator


042915 Legato Merlin 24vDC 1

042923 External Air Filter Housing. 1

042917 Legato Lead Merlin 2cMale 10mt 1

042924 Legato Service Kit-5000 1

11.14 116372, Merlin Spares; bearings


007412 Bearing 61904 ZZ s/steel 2

007459 Bearing W61804-2RSI *** 2

091651 Long Spindle 2

193401 Bronze Bearing 18/25x16 4

11.15 116373, Merlin Spares; springs


002950 Pressure Spring 1

002956 SS Pull Spring 1

002951 48 Coil Compression Spring 2

002952 118 Coil Compression Spring 2

11.16 116374, Merlin Spares; milk pump


193290 MK2 Rotor Cover+FP66 Pump 1

035571 40mm Flap Valve(FP66 Pump) 5

035144 M10 Handnut 2

007671 FP66 Back Plate Seal. 5

038004 Pump Casing Seal Oring EPDM. 5

092407 Rotor Seal(For FP66 Pump). 5

Ref / Pt.No: 006720


Revision: 12

July 2013

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11.17 116375, Merlin Spares; arm electrical


094697 Crimp Contact 5556TL Female 25

094698 2W Mini Fit Rec 5557-02R 1

094699 2W Mini Fit Plug 5559-02P 1

094701 18W Mini Fit Recept 5557-18R 1

094702 3W Term Housing 6471031 1

094703 5W Term Housing 6471051 1

094704 7W Term Housing 6471071 1

094705 8W Term Housing 6471081 1

094706 9W Term Housing 6471091 1

094707 10W Term Housing 6471101 1

094708 12W Term Housing 6471121 1

094709 17W Term Housing 6471171 1

094710 20W Term Housing 6471201 1

094711 6w Molex Housing 9503061 1

094712 Crimp Terminals 4809 P914L 100

094714 14W IDC Fem Socket 1



094760 14w Term Block 6471141 1

094761 18w Term Block 6471181 1

094762 24w Term Block 6471241 1

094745 4w Term Housing 6471041 1

095016 Pre"A" Multicore"4" Cable Assy 1

11.18 116376, Merlin Spares; pneumatic vlvs


091018 Tyco 20mm Miniflow C/O Valve 1

091088 2002 Compact Piston Vlv 2/2 1

091122 2031Compact Dia(15)Vlv 2/2 Way 1

091119 2031Compact Dia(8)Vlv 2/2 Way 1

092595 1 1/2"Dia SS Butterfly Vlv Asy 1

091048 EPDM Seal For Series 5 BF Vlv 1

092901 Burket Valve 20dia 8bar 4

11.19 116377, Merlin Spares; teat rollers


091958 C'sk Fabric Cover Retaing Ring 4

091066 V910 Pneu Motor 1

092395 Roller Brush (Full Bristle) 2

092492 Roller Brush (Half Bristle) 2

007460 20x30x7 CC NBR Oil Seal *** 4

Ref / Pt.No: 006720


Revision: 12

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11.20 116378, Merlin Spares; overlays


094730 Overlay (Replacement) 1

094732 Robot Overlay 1

11.21 116379, Merlin Spares; miscellaneous


007852 Rubber cable clamp 2

007418 30x17x3 Nylon Ring *** 2

005110 Lk2a Plastic Cable Tie 100

007465 Drive Roller 1

007466 Double block sensor 2

061810 Mk2 24vDC Motor Assy 1

030206 36nb Strt Rbr Connector 1

022105 12.5nb x 60deg Bend [U1cpm] 4

033471 Mlk Mtr/Mlk Ln Connecting Tube 1

070198 Lid Washer 1

070287 Plastic Lid (With Hole) 1

007668 "O" Ring 146id x 2 Section *** 4

094753 Emegy Stop Swtch Red a02mxb22m 1

094754 Switch Block a02502 n/c 1

005162 Blue Ferrule(2.5mmSQ)458-780 20

005164 Yellow Ferrule(1.0mmSQ) 20

094849 Enclosure Assy 1

007816 Cable Block 1

193404 FTL Plastic Bush 4

091791 SS Bush 2

045277 Servac Regulator Service Kit 4

11.22 116380, Merlin Spares; roof box


094662 Din Feed Thro Term Red 2

094663 Din Feed Thro Term Black 2

094322 Relay Base DPCO(RS 353-966) 2

094329 24vDC Relay DPCO G2R-2-SN 2

11.23 116381, Merlin Spares; large pump


007776 Peristaltic 24vDC Pmp 175rpm

007779 Pump Front Cover

007780 8mm x 2.4mm Autoprene Tube

007777 Rotor/Roller Assy

007778 Pump Housing

Ref / Pt.No: 006720


Revision: 12

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11.24 116382, Merlin Spares; small pump


193830 Peristaltic 24vDC Pump 1

007781 Housing (Screw On) 1

007782 Rotor For Autoprene 1

004797 Tube Spare 4.8mm 1

007781 Housing (Screw On) 1

004780 Footvalve (NON RETURN) 2

054088 Backplate For M550 Peristl Pmp 1

11.25 116383, Merlin Spares; teat spray pump


193641 Air Driven Pump(20LPM 6.9BAR) 1

007773 Spray Nozzle 1

091896 Jet Removal Tool Assy 1

11.26 116385, Merlin Spares; foremilk manifold


092898 11mm Polypropylene Ball 4

092899 18mm 55 Shore Natl Sil Ball 4

193752 90deg Rubber Bend 4

193745 LH End Plate S/Assy 1

193746 RH End Plate S/Assy 1

193739 Ball Chamber-Spare(Coarse) 4

193742 LH Manifold Body 1

193743 RH Manifold Body 1

193749 Rejection Manifold Gasket 4

11.27 116386, Merlin Spares; Arm PCBs


094793 Laser Card Kit 1

094770 Rbt PCB CP-10(Spare) 1

094771 Rbt PCB MELK-3 9.1185.0565.2 1

094772 Rbt PCB Robot-3 9.1185.0564.1 1

094623 Rbt PCB GSD15/CAL-1 1

094590 PCB (BPI0SD-15/B) 1

094778 Rbt PCB PM-VD24/F PSU 1

094779 Rbt PCB KBDP-2(Spare) 1

094782 Rbt PCB LIA-3 9.1185.0540.5 1

094783 Rbt PCB CDAP2 5.1002.2917 MK3 1

Ref / Pt.No: 006720


Revision: 12

July 2013

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11.28 116387, Merlin Spares; Fusion PCBs


099714 FwCC PCB Excl RF Unit 1

133534 Ideal PCB + Display(Fullwood) 1

193123 4QC Top&Bottom PCB f191c/f192d 1

193125 4QC Flow Cells(Factory Fit) 1

193093 4QC Conducty Sensor Flow Cell 2

099207 Merlin Level Sensor PCB 1

099716 USB-RS485 Convertor 1

099191 Tiny Terminal K/B PCB 1

099192 Tiny Terminal Display 4Line 1

099198 Tiny Term Cntl PCB Assy 1

094748 TT/FDS Ribbon Loom 1

033573 Antennae(Low Freq)Blue 1

11.29 116388, Merlin Spares; Festo cylinders


107410 Mother Ship Cylinder 40/200 1

107469 Festo MK3 S-Lina 1

107412 Teat Motor Cylinder 1

107413 Shut-Off Cylinder 25/15 1

107414 Turn Cylinder 50/270 1

107416 Rear Gate Cylinder(0400) 1

107417 Front Gate Cylinder (0500) 1

107610 Cylinder DZF-25-100-A-P-A> 2

11.30 116389, Merlin Spares; Festo air ctrl


107419 Air Prep M/Fold(Two Gauges) 1

107420 Air Prep/Dump Vlv(One Gauge) 1

11.31 116390, Merlin Spares; Festo tube


107393 6od x 4id PUN-H Blue Tube 50

107405 8mm Blue Tube 10

107403 4mm Blue Tube. /mt. (50mtCoil) 10

11.32 116391, Merlin Spares; Festo CAN Block


107626 Vlv "K" Type VMPA1-M1H-K-PI 2

107627 Vlv "M" Type VMPA1-M1H-M-PI 2

Ref / Pt.No: 006720


Revision: 12

July 2013

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11.33 116392, Merlin Spares; Festo arm Block


107628 CPV Mod "M"Type CPV10-M1H-5lS 2

107629 CPV Mod "C"Type CPV10-M1H-2XGL 2

107621 Top Hat-CPV10-GE-MP-8 1

11.34 116393, Merlin Spares; Festo arm solnd


107512 Sckt Conn Cable-KMYZ-9-24-2.5 2

107624 Solnd Vlv(CPE10-M1BH-5/3G-M7-B 2

107477 Valve CPE10-M1H-3GL-M7 2

11.35 116394, Merlin Spares; Festo S-lina


107529 2/2 Valve for S-Lina 2

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

11.36 116395, Merlin Spares; Phoenix


094438 Can Open ILCAN BK-TC 1

094439 Can Open IB IL 24 PWR IN-PAC 1

094440 Can Open IB IL 24 DI2-PAC 1

094441 Can Open IB IL 24 DO 16 1

094442 Can Open FLKM 14-PA-INLINE/OUT 1

094443 Can Open Cable 1

094444 Relay PLC-BSC-24DC/21HC & Base 1

094445 Relay PLC-V8L/FLK14/OUT 1

094446 Relay PLC-BSC-24DC/21 & Base 1

094427 Relay-PLC-V8/FLK14/Out 1

094430 Relay-PLC-ATP B 1

094456 Relay Phenix 2961105 1

094459 12A Relay 10

094447 Input PLC-VT/LA 1

094448 Fuse Holder ST4-FSI/C-LED24 1

094449 3a Fuse (RS493-6969) 10

094450 5a Fuse 10

Ref / Pt.No: 006720


Revision: 12

July 2013

006720 Page 107

11.37 116396, Merlin Spares; Electrical cabt


094260 Plugtrab Unit-Surge Suppressor 1

094265 6.3A Fuse Terminal 1

094266 Link Terminal 1

094267 25A Fuse Terminal 1

094270 Safety Relay(ESM-BA303) 1

094272 Contactor (LC1D09BD) 1

094273 Contactor (LAD22) 1

094274 Overload (LRD10) 1

097702 Fuse 6.3at 20x5 A/S Glass 10

063748 Fuse 10a Qb Glass 1 1/4x1/4 10

094666 Fuse HRC Ceramic 5x20 4A F 10

094665 Fuse HRC Ceramic 5x20 2A F 10

094286 24V Relay(6012.9024.0040) 1

094291 Soft Start Unit(ATS01N125FT) 1

094294 RCCB's(C60HC16R30) 1

094428 Contact-QUINT-PS-100-240AC 1

094452 Transformer 1ph 240/24vAC 50va 1

094313 Toiroidal Transformer-Lintron 1

11.38 116397, Merlin Spares; Wash box


193673 Nozzle for Laser 1

107512 Sckt Conn Cable-KMYZ-9-24-2.5 2

107477 Valve CPE10-M1H-3GL-M7 2

007868 Type 200 Mini Solenoid V/v *** 2

11.39 116398, Merlin Spares; External


133593 Afilite Cntl Box Only 1

133503 Afiflo 2000 Body Assy(10m) 1

007337 SGT853 Stepper With Gearbox 1

045011 Digital Vacuum Gauge 1

11.40 116399, Merlin Spares; Festo Cylinder repair kit


107524 Mothership Seal Kit 1

107426 40mm Cylinder Repair Kit 1

107518 Repair Kit- 32mm CRHD cylinder 1

107322 Repair Kit [80mm Cylinder] 1

Documents

Merlin Spare Parts Manualtestpacko.businesscatalyst.com/assets/006720-merlin-2-pièces... · Ref / Pt.No: 006720 Merlin Spare Parts Manual Revision: 12 July 2013 006720 Page 11 Ref