Q3 User Manual
Contents
1. button All producer warnings are displayed the same way as the slow cooling warning In the table on pages 18 22 you can find an overview of all the warnings their settings and the description of these warnings In this table you can also find a list of possible causes and solutions 2 3 2 Regulatory Alarms When a Regulatory Alarms occurs a screen similar to the image below will appear SYSTEM POWER WAS OFF When an alarm occurs the alarm light will blink on and off The audible alarm signal will sound In order to stop the alarm tone and the alarm light the producers must acknowledge the alarm by tapping anywhere on the bar TURN OFF ALARM Dairy Cheq Q3 User Manual V2 2 October 2014 Page 9 When the bar TURN OFF ALARM is touched the following screen will be displayed SYSTEM POWER WAS OFF GO BACK TO HOME MORE INFO ON ALARM The warning sound will stop and the light will turn off All alarms are displayed the same as this POWER OUTAGE warning In the table on pages 23 24 you can find an overview of all the alarms their settings and the description of these warnings In this table you can also find a list of possible causes and solutions To go back to the main screen tap GO BACK TO HOME button This will bring you straight back to the main screen as shown on page 7 For more information related to the alarm touch the MORE INFO ON ALARM button 2 4 Changing language2. sssssesssssseen 18 3 Table 1 Overview Producer Warnings cccccesseeeeeeeeeeeseceeeeaeeeeeeeseeaeeeessaeaseeeeesaeees 20 Table 2 Overview Regulatory Alarms seeeeesssssesseeeeeeene nennen nnns 24 4 Troubleshooting ee 27 poco m 28 6 ian SOME ANC Orage MR ERE 28 rau ncs 29 6 Waste Maternal RMRNT 29 9 Warning Symbols m 29 Appendices A Technical specifications ccccceeececcesseecceeseeecceuceeseuseeecsaeeeeseuseeessugeeessageeessauseesseaes 30 Dairy Cheq Q3 User Manual V2 2 October 2014 Page 3 ain Bing 1 0 Introduction Dairy Cheq Q3 has been designed to monitor processes involved in the harvesting of milk on the farm No matter what type of operation you may have Dairy Cheq Q3 will monitor these processes accurately and reliably Dairy Cheq Q3 is a powerful management tool for the producer and will help in shipping consistently high quality milk from your farm It is also an excellent tool for the dairy processor to recognize the highest possible quality of the milk collected The Dairy Cheq Q3 monitors among other things the temperature of the milk during storage the agitation process in the tank as well as a number of cleaning conditions during the tank and pipe line cleaning processes 1 1 Disclaimer Th
3. e 5 minutes after e Check if pre milk is detected in cooler is activated tank tank temp is e Pre cooling not turned on e Check solenoids Default 27 C above 27 C 81 F Malfunction of pre cooling and valves or 80 F No Pre cooling the pre set value valves solenoids e Check coolant Setting range detected OR during 2 e Malfunction in the supply supply and or the 235 C milking tank temp or temperature of coolant temperature of the is gt 5 C 41 F water or glycol coolant when AND pipeline temp entering the pre is gt 27 C 80 F cooling system e Battery needs to Default alarm Voltage is below 2 5 e Battery drained be checked or setting at 2 5 17 Low battery yolis replaced Volts or lower e Call Dealer Note Damage to the Dairy e Check for power ri ean l shorts of the cicuit p e Breaker tripped shorts brown ONG WAON e Lighting strike close to the pecan UIS DACKEN outs Power was off between 30 seconds dedi at the side panel lightning and 5 hours ind e Use generator S A POWEN ee according to the bise v malfunctions proper procedures of generators are not covered under warranty Dairy Cheq Q3 User Manual V2 2 October 2014 Page 23 CRY ing 3 Table 2 Overview Regulatory Alarm un of More details Possible causes Possible solutions T Regio Alarm e Milk temperature has been Canadian Regulations 5 C e Check if cooler is over 5 0 C Canadian T Regulations 45 F runn
4. Page 22 e Maximum conductivity detergent was less than than set value Default 20 No pipe wash detected within 1 hour of the end of milking Temp reading has been too high or too low for 15 minutes gt 85 C or lt 5 C OR Sensor has failed 18 hrs have passed since last pipeline wash Temperature reading gt 85 C 185 F or lt 5 C 23 F for 15 minutes No change in sensor reading for 24 hours During 1st milking if milk temperature is gt 14 C 57 F after 30 minutes after the tank sensor detects milk and there was not a 0 5 C 0 8 C within the last 10 minutes OR tank temperature gt 45 F for more than 15 minutes without agitation e Detergent barrel empty e Pinched hose e Hole on line e Fuse blown automatic washer e Orientation of sensor cup and sensor probes e Dirty probes i e calcium build up e Broken or nicked wire e Wash was not initiated e Power Outage e Malfunction of pump e Delayed pipe wash due to increased milking time e Skipped pipeline wash e Pipeline wash started but system trapped out prior to circulation e Faulty diverter valve dumped wash cycle prior e Elbow plugged up with debries e Sticky switch milk oil water e Partly or complete sheered wire e Sensor part breakdown e Cooling not switch on by the operator milker e Malfunction of cooling equipment e Inefficient or no airflow through the radiator e Agitation
5. always observe the safety measures When using the side door of the main enclosure do close right after the required procedures are finished General safety In the event of repairs to Dairy Cheq Q3 big or small remember the following warning Always turn the main power supply of the Dairy Cheq Q3 off before doing any work on the unit 6 Transport and storage During transport and storage the equipment must be adequately packed i e impact resistant and protected against moisture dust or other harmful substances The minimum storage conditions are as follows e Clean and dust free environment e Away from caustic and corrosive substances and gases e Air humidity between 10 and 90 Any transport and storage activities other than ordered by Dairy Cheq are at the owner s risk and are not covered by the Dairy Cheq warranty Page 28 Dairy Cheq Q3 User Manual V2 2 October 2014 7 Maintenance For maintenance of Dairy Cheq Q3 please observe the following general rules e Keep the area for Dairy Cheq Q3 frost free e Keep the area clean and dust free e Keep the air humidity between 10 and 90 Make sure the area is properly ventilated keeping the electrical parts dry e Make sure that all components remain dry and avoid splashing water and dirt e Keep Dairy Cheq Q3 away from caustic or corrosive agents e Do not clean Dairy Cheq Q3 with running water use a damp cloth instead e Your dealer will be able to give profess
6. Too much d O e Timer mechanism of e Service agitation 300 min agitation pial waa nl agitator is bad causing system Setting range Bir beeveenanilin agitation to stay on e Check proper 10 900 min 9 Manual Switch is on fucnctioning of the periods anlar e Tank washing was not Siarinewash ee e Check functioning Default 80 Tank empty too passed since milk e Tank washing was oidhsswaekRerune ire long without was picked up and initiated but washer s Checltunchonm Setting range washing tank wash has not malfunctioned of the Sica 12 100 hrs l started yet e Circulation pump Him malfunctioned ili Pending on e Detergent barrel empt B oss pty e Check supply the type of s Hole on line barrels soap and the e Maximum e Check equipment instructions of e Fuse blown automatic l conductivity of hot e Clean probes with the soap Insufficient soap washer l 7 duin danteuash wash cycle was EE E R Ont SEnSOP EU soft brush if supplier g less than set value a h diss P needed settings value Default 20 coal ar Ic e Check wiring from should be e Dirty probes i e calcium concorto the Q3 over 25 after build up unit a successful e Broken or nicked wire wash Dairy Cheq Q3 User Manual V2 2 October 2014 Page 21 Insufficient soap during pipe wash No Pipeline cleaning detected Tank 1 sensor fault detected No pipe wash detected Pipe 1 sensor fault detected Vacuum sensor fault detected No cooling detected
7. V2 2 October 2014 Page 5 fern ang Dairy Cheq Q3 can monitor the following processes based on the sensors installed e The cooling of the milk during and after milking e The temperature of wash cycles for both the pipeline s and the tank s e The functionality of the plate cooler s e The agitation processes in the tank e An indication of detergent in the wash water All these signals are logged and stored in the internal memory These processes are monitored and compared to the boundaries that are established by settings in the unit When boundaries are crossed Dairy Cheg Q3 will generate either a producer warning or a regulatory alarm These are explained in chapter 2 3 2 1 Initial Start up of the Dairy Cheq Q3 When Dairy Cheq Q3 is installed a certified Dairy Cheq Technician installs the sensors and calibrates the tank sensor When you first turn on and begin using the Dairy Cheq Q3 calibration has already been conducted by the technician and processes will be monitored The unit is designed to monitor your milking processes 24 7 all year around Therefore the power needs to remain on at all times If power is lost due to a power outage or a breaker fault in the main hydro panel the unit will start up automatically when power resumes and or breaker is reset assuming it wasn t turned off When power resumes the screen will show a little figurine on the top left corner the Linux Penguin which indicates that the u
8. ess ec ents RT 4 SESS 4 Z OPC lal OWN NNRTERERRTNENR nm 5 20 CCN Kal LM ORM HOM METRE TUTTI UU TT 5 2 1 Initial start up of the Dairy Cheq Q3 ccccccceccceeeeeeseeeeeeeeeeessaaeeeeeeeeeeeseaas 6 2 2 The Home Main Screen cccccseeecceccceeseceeeceeeeeeeeeceeeeeceeeesaueeeeesseaneeeseeaaages 7 2 3 Producer Warnings and Regulatory Alarms ccccccccccscccsssssssssssseeeeeeeeeeeeeees 8 2 9 7 Producer Warnings aestu orte iad ii 8 2 3 2 Regulatory Alarms ccccccccccssseeccceseeecceseeecseseecseseeeseaseeessageeessaeees 9 2 4 Changing Language cccccceece cece eee e eee e ence eeeeeneeeeeeeaeeeaeeae nnns 10 2 Mem CGO O MTM ee eR cere ne A 11 2 5 1 FICKUD RODO cis c cpacxaueriscananchone tantvsncincauans a e a raaa ani 11 ZRSEAVI tau 12 20 Alani HITOY M ES 12 2 5 4 Data and Reports osos cviuds ciega due aceieatantsisumiaenadccnasadiavsandiancunmasine 13 2x OF CIN aesctietgec arden esas ucunhoctg asacatn tec tvesnesb see see EE 13 2 5 6 Changing date and timMe ccccccccccesseeeeeeeeeeeeeeeeseaeeeeeeeeseaeeeeeeesaaess 15 Overview Producer setting menu chart ccc cece eee eee cece eeaeeeeeeaeeeaes 16 2 0 Other Te d EOS ocdeicncosusaiinctieen cus ETna haus bee duin opua Na abate nad Note a eaer iiei 17 E su IO GOI RN EURO 17 2 Operation with Milking Robots
9. in the main screen The language can be changed by tapping the language icon The next screen will be displayed as follows o c Te 45 9 3 6 LAST TANK WASH 54 4 C b d English A MILK IN TANK CURRENT TANK TEMPERATURE LAST PIPE WASH PREV NEXT c E g Pickup Report Sensors Alarm History Data and Reports Settings Mon Jan 6 11 32 AM Tap on the up or down button to find the language required English French or Spanish and tap SAVE SETTING to save your selection and bring you back to the main screen Tapping the CANCEL button will return you to the main screen without saving changes Page 10 Dairy Cheq Q3 User Manual V2 2 October 2014 2 5 The menu icons Mon Jan 6 11 32 AM T 45 9 3 6 LAST TANK WASH 54 4 C MILK IN TANK CURRENT TANK TEMPERATURE AST PIPE WASH Alarm History Data and Reports The icons on the bottom will guide you to the specific menus as mentioned The five menus contain the following information 2 5 1 Pickup Report Menu Pickup Report provides the following information for the Bulk Tank Milk Grader e current temperature of the milk in the tank e wash temperatures of both pipeline and tank e any Regulatory Alarms that occurred during the harvest of this tank of milk Driver Pickup Report TANK ONE C 3 6 ALARM TYPE Date Time MILK IN TANK SS ao See Milk too warm Apr 27 9 45AM 45 9 C LAST TANK WASH 54 4 C
10. 2 hours Ure eee of the end of milking MILK TOO WARM IN TANK 1 APR 27 11 24 AM Rian oaned Dn 11 24AM Apr 27 2012 Acknowledged At Note 8 45PM Apr 27 2012 Condition Cleared At 5 31PM Apr 28 2012 Alarm Length 20hrs 15 min Cc C 8 Maximum Milk Temperature 14 3C Tapping the ADD A NOTE button will display the keyboard screen so that notes can be added for a particular alarm or warning j BACK C Alarm Information B ist Forgot to turn on cooler because a calf was bom during making MILK TOO WARM Milk needs to be under 5C within 2 hours of the end of milking a DDOBBBBOBDBOO 8 45PM Apr 27 2012 vm DODDDOODBED 5 31PM Apr 28 2012 Mang DBSDOSSDSESBSE 20hrs 15 min pog Maximum Milk Temperature Alarm Occurred On 11 24AM Apr 27 2012 Page 12 Dairy Cheq Q3 User Manual V2 2 October 2014 ear It could be useful to add a note to this alarm for future reference In some regions it is mandatory to show corrective action against Regulatory Alarms With this function the producer can store it right on their Dairy Cheq Q3 If an audit takes place and the Regulatory Alarms are downloaded the notes belonging to the Regulatory Alarms will be shown conveniently beside the specific Regulatory Alarms With Dairy Cheq Q3 Data Analyzer software you can easily download the information stored in Q3 Using the USB port located on the side panel of Q3 you can transfer data to your PC to review all your
11. Blend 2 temperature too high Time evaluation time range 1 300min e OR over 11 C 52 F e 1 hour after the end of milking 3B Milk too cold e Milk temperature is lower than 1 C or 34 F for more than 15 minutes e Tank temperatures dropped too low that could lead to freezing of milk on tank surfaces Low temperatures possibly due to e Low volume of milk in tank when tank is on full cooling capacity e Too little agitation or no during cooling of low volumes of milk e Thermostat set too low e Faulty thermostat e Adjust setting on thermostat e Replace thermostat e Check for proper agitation action in the tank Default 1 C or 33 9 F Setting range 0 C 5 C or 32 F 41 F a e Turn on cooler Default e Failure to turn on agitation e Check both 4 minutes while milking duri l agitator s shaft s uring a e One of multiple agitators turning period of 70 e Less than 4 minutes has stopped working e Check that milk is minutes 4 Insufficient A o n H i bbs e properly agitated agitation P A AAOS E SACRE APNS inside tank Setting range period of 70 gear boxes broken Check agitator 0 60 minutes minutes e assembly of agitation e Timer mechanism o durina a e Check functionin g agitator s is are aimer g period of malfunctioning 10 300 min e Check if setting is e Slow cooling if agitation on timer no A u hes been and cooling are linked manual Default 5
12. Dairy Cheq Q3 User Manual V2 2 October 2014 Thank you for purchasing Dairy Cheq Q3 We are confident that you will value the improved capabilities We have developed Dairy Cheg Q3 with the experience of over 10 000 previously installed monitoring devices You will quickly discover how effortlessly Dairy Cheq Q3 will save you time milk and therefore money Preface This manual has been made for the end user the dairy producer The manual aims to assist you in using your Dairy Cheq Q3 to its full range of capabilities The new user interface will allow you to go through the different menus with ease and confidence Please remember You will get the most out of your investment by reading this manual in its entirety Follow the instructions and suggestions in order to maximize the value of the data that Dairy Cheq Q3 can provide gt Keep this manual in a dry location in the vicinity of the Q3 for quick reference gt A copy of this manual will be available on the Dairy Cheq website www dairycheq com Introducing Q3 Data Analyzer Software Dairy Cheq Q3 Data Analyzer software is available so you can easily transfer data stored in your Q3 to your PC The software will also allow you to view and analyze your data in real time as well as record and print your COM Record 17 Please visit www dairycheg com for more information Q3 Graphic Analysis import Q3 Data G info s Q He C Users eidem Desiaep Q3 leg 14 25 424 2014 lloy
13. If your Q3 monitors 2 tanks you will be prompted to select which tank you wish to see the pickup report for as per the image below TANK SELECTION TANK 1 TANK 2 Dairy Cheq Q3 User Manual V2 2 October 2014 Page 11 2 5 2 Sensors Menu 2 This menu gives present sensor readings regarding the status of the installed sensors You can tap the icon for the specific sensor you need the information on When you tap on an icon you will see more detailed information regarding that particular sensor For example information about the tank sensor is displayed as follows SENSOR VALUE 4 ow _ THIS SENSOR IS LJ Pipelines Vacuum Water Pressure Connectivity WORKING Tank 1 Ta 6 8C All tank sensors seem to be working KA 2 Qo m P d uini debe lender Tank 2 Tm 5 4C us R 1 866 849 3610 Lc n 6 8C Outputs Acid Level Detergent Level Prox Inputs Calibrate 5 3 Alarm History Menu The most recent 100 alarms and warnings are shown and can be reviewed in this menu The date and time for each alarm and warning occurrence are displayed here It is also possible to view additional information such as the notes that were made in relation to that specific alarm Tapping on the Alarm i e MILK TOO WARM IN TANK 1 on the left side of the screen displays the alarm information screen C17 Alarm History C eo Alarm Information ALARM TYPE Occurred MILK TOO WARM Milk needs to be under 5C within
14. ate cooling e Milking speed has increased equipment either by the herd due to improvement of genetics or expansion of the capacity of the milk equipment Tank temperatures dropped too low that could lead to freezing on tank surfaces or freezing of e Milk temperature is lower milk in tank Low temperatures e Run tank on part than 0 5 C or 33 F for more possibly due to cooling capacity Hee d than 15 minutes e Low volume of milk in tank e Not a regulatory parameter in when tank is on full cooling e Set thermostat US capacity higher e Too little agitation during cooling of low volumes of milk e Thermostat set too low ipfe dues e Failure to turn on agitation INSUFFICIENT e Agitation time is less than 4 i ib 4 nies uen eue at 70 while milking e Check that switch is gap e One of multiple agitators has turned on min sOn hetime h een stopped working e Check that all NEN l e Mechanical breakage of agitators are running agitation cycles is gt 70 oer dos SEMEN m ies agitator s sheared pins gear e Check agitator This doesn t necessarily boxes broken paddle assembly meet PMO at this time stretched belt Check functioning of e Timer mechanism of agitator s the timer is failing AGITATION This could be US regulatory PMO states it must be agitated Page 24 Dairy Cheq Q3 User Manual V2 2 October 2014 e Slow cooling if agitation and cooling are linked e Timer mechanism of agitator is e Check co
15. ction to solve the problem 2 3 1 Producer Warnings Page 8 When a Producer warning occurs a screen similar to the image below will appear Slow Cooling in Tank 1 TURN OFF WARNING When this warning is shown the alarm light stay on The audible alarm signal will also sound In order to stop the alarm tone and the light the producer must acknowledge the warning by tapping anywhere on the bar TURN OFF WARNING In this example Dairy Cheq Q3 generated a warning of slow cooling This occurs 10 minutes after the end of milking when Dairy Cheq Q3 detected a temperature decrease that would not be sufficient to reach the required temperature 1 hour after the end of milking After the first milking this time is 2 hours all other consecutive milkings will be monitored for 1 hr after the end of milking If after the 1 or 2 hrs the milk temperature in the bulk tank is not below the set Regulatory requirement a Regulatory alarm will be generated Dairy Cheq Q3 User Manual V2 2 October 2014 V dairy eq When the warning is acknowledged the following screen will be displayed Slow Cooling in Tank 1 GO BACK TO HOME MORE INFO ON ALARM The alarm sound will stop and the alarm light will turn off To go back to the main screen tap the GO BACK TO HOME button This will bring you straight back to the main screen as shown on page 7 For more information related to the warning tap the MORE INFO ON ALARM
16. d the vacuum would be off and cooling should be completed within 2 hours Therefore if the vacuum is off thus milking has finished but if agitation continued for 5 hours it is highly likely that there is a problem with the agitation timer or the cooling system As in other cases listed above there is no equivalent non milking time for a robot system and there is no vacuum signal to monitor when milking is not happening Therefore in a robot setup the Too Much Agitation alarm will only trigger if the milk temperature is below 5C and the agitation has been on continuously for 5 hours NO COOLING DETECTED START COOLING WARNING The No Cooling Detected warning serves as a reminder to producers to start their cooling system when working in a milk parlour or tie stall setup Since the cooling initiation is automated in robotic milking setups this warming is not active in robot mode NO MILK DETECTED WARNING The No Milk Detected warning serves as a warning to producers to check if the tank valve is open if the vacuum has been on for a certain amount of time and no milk has been detected in the tank Since the valve control is automated and there is no vacuum signal in a robotic milking setup this warning is not active in robot mode Q3 Milking Times Robot versus other installations In a parlour or tie stall setup the start of milking is detected if the vacuum has been on for at least 30 minutes and milk has been detected in the tank T
17. d Port 3 Pat COM FR 7 Pot Terk 1G Part Tek 2G Date Fadey Apd 11 2014 Tme 120126 PM ch Select v 313 S 421204 Ge fwttndDse uaau g Data Channel 3 239 Fd FEE 3 E e L L 3 P 4 H 553 eligio2zoavvu MM i n Anda ORES sts PPE AF 4 004 Temperature Units Wednesday het 45 Me y um 652 Tank 1 Vacuum Or gt Us a Wedresday Aed 75254 PM Tark 1 Vacuum Of 94 29 14 94 11 14 94 13 14 24 15 14 04 17 14 94 1014 PART Wednesday Ad 80533 PM Tork 1 Vacuum On 04 10 14 04 12 34 24 14 14 34 16 14 04 8 14 2420 4 54 22 4 17589M Tark 1 Vacuum Off 1 i COM Record 17 CQM Record 17 Deviation and Corrective Action Record Date Time M Problem or Deviation i e Description of Corrective Action Taken Signature at went wrong i e how wasit fixed lc April 10 2014 1 40 03 AM 40 03 AM TANK 1 TOO MUCH AGITATION REGULATORY 1 TOO MUCH AGITATION REGULATORY FAULTY FAULTY CONTROLLER Thursday April 10 2014 April 10 2014 1335 PM 33 15 PM TANK 1 TOO MUCH TANK 1 TOO MUCH AGITATION REGULATORY REQUATOR Saturday April 12 2014 7 22 19 AM TANK 1 BLEND TEMP TOO HIGH REGULATORY iei COOLERTAP NOT OPEN Tuesday April 15 2014 April 15 2014 7 35 58 PM 35 58 PM TANK 1 MILKTOO WARM REGULATORY 1 MILK TOO WARM REGULATORY Dairy Cheg Q3 is a trademark of Dairy Cheq Inc Page 2 Dairy Cheq Q3 User Manual V2 2 October 2014 Table of Contents PAY TAUPO CG OU ERR
18. data with customizable views Please visit www dairycheq com for more information 2 5 4 Data and Reports In Data and Report menu you will be able to retrieve data in numerical and graph form For example tapping on the the tank icon will graphically display the tank temperature history Graphs can also be displayed for pipelines Q CU QED m ORE a Tanks Pipelines Pickup Times Milking Times Wash Reports 4 20 3 Lir Lom 21 38 22 50 0 02 1 14 2 26 3 38 4 50 3 25 3 26 3 28 3 29 3 30 3 31 4n EE c E E Temp C Save to USB System Info Clock Changes 2 5 5 Settings This menu allows access to the settings of Dairy Cheq Q3 They are divided in three levels of accessibility 1 Userlevel 2 Service level 3 Regulatory level For example To modify settings related to the Tank Cooling Tap on the Tank Cooling icon in this menu will display the Tank cooling settings screen BACK Settings CID OCC Tank Cooling Settings Tank Cooling Set Clock General Calibrate Screen Value Default Setting 56 Tank 1 Start Cooling Time 30 min 45 min Tank Wash Pipelines Plate Cooling Conductivity Additional Sensors Dairy Cheq Q3 User Manual V2 2 October 2014 Page 13 Tapping on the setting information i e Tank 1 Start Cooling Time on the left side of screen will bring you to the next screen that allows you to modify the boundary for this producer warni
19. e did not reach the minimum threshold of Default 40 C or 104 F e Power was off for more than 5 hours e Malfunction of controlled washer unit e Overall wash temperature was too low reducing the amount of time the temperature was over the threshold limit e Volume of water too small to heat stainless steel tank e Not fully draining tank between wash cycles e Malfunction of controlled washer unit e Malfuction with water heater e Too slow filling of sink e Malfunction of the check valve e Ambient temperature too low e Breaker tripped e Lighting strike close to the building e Main power loss e Check to see if drain fully opens between cycles and all water drains before next cycle fill begins e Check settings on washer control unit e Check if there was hot water usage overlap such as washing the tank too soon after the pipeline e Check to see if drain leaks during fill up reducing water volume e Check to see if drain fully opens between cycles and all water drains before next cycle fill begins e Check settings on washer control unit e Check water heater e Insulate sink e Repair valve e Increase temp of the water heater e Check for power shorts of the cicuit e Reset the breaker at the side panel e Use generator according to the proper procedures Dairy Cheq Q3 User Manual V2 2 October 2014 4 Trouble Shooting Possible solution Dairy Cheg Q3 Is not responding e Powe
20. e area where Dairy Cheq Q3 will be installed must be clean and dry Do not clean Dairy Cheq Q3 using running or high pressure water Any use of Dairy Cheq Q3 other than described in this manual is strictly prohibited due to possible unforeseen hazardous situations The area in which the Dairy Cheq Q3 is being used must be properly ventilated clean and free of dust caustic and corrosive gases and substances and with air humidity between 10 and 90 Power supply must also meet the specifications shown in the appendix The unit operates on 100 240VAC power We urge you to use caution with the electrical parts of Dairy Cheq Q3 Acertified electrician is to provide the receptacle when applicable in your installation of Dairy Cheq Q3 A certified Dairy Cheq technician can assist you with the installation and start up of the unit The manufacturer will not assume any liability for adjustments or modifications made to the operation principle or controls of the Dairy Cheq Q3 Any form of claim under warranty and manufacturer liability is excluded if any or all of the above terms and conditions are not adhered to The producer will remain responsible for the storage of milk in the tank and consequently for the quality of the milk at all times That is the reason why you should act appropriately on every warning or alarm message from Dairy Cheq Q3 check the temperature of the milk after every milking cycle and visually inspect the cleanliness of
21. he end of milking is detected when the vacuum is turned off Since a robot setup does not have a vacuum sensor a different method had to be used If the tank is empty and clean then the milk start time is judged as the moment that milk is detected in the tank If milk has been in the tank for at least 5 hours and then a robot enters wash mode that moment is judged as the end of the first milking period When the robot exits wash mode that moments is the start of the Page 18 Dairy Cheq Q3 User Manual V2 2 October 2014 subsequent milking period The end of the subsequent milk period will be judged as the moment at least 5 hours later that a robot enters wash mode Q3 Robot Installation When a Q3 is installed in a robot setup the main difference versus a parlour or tie stall setup is that no vacuum sensor is used and that instead a wash signal must be supplied from a robot In Ontario each individual robot pipeline must be monitored using a pipeline sensor and a wash signal must be supplied from each robot If 1 2 or 3 robots are to be monitored then all the signals are run into the Q3 enclosure If 4 to 6 robots are to be monitored then an additional expansion box must be installed to accept the additional sensors The Q3 is also capable of monitoring the milk and wash cycles of buffer tanks If a buffer tank is to be monitored then the additional expansion box must be installed Please note that a single expansion box is suffic
22. hen cooler is Alarm is set to soon Milk has Increase the alarm time in the settings on and agitator is moving not reached the sensor yet menu Tank Start cooling Alarm with 10 minutes All alarms have specific explanations via the display of Dairy Cheq Q3 When an alarm is acknowledged tap More Info on Alarm and the Alarm Information screen is displayed see page 12 for reference Never attempt any service on the Dairy Cheq Q3 outside the guidelines of the unit Be aware that this can void your warranty Skilled personnel can assist you with possible issues and will be more then wiling to assist you in restoring the situation back to normal as soon as possible Dairy Cheq Q3 User Manual V2 2 October 2014 Page 27 T ang 5 Safety Always observe the following safety instructions Operation All operators must be familiar with this manual Hygiene Observe the usual sanitation regulations in terms of milk processing for human consumption Electricity Allow only qualified Dairy Cheq trained technician to work on Dairy Cheq Q3 Use a licenced electrician for all your electrical work Water Do not use a high pressure cleaner for cleaning parts Do not rinse the Q3 parts with water Do not use caustic or corrosive cleaning agents for cleaning the equipment Only use a damp cloth for cleaning Dairy Cheq Q3 Doors and latches Do not remove the doors latches or open enclosure other than for maintenance In that case
23. ibly due to than 15 minutes e All compressors not during a 2nd milking turned on or not e Milk temperature is functioning properly gt 50 F for more e Power outage or breaker than 15 minutes switch Only on 2nd milking e Freon pressure low e Blockage of cooling radiators e Check if cooler is running e Check compressor level e Check radiator on cleanliness and free access of air e Check functioning of plate cooler when applicable Note Always have trained personal do the repair on cooling equipment and or electrical Default 5 C or 45 F 180 min Setting range 1 5 C 34 45 F Time range 1 300 min components Default 10 C or 50 F for 15 min e Check if cooler is turned on e Check if breaker is tripped e Check Freon pressure e Check that cooling radiators are cleaned e Check the functionality of plate cooler e Plate cooler malfunction cleanliness during milking valves etc e Milk temperature e Same as above Default has been over 5 0 C or 41 F 4 5 C Canadian Regulations 45 F US Regulations for more than two hours after the first milking cycle or more than 4 hours from the beginnin 3A of milking ris d e Same as above Milkings that go beyond this time e OR milk temperature has been over 4 5 C for more than one hour after any subsequent milking cycle Page 20 Dairy Cheq Q3 User Manual V2 2 October 2014 Setting range 1 40 C or 34 104 F
24. ient to monitor 4 to 6 robots AND a buffer tank Q3 CONNECTION SCHEMATICS Multiple Robots 4 to 6 lt PIPE SENSOR lt PIPE SENSOR A A WASH SIGNAL TANK gw e TANK me WASH SIGNAL lt PIPE SENSOR lt PIPE SENSOR WASH SA lt PIPE SENSOR lt PIPE SENSOR l WASH EA WASH SIGNAL Q3 ae Q3 EXPANSION TANK SENSOR Measures milk and wash temperatures Also monitors tank agitations PIPE SENSOR Measures pipe wash temperature and monitors plate cooler function WASH SIGNAL Indicates when robot is washing Dairy Cheq Q3 User Manual V2 2 October 2014 Page 19 Gin Bing 3 Table 1 Overview Producer Warnings mea of More details Possible causes Possible solutions Producer usu Here you can e Cooling stopped RT functioning properly or not e For milking times lt at all possibly due to Mis Ed e Cooler not turned on n o eis o e Power outage or breaker reach 5 C or 45 F swich 120 minutes after Slow Cooling the end of the 1st ae eke milking or 60 dice aerie radiators with dust and or end of the 2nd an milkings e Plate cooler malfunction during milking e Radiator inlet doors closed or blocked change the level on which the alarm will occur The range and default values are displayed in this menu e Cooling capacity is unable e Warning that the to keep milk temperatures milk temperature is below 11 C or 50 F gt 10 C for more poss
25. ing Regulations 45 F US Cooling stopped functioning e Check compressor Regulations for more than level two hours after the first ed PEIUS ahora e Check radiator on milking cycle or more than4 Cader er ee ee cleanliness MILK TOO hours from the beginning of Bower outage or breaker switch Check functioning of milking for Milkings that go plate cooler when WARM mae e Freon pressure low beyond this time applicable e OR milk temperature has j di ies radiators e Always have trained bear over 5 0 C for more e Plate cooler malfunction during personal do the than one hour after any ING l repair on cooling subsequent milking cycle e Faulty vacuum switch the Bdulbmentand or TTR does not know that milking CP e OR over 11 C 1 hour after is taki 9 electrical the end of milking lend piace components Cooling capacity is unable to keep milk temperatures below 11 C or 50 F possibly due to e All compressors not turned on or not functioning properly e Power outage or breaker switch e Check functioning of e Milk temperature is higher SEON PE UO ae Aaa BLEND than 11 C Can 50 F US Blockage of cooling radiators neck breaker D TEMPERATURE for more than 15 minutes e Plate cooler malfunction during e Check freon level TOO HIGH during a second or milking MN Check radiators subsequent milking Capacity of the condensing unit e Check functioning of is maxed out while milk plate cooler production has increased e Upd
26. ional maintenance advice regular checks by your dealer are recommended 8 Waste Material Discard any waste material in compliance with the current local regulations for waste materials 9 Warning Symbol This symbol is intended to alert the user to the presence of important operating and servicing instructions This symbol is intended to alert the user to the presence of dangerous voltage within the inside of the product that can cause electric shock severe injury and or death Dairy Cheq Q3 User Manual V2 2 October 2014 Page 29 Bare Appendix A Technical specifications General Dairy Cheq Q3 general enclosure Casing material Fibre enforced Polycarbonate Weight 5 Ibs Approximate dimensions 4 v 110 mm 14 375 mm un 10 5 275 mm Electrical Supply voltage 100 240 VAC 10 50 60Hz N L Ground Output relay 12V 1A Expansion box Modem 2 60 mm 4354 120 mm 4 5 110 mm 12 305 mm am Y 7 5 195 mm 9 4 245 mm 6 155 mm Page 30 Dairy Cheq Q3 User Manual V2 2 October 2014
27. is not functioning and cooled milk is only at the bottom of the tank e Check supply barrels with detergent e Check equipment e Clean probes with soft brush if needed e Check wiring from sensor to the Q3 unit e Check if power is present e Check functions Call Dealer e Adjust settings e Check functions Call Dealer e Check if elbow is clear of debries e Call Dealer e Switch on cooling e Check cooling proper functioning of equipment e Check for good airflow through the radiator of the cooling system No obstruction or build up of dust and debris e Check proper functioning of agitation system s Dairy Cheq Q3 User Manual V2 2 October 2014 Pending on the type of detergent and the instructions of the soap supplier settings value should be over 25 after a successful Default 80hrs Setting range 12 100 hrs Default 45 min Setting range 1 120 min e Valve left open after the Valve of the Default 45 During 1st milking wash cycle of the bulk bulk tank mins into empty tank no tank e Insure milk line Setting range milk has been e Milk line is not above the output is above 1 120 mins detected in the tank bulkbtank inlet and safety the inlet of the at sensor AND the switch is malfunctioning bulk tank Check No milk detected in tank vacuum has been on e Milk line is leaking after proper functioning for 30 minutes the pump at the receiving of the safety unit switch
28. l need to contact Dairy Cheq to discuss if your modem can be moved to another location to improve cellular reception RSSI Integer 18 RSSI dBm 77 RSSI Bars 5 BER 0 Please note that notications require a cellular network connection which is not operated by Daiy Cheq We recommend to check Dairy Cheq Q3 s modem status screen periodically Dairy Cheq Q3 User Manual V2 2 October 2014 Page 17 Gag ang 2 Operation with milking robots Q3 Operation with Milking Robots The Q3 is designed to work with milk parlours tie stalls and up to 6 milking robots The overall operation of the unit is very similar in each of these cases and the user will not experience any great difference in how to navigate the menus and what information is available However there are some important differences in regards to the internal operation that affect what conditions may trigger alarms and what signals are required during installation Q3 Alarm Differences Robot vs other installations MILK TOO WARM ALARM In Canada milk must be cooled below 5C within 2 hours of the end of a first milking and within 1 hour of the end of a subsequent milking However in a robot setup there is no end of milking in the conventional sense since robots can milk almost continuously For this reason a Q3 configured for Robot operation will monitor milk cooling from the moment that milk firsts enters an empty tank Measured from that moment the
29. milk in the tank must be cooled below 5C within 4 hours If a robot enters wash mode after these initial 4 hours plus 1 additional hour i e 5 hours total have passed then that moment is considered to be the end of the first milking cycle Once the robot exits its wash cycle a subsequent milking cycle begins From the beginning of the subsequent milking cycle the milk must again be cooled to below 5C within 4 hours SLOW COOLING WARNING In milk parlour and tie stall setups the slow cooling warning was based on a prediction from the end of milking that the milk would not be cooled fast enough to prevent a milk too warm alarm or warning Since the End of Milking is not used to determine milk too warm conditions for a robot setup the slow cooling warning is not active in robot mode BLEND TEMPERATURE TOO HIGH ALARM This alarm occurs if the milk temperature is over 10C on a subsequent milking The Q3 will determine that the tank is in a subsequent milking mode if a robot has entered and exited wash mode and milk has been in the tank for at least 5 hours TOO MUCH AGITATION ALARM In milk parlour and tie stall setups the Too Much Agitation alarm is triggered if the vacuum is off and there has been continuous agitation in the tank for 5 hours The reason for requiring the vacuum to be off is that during milking the vacuum would be on and agitation could occur continuously as the cooling system is running However once milking has complete
30. ng Tank 1 Start Cooling Time LJ B CANCEL SAVE The same steps can be followed in changing user settings for other parameters in this menu All other menus are displayed in the same manner An overview of all the producer settings can be found on page 16 The User level parameters are accessible for the user without any restrictions Service and regulatory REG settings are restricted by passwords that change daily Tapping on the Service or REG button will reveal the password screen Tank Cooling Settings Value Default 53 Tank 1 Enabled Yes Yes Ej 54 Tank 1 Proximity Switch Enabled Yes Yes E 55 Tank 1 Proximity Switch Source Board 1 D1 Board 1 D2 62 Tank 1 dT Not Agitating 2 4 24C 63 Tank 1dT Agitating 1c T ancei Additional Sensors Icon Tank Cooling Tank Wash Pipelines Plate Cooling oj Set Clock General Calibrate Screen A Additional Sensors 5 0 o Water Pressure Vacuum Communication Import Settings Additional Sensors Page 14 Dairy Cheq Q3 User Manual V2 2 October 2014 dair che fhairg Settings related to water pressure vacuum communication and import settings can be accessed through the Additional Sensors icon Note that is possible that one or more of the choices are not applicable for your configuration as the sensors might not have been in your choice of the purchase of the Dairy Cheq Q3 kit E g Vacuum water pres
31. ng Producer Page 16 Dairy Cheq Q3 User Manual V2 2 October 2014 2 6 Other Features 2 6 1 Modem In order for Dairy Cheq Q3 to send you alerts when an alarm occurs you need to tell it what phone numbers or email addresses you want the messages to be sent to You also need to enable the email and or SMS service To enter a phone number navigate to Settings Additional Sensors Communications You will need to contact Dairy Cheq and get the service password for the day Enter the password and go into the Service Menu You may enter up to 5 phone numbers and email addresses by tapping on setting 11 through 15 and 18 through 22 respectively SMS and email may be enabled by changing menus 10 SMS Enabled and 16 Email Enabled from No to Yes Menu 17 Email Server is not currently used Communication Settings Communication Settings Setti Value Default Setti Value Default 16 Email Enabled No No 10 SMS Enabled No No 17 Email Server 0 0 11 SMS Phone Number One 555 555 5555 555 555 5555 0 0 Ua tu 12 SMS Phone Number Two 0 0 19 Email Address Two 0 0 13 SMS Phone Number Three 0 0 20 Email Address Three 0 0 0 0 21 faal Addis Foar 0 0 14 SMS Phone Number Four 22 Email Address Five 0 0 15 SMS Phone Number Five 0 0 If you are not receiving SMS or email messages after enabling the features navigate to Sensors Connectivity Modem The third line RSSI BARS should be at 3 4 or 5 If it is at 0 1 or 2 you wil
32. nit is being initialized Within 30 60 seconds the main screen is displayed and immediately gives you the current data as well as the recent wash temperatures of the wash cycles Attention Dairy Cheq strongly recommends the installation of a 120 VAC surge protection between the receptacle and the plug of the power cord of the Dairy Cheq Q3 The closer this surge protector is to the unit the lower the risk for lightning damage becomes Note There is no warranty on the unit when damage occurred due to a lightning strike or ill use of an emergency power generator These events may be covered under your general insurance Page 6 Dairy Cheq Q3 User Manual V2 2 October 2014 Aer 2 2 The Home Main Screen When all settings are within the boundaries and the milk in the tank is cooled to required temperature the display screen of the Q3 will look like the image below Mon Jan 6 11 32 AM 1 45 9 C 3 6 LAST TANK WASH m 54 4 C MILK IN TANK CURRENT TANK TEMPERATURE LAST PIPE WASH You can observe the following information e The date and time at the top left e Language icon on the top right which allows you to select the preferred language e Milk is in the tank e Current temperature is 3 6 Celsius 38 F e The previous Tank wash which impacts the quality of this milk was 45 9 C 115 F e The previous Pipe Line wash which impacts the quality of this milk was 54 4 C 130 F The menu b
33. oling unit e Check timer e Check that timer is in e Agitation time is longer than 300 minutes and vacuum is TOO MUCH NOT on Typically when not bad causing agitation to stay AGITATION milking in ne a regulatory parameter In Switch is turned on manual e Faulty vacuum switch e Milk has been in the tank for MILK IN TANK more than 80 hours e Delayed milk pickup due to e g FOR TOO weather conditions LONG e This doesn t necessarily e Partial pickups meet PMO at this time e Possible causes e Delayed milk pickup e Skipped tank washes TANK EMPTY TOO LONG e 2 hrs haved passed since WITHOUT the tank was emptied and no WASHING wash has been detected e Failure of tank wash detection due to malfunction of tank washer pump motor impeller spray ball clogged up etc e Not enough hot water to reach desired temperature e Volume of water too small to heat stainless steel tank e Lack of circulation during wash INSUFFICIENT e Maximum wash temperature cycle malfunctioning pump TANK WASH did not reach a minimum spray ball or impeller TEMPERATURE threshold of 40 C OR 104 F Not fully draining tank between wash cycles e Malfunction of controlled washer unit e Cold and hot mixing due to faulty solenoid valve e Overall wash temperature was too low reducing the amount of time the temperature was over the threshold limit e Volume of water too small to heat stainless steel tank e Not fully draining tank be
34. r outage Check power source at receptacle Breaker trip due to overload Check cause of power outage and try to lightning incorrect usage of restore power or use an appropriate power generator power generator Check breaker of the Q3 at the side door Reset by pushing the button If the breaker trips again call your local service technician for assistance Producer warnings go off too much e Setting of warning boundary is Check boundary in the settings menu of too close to the actual levels the specific process and adjust to a reached more flexible range Touch screen is not responding e Screen requires calibration Go to Settings menu and find under correctly General the Screen Calibration Alarm memory card full e Data filled up the memory card Keep the existing memory card in a safe and dry place and replace it with a new card Battery low e The backup battery inside the Replace the battery by shutting down Dairy Cheq Q3 is below 2 5 the Dairy Cheq Q3 and disconnecting it Volts from the receptacle Open the front door of the Q3 and find the battery on the bottom right Battery type CR2032 Alarm light does not come on Lamp malfunction Call service technician for assistance during an alarm Wire issue broken or pinched Relay issue in Q3 Temperature alarm when tank is Possible ice on the bottom of the Check thermostat settings or call cooling being emptied or agitated tank technician for Bulk Tank Start cooler alarm w
35. sure or other sensors 2 5 6 Changing date and Time To change the time tap the set clock icon The next screen displayed is F3r Occo Tank Cooling Tank Wash Pipelines Plate Cooling Gonductivity Set Time Set Date Set Clock General Calibrate Screen Additional Acid Sensors Tap the set time button to display the next screen Settings OGD Tap the Hours Minutes or AM PM that you wish to change Simply tap which part in the time box needs to be changed hour minutes or AM PM In this example the AM PM is chosen Change the values with the arrows to decrease or increase the value When satisfied with the change tap Save which will save your settings in memory and brings you back to the Time and Date selection screen To change the date the service password needs to be entered Note that time changes are logged in memory and can be viewed by tapping the Data and Reports icon on the home main screen then Clock Changes Dairy Cheq Q3 User Manual V2 2 October 2014 Page 15 dairy Cano Overview Producer Settings Menus Wumber ames Sets mens _ Permission evel Name English Settings menu Permission Level A4j languge General Producer 59 Tank 1 Max Cooling Time From Beginning of Milking Tank Cooling Producer 66 TankiWashigTime Tank Wash Producer 80 TankiMinimumAcidlevl Acid Producer 110 Tank 2 Max Cooling Time From Beginning of Milking Tank Cooli
36. the inside of the tank after every cleaning cycle Dairy Cheq Inc cannot be held responsible for any loss of milk For further information contact Dairy Cheq Inc Toll free 1 866 849 3610 60 Northland Road Unit 7A Local 519 746 6150 Waterloo ON N2V 2B8 Email info dairycheq com Canada www dairycheq com Page 4 Dairy Cheq Q3 User Manual V2 2 October 2014 2 Operation 2 0 General Information Dairy Cheq Q3 is equipped with a full colour touch screen As in the picture above the temperature of the milk in tank is clearly displayed and easy to read from a distance when entering the milk house The screen colours give the following indication e Green indicates milk is in tank e Blue indicates wash cycle e Producer Warnings will be indicated with a yellow screen see page 8 e Regulatory Alarms will be indicated with a red screen see page 9 As shown above the side access panel allows easy and safe access to On off button Memory card USB port USB port Breaker reset switch apfohnh In normal operation the main front door of Dairy Cheq Q3 should remain closed at all times Only a certified technician is allowed to work in the area where 100 240 VAC comes into Dairy Cheq Q3 Please do not open the front door of Dairy Cheq Q3 When not in use the side door should also be securely closed to avoid any moisture liquid and or dust from entering into Dairy Cheq Q3 Dairy Cheq Q3 User Manual
37. tween wash cycles TANK WASH INSUFFICIENT Wash temp did not stay above minimum temp TME OVER threshold of Default 40 C or ii uri 104 F for at least 4 minut TEMPERATURE ue Default 4min Dairy Cheq Q3 User Manual V2 2 October 2014 auto e Check vacuum e Check procedures e Check proper functioning of wash equipment pumps soap dispensers when applicable distribution lines of water and soap screens in water spray balls lines etc Check if there was hot water usage overlap such as washing the tank too soon after the pipeline Check to see if drain leaks during fill up reducing water volume Determine if restrictors reduce water volume too much during fill Check to see if pump circulates water Check to see if impeller or spray balls are plugged and if the back wall is reached Check to see if drain fully opens between cycles and all water drains before next cycle fill begins Check settings on washer control unit Check if there was hot water usage overlap such as washing the tank too soon after the pipeline Check to see if drain leaks during fill up reducing water volume Page 25 PIPE WASH INSUFFICIENT TIME OVER MINIMUM TEMPERATURE INSUFFICIENT PIPE WASH TEMPERATURE 5 POWER WAS OFF Page 26 e Wash temp did not stay above minimum temp threshold of Default 40 C or 104 F for at least 4 minutes Default 4min e Maximum wash temperatur
38. uttons at the bottom from left to right e Pick up report provides the data belonging to this tank of milk to the Bulk Tank Milk Grader e Sensors all information about the sensors is found here e Alarm History the most recent 100 alarms are stored here e Data and reports here you will be able to retrieve all kinds of data both in numerical and graphical format It can give an overview of the performance of the various systems in the milk house e Settings these are the menus to set the various parameters You will find that the service and regulatory settings are shielded by a password which changes daily If your Q3 is set up to monitor 2 tanks then the display screen will look like the image below Mon Jan6 11 32AM TANK 1 TANK 2 vu NN 4 1 SD e 47 4 C WASH ST TANK WASH LAST PIPE WASH Dairy Cheq Q3 User Manual V2 2 October 2014 Page 7 Gin Bing 2 9 Producer Warnings and Regulatory Alarms Dairy Cheq Q3 has both producer warnings and regulatory alarm levels built into the logic of the unit A regulatory alarm occurs when a boundary is violated due to an incident or malfunction of equipment For example milk temperature during storage may not go below 0 5 C 33 F A producer warning can be set before the Regulatory Alarm level is reached In this example the warning level can be set at 1 0 C 34 F This allows time to diagnose the problem determine the cause and take corrective a
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