AfiMilk AfiFree 155i User manual



Kibbutz Afikim, 15148, Israel



+972-4-675-4811

Fax

+972-4-675-1862

[email protected]

http://

www.afimilk.co.il

Product P/N 4199400

Manual P/N 9040322

Version: 1.1, May 2009

Milk Meter

Installation Manual

ii P/N 9040322

Without limiting the rights under copyright law, this publication, or any part thereof, may not be

reproduced, stored, or introduced into a retrieval system, or transmitted in any form, or by any method,

for any purpose, without the prior written permission of SAE Afikim.

This publication describes the state of this product at the time of its release, and may not reflect the

product at all times in the future.

Software License Terms

The software and the system design are the property of SAE Afikim.

The software is supplied to the buyer to be used solely for its stated purposes. It is strictly forbidden to

make copies of the software or transfer it in any manner, for any purpose, to a third party.

In addition to application software specifically developed by SAE Afikim, the system makes use of

certain third party utilities and system software. These are licensed for a single user. They must not be

copied in any manner, for any purpose, by the purchasers, their employees, or anyone else.

The license to use the software is granted to the user only for the specific system it is installed on by

SAE Afikim, or its authorized distributors and representatives.

The purchaser shall not modify the software in any manner.

If the computer is supplied by SAE Afikim, it is strictly forbidden to install any software that is not

supplied by SAE Afikim.

WARNING

It is the customer's responsibility to install, operate, and maintain the

system in accordance with all applicable codes, regulations, and safety

measures

High voltage transients, surges, and other power irregularities can cause

extensive damage. It is the user's responsibility to provide a power

protection system.

Use electrical equipment only in a manner specified by the manufacturer.

Improper use impairs the protection provided by the equipment.

Do not use AfiFree155i for any purpose other than those detailed in this

manual

CAUTION

This system has been checked for viruses prior to supply.

If in the course of a service call a virus is detected, removal of the virus, and

any software or hardware repairs resulting from it, will be charged to the

purchaser.

DISCLAIMER

The contents of this manual may be revised to incorporate changes and

improvements without prior notice and without obligation.

Every effort has been made to ensure that the information is complete and

accurate at the time of publication. Nevertheless, SAE cannot be held

responsible for errors or omissions.

Trademarks, patents, and copyrights apply.

May 2009 AfiFree Terminal 155i Installation Manual iii

Revision History

Version

Date

ECR

Pages

Description

SME

Writer

1.1

May

2009

All

First version

Avi ben

Joya

Jonathan

Matt

Referenced Documents

P/N

Document Title

9040150

AfiCom 1 Installation Manual

9040646

AfiWash Installation Manual

9040610

AfiPass64 Installation Manual

4022900

IDeal Installation Manual

AfiShepherd (AfiSheep, AfiGoat) User Manual

9040148

AfiFarm 3 Configuration Manual

iv Chapter 1 System Objectives and Functions P/N 9040322

Table of Contents

Chapter 1 System Objectives and Functions....................................................11

Purpose...................................................................................................................11

AfiFree155i in a Computerized Flock Management System............................11

AfiFree155i Stand-Alone System .....................................................................12

Principle of Operation and Installation..................................................................12

AfiFree Body .....................................................................................................14

Terminal 155i....................................................................................................15

AfiFree Wash Controller and Wash Control Valve ..........................................17

Connections Boxes............................................................................................18

Valve Installation Kit for AfiFree.....................................................................20

System Components ..............................................................................................21

Minimum Requirements........................................................................................25

Chapter 2 Site Preparation Requirements .......................................................27

Component Positioning Requirements ..................................................................27

AfiFree Body Positioning..................................................................................27

Terminal 155i Positioning.................................................................................28

Connection Box Positioning .............................................................................28

Wash Controller Positioning.............................................................................29

Wash Control Valve Positioning.......................................................................29

Positioning Optional External Start Buttons.....................................................29

Physical Infrastructure Requirements....................................................................30

Milk Line...........................................................................................................30

Vacuum Line.....................................................................................................30

Washline............................................................................................................30

Physical Interfaces to Components........................................................................30

Electrical Requirements.........................................................................................30

Power Supply Requirements.............................................................................31

Wiring Requirements........................................................................................32

Grounding Requirements ..................................................................................32

Computer Requirements ........................................................................................32

Chapter 3 Mounting and Wiring.......................................................................33

Checking Jumpers in the Plug-in Connection Box................................................33

Mounting the Connection Box...............................................................................34

Mounting and Wiring the AfiFree Body ................................................................34

Mounting the AfiFree Body Bracket .................................................................34

Leveling the AfiFree Body Bracket ..................................................................36

Mounting the AfiFree Body...............................................................................37

Wiring the AfiFree Body...................................................................................37

Mounting and Wiring Terminal 155i.....................................................................39

Terminal 155i Bracket Mounting......................................................................39

Mounting the Terminal 155i .............................................................................41

Wiring Terminal 155i........................................................................................41

Wiring the Power Cable.........................................................................................42

Wiring the Power Cable to an AfiFree Connection Box...................................42

May 2009 AfiFree Terminal 155i Installation Manual v

Connecting the Power Cable to a Plug-in Connection Box ..............................42

Wiring the Solenoids..............................................................................................43

Wiring Solenoids to an AfiFree Connection Box..............................................43

Connecting Solenoids to a Plug-in Connection Box.........................................43

Wiring the Pulsator ................................................................................................44

Wiring the Pulsator to an AfiFree Connection Box ..........................................44

Connecting the Pulsator to a Plug-in Connection Box......................................45

Mounting and Wiring an External Start Button.....................................................45

Mounting an External Start Button ...................................................................45

Wiring an External Start Button........................................................................45

Wiring the Communication Cable .........................................................................47

Wiring to an AfiFree Connection Box..............................................................47

Connecting to a Plug-in Connection Box..........................................................48

Installing a Shut-off Valve Using the Valve installation kit for AfiFree...............48

Mounting and Wiring the Wash Controller ...........................................................50

Mounting the Wash Controller..........................................................................50

Wiring the Wash Controller and Setting DIP Switches ....................................52

Mounting the Wash Control Valve........................................................................54

Installing the Vacuum Line for the Wash Control Valve ......................................55

Chapter 4 System Configuration .......................................................................58

Configuring AfiSheep/AfiGoat...............................................................................58

Configuring the Parlor.......................................................................................58

Configuring Milk Meters .......................................................................................61

Configuring Milk Meters in a Computerized Flock Management System.......61

Configuring Milk Meters in a Stand-alone System...........................................68

Setting Up the Wash Controller.............................................................................70

Wash Controller Principles of Operation..........................................................70

Wash Controller Configuration.........................................................................71

Testing AfiFree155i Performance..........................................................................73

Configuring AfiFree 155i Parameters....................................................................74

Introduction to the AfiFree 155i Parameters.....................................................74

Notes to Parameter Table..................................................................................76

Setting Parameters from Terminal 155i.................................................................77

Reading and Setting Parameters........................................................................77

Central Activation of Milking/Cleaning Mode.................................................77

Cluster Clearance ..............................................................................................78

Raising or Lowering Clusters............................................................................78

Stimulation ........................................................................................................78

Milk Diversion ..................................................................................................78

Milk Remainder.................................................................................................79

Sweep ................................................................................................................79

Viewing software version..................................................................................79

Setting Parameters in AfiSheep/ AfiGoat..............................................................79

Group Retrieval.................................................................................................79

Auto Program....................................................................................................80

Calculating and Setting the GParameter ..........................................................81

Chapter 5 Troubleshooting.................................................................................85

Searching for an Electrical Problem ......................................................................85

vi Chapter 1 System Objectives and Functions P/N 9040322

Chapter 6 Corrective Maintenance...................................................................89

Maintenance Policy................................................................................................89

Silicone and Rubber Component Replacement.....................................................89

Replacing AfiFree155i Bodies...............................................................................89

Removing a Malfunctioning AfiFree body .......................................................89

Installing a Replacement AfiFree body.............................................................90

Replacing a Terminal 155i.....................................................................................90

Preparing the Computer ....................................................................................90

Removing a Malfunctioning Terminal 155i......................................................91

Installing a Replacement Terminal 155i ...........................................................91

Checking and Preventive Maintenance..................................................................91

Pre-Milking Checks ..........................................................................................91

Post-Milking Checks.........................................................................................92

Chapter 7 Parts Lists ..........................................................................................93

Vacuum Shut-Off Valve Installation—Replacement Parts List............................93

AfiFree Body—Replacement Parts List ................................................................95

Terminal 155i—Replacement Parts List................................................................96

Appendix A User Information and Instructions..................................................97

Terminal 155i Modes and Settings........................................................................97

Operating Modes...............................................................................................97

Terminal 155i Settings......................................................................................98

Terminal 155i User Procedures .............................................................................99

Cancelling ACR ................................................................................................99

Displaying/Hiding Animal Identification Number .........................................100

Message Sub-Mode Procedures......................................................................100

Terminal 155i Display Fields ..............................................................................104

Display Fields under AfiSheep/ AfiGoat........................................................104

Display Fields under Standalone Configuration.............................................111

Enabling and Disabling Display Fields...........................................................115

Terminal 155i Alarms..........................................................................................116

Alarm and Malfunction Indicators..................................................................116

Appendix B Milking System Cleaning Guidelines............................................118

Cleaning Recommendations ................................................................................118

Chemical Dispensing Pumps ..........................................................................119

Vacuum Pump.................................................................................................119

Liquid Volume ................................................................................................119

Temperature and Cycle...................................................................................119

Cleaning Exterior Surfaces .............................................................................120

Performing an Acid Wash....................................................................................120

May 2009 AfiFree Terminal 155i Installation Manual vii

List of Figures

Figure 1: Terminal 155i units connected to AfiSheep/ AfiGoat................................. 11

Figure 2: Terminal 155i units not connected to AfiSheep/ AfiGoat........................... 12

Figure 3: Typical AfiFree155i Layout........................................................................ 13

Figure 4: The AfiFree Body........................................................................................ 14

Figure 5: Terminal 155i Panel.................................................................................... 16

Figure 6: Terminal 155i LCD Display........................................................................ 16

Figure 7: AfiFree Wash Controller............................................................................. 17

Figure 8: AfiFree Wash Control Valve....................................................................... 18

Figure 9: AfiFree Connection Box.............................................................................. 19

Figure 10: Plug-in Connection Box (PICB) ............................................................... 19

Figure 11: Power and Communication Cables........................................................... 19

Figure 12: Extension Tail Spacing on Power/Communication Cable........................ 20

Figure 13: Mounting the AfiFree Body Bracket with a Valve Installation Kit .......... 35

Figure 14: Leveling the AfiFree Body Bracket –Roll Axis....................................... 36

Figure 15: Leveling the AfiFree Body Bracket –Pitch Axis...................................... 36

Figure 16: Bracket Lock............................................................................................. 37

Figure 17: AfiFree155i Wiring................................................................................... 38

Figure 18: Welding the Terminal 155i bracket to a pipe............................................ 39

Figure 19: Terminal 155i bracket attached with bands to a pipe................................ 40

Figure 20: Terminal 155i bracket bolted to a cabinet................................................. 40

Figure 21: Orienting Terminal 155i to its bracket...................................................... 41

Figure 22: Power Cable Wiring.................................................................................. 43

Figure 23: Connecting the PC..................................................................................... 47

Figure 24: Communication Cable Wiring for a PICB................................................ 48

Figure 25: Mounting Shut-off Valve for AfiFree Body—Milk Inlet on Left ............. 49

Figure 26: Mounting Shut-off Valve for AfiFree Body—Milk Inlet on Right........... 50

Figure 27: Mounting Wash Controller........................................................................ 51

Figure 28: States of DIP Switches DSW1, DSW2, DSW3, and DSW4..................... 53

Figure 29: Socket and DIP Switch Locations............................................................. 53

Figure 30: Wash Control Valve Attached................................................................... 54

Figure 31: AfiFree Wash Control Valve Vacuum Line.............................................. 57

Figure 32: Parlor Configuration Dialog Box.............................................................. 60

Figure 33: AfiMen Real Time Window - Milk Tab.................................................... 62

Figure 34: Milk Parameters Dialog Box..................................................................... 62

Figure 35: AfiMen Real Time Window - Track Tab................................................... 63

Figure 36: AfiFree 155i Software Files ...................................................................... 67

Figure 37: AfiFree Cleaning System .......................................................................... 70

Figure 38: DSW1 and DSW2—DIP Switch Options for ........................................... 72

Figure 39: DSW3—DIP Switch Options.................................................................... 73

Figure 40: The Auto Program Check Box.................................................................. 80

viii Chapter 1 System Objectives and Functions P/N 9040322

Figure 41: AfiSheep/AfiGoat Parameters Screen.........................................................82

Figure 42: Parts for Attaching Vacuum Shut-Off Valve.............................................94

Figure 43: AfiFree body Exploded View.....................................................................95

List of Tables

Table 1: AfiFree155i Components ..............................................................................21

Table 2: Accessories for AfiFree Connection Box Wiring..........................................23

Table 3: Plug-in Wiring System..................................................................................24

Table 4: Distance between AfiFree Body Outlet and Milk Line .................................27

Table 5: Power Cable Specifications and Minimum Power Requirements ................31

Table 6: Specifications for Wiring Connected in Control Box...................................32

Table 7: Jumper Configuration in Plug-in Connection Box........................................33

Table 8: Wiring a Non-AfiMilk Solenoid ....................................................................44

Table 9: Wiring a Non-AfiMilk Pulsator .....................................................................45

Table 10: Wiring a Non-AfiMilk External Start Button...............................................46

Table 11: AfiFree Wash Controller Hardware ............................................................51

Table 12: AfiFree Wash Controller Wiring and DIP Switch Positions.......................52

Table 13: Wash Controller Activation –Connection and Settings .............................53

Table 14: AfiFree Wash Control Valve Vacuum Line Parts List................................56

Table 15: Parlor Type Icons ........................................................................................59

Table 16: Abbreviations for Animal Types.................................................................69

Table 17: Wash Controller Time Parameters Functionality........................................71

Table 18: Wash Time Intervals ...................................................................................72

Table 19: Terminal 155i parameters............................................................................74

Table 20: Flow control pulsation curves .....................................................................76

Table 21: Troubleshooting Guide................................................................................85

Table 22: Shut-Off Valve Installation—Replacement Parts List................................94

Table 23: AfiFree body Replacement Parts List..........................................................95

Table 24: Terminal 155i Replacement Parts List........................................................96

Table 25: Operating Modes and their Indicators.........................................................97

Table 26: Changing Operating Mode..........................................................................98

Table 27: Display field enablement and disablement................................................115

Table 28: Alarm and Malfunction Indicators............................................................117

May 2009 AfiFree Terminal 155i Installation Manual ix

Manual Overview

This manual contains information and instructions for a technician to mount, wire,

and configure the AfiFree Body, Terminal 155i, and Wash Controller system. The

manual follows the sequence of procedures for installation and configuration of the

system.

The appendices contain information regarding how to use AfiFree 155i, and

especially Terminal 155i.

How this Manual Is Organized

Chapter 1

System Objectives and Functions –purpose, features, operating

basics, and included components

Chapter 2

Site Preparation Requirements –The physical and electrical

infrastructure, utilities, and supplies that must be ready before starting

installation

Chapter 3

Mounting and Wiring –Instructions for physical mounting and

electrical wiring of components

Chapter 4

System Configuration –Software configuration, Wash Control setup,

and performance testing

Chapter 5

Troubleshooting –Instructions for troubleshooting potential

installation and configuration faults

Chapter 6

Corrective Maintenance –Instructions on parts requiring annual

replacement, replacing AfiFree155i units, and updating software

Chapter 7

Parts Lists –Inventory of replaceable components

The following appendices are provided:

Appendix A

User Information and Instructions

Appendix B

Milking System Cleaning Guidelines

x Chapter 1 System Objectives and Functions P/N 9040322

Conventions Used in this Manual

Important information is highlighted in a frame, as explained below:

WARNING

Actions requiring special attention to avoid a possible hazard to personnel.

For example, working with high voltage components.

CAUTION

Actions requiring special attention to avoid possible damage to equipment

or livestock.

For example, avoiding the use of detergent, that may damage the AfiFree

Body.

NOTE

Hints and recommendations for working efficiently.

For example, optimal cleaning techniques.

Abbreviations and Terms

Abbreviation

Meaning

ACR

Automatic Cluster Removal

AWG

American Wire Gauge

LED

Light Emitting Diode

Normally Closed

Normally Open

PICB

Plug-in Connection Box

Receive

Transmit

VAC

Alternating Current Voltage

VDC

Direct Current Voltage

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