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AfiMilk AfiFree 155i Installation Manual Download Page 1

 

 

 

 

 

 

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 

Summary of Contents for AfiFree 155i

Page 1: ...Kibbutz Afikim 15148 Israel 972 4 675 4811 Fax 972 4 675 1862 market afimilk co il http www afimilk co il Product P N 4199400 Manual P N 9040322 Version 1 1 May 2009 Milk Meter Installation Manual...

Page 2: ...atives 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 Copyright...

Page 3: ...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...

Page 4: ...r 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...

Page 5: ...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 Config...

Page 6: ...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...

Page 7: ...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 Fi...

Page 8: ...n 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 S...

Page 9: ...eparation Requirements The physical and electrical infrastructure utilities and supplies that must be ready before starting installation Chapter 3 Mounting and Wiring Instructions for physical mountin...

Page 10: ...ng 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 efficientl...

Page 11: ...m Both uses are described below AfiFree155i in a Computerized Flock Management System When connected to AfiSheep AfiGoat AfiFree155i performs many tasks essential to a profitable dairy operation such...

Page 12: ...ng the cluster when milk flow drops below a predetermined rate automatic cluster removal Figure 2 below illustrates AfiFree 155i not connected to AfiSheep AfiGoat Figure 2 Terminal 155i units not conn...

Page 13: ...May 2009 AfiFree Terminal 155i Installation Manual 13 Figure 3 Typical AfiFree155i Layout...

Page 14: ...and an electronics compartment The milk chamber collects measures and transfers the milk to the receiver vessel The electronics compartment manages operation of the AfiFree Body Pigtail cable Milk cha...

Page 15: ...as follows Vacuum shutoff valve Cluster remover Pulsation control two outputs The RS485 ports are as follows PC communication line Milk meter communication line Display and keyboard The front panel Fi...

Page 16: ...16 Chapter 1 System Objectives and Functions P N 9040322 Figure 5 Terminal 155i Panel Figure 6 Terminal 155i LCD Display...

Page 17: ...ntroller Figure 7 operates the AfiFree Wash Control Valve which controls the diaphragm to close and open the outlet from the AfiFree Body This allows the AfiFree Body to completely fill and drain alte...

Page 18: ...ction Box Figure 9 is a watertight junction box with terminal blocks for connecting power and communication wires The following equipment is interconnected through the AfiFree Connection Box AfiFree B...

Page 19: ...connections are made as follows The components of AfiFree155i connect to the Plug in Connection Box PICB see Figure 10 entirely by means of ready wired plugs and sockets The power and communication ca...

Page 20: ...shut off valve and connecting it to the AfiFree Body It also includes a generic milk meter bracket for distancing the AfiFree Body from the parlor wall if required The valve installation kit enables...

Page 21: ...AfiFree Body and Bracket Set AfiFree Body Measures milk quantity and controls cluster removal 4299120 4299130 See page 14 AfiFree15i5 Body Bracket Secures AfiFree Body to parlor wall or to generic mi...

Page 22: ...unication adapter between PC AfiFree 155i and identification system includes AfiPort P8 Connector Cable and Termination Resistor 4098550 See AfiCom1 Installation Manual Generic Milk Meter Bracket opti...

Page 23: ...ects between AfiFree155 body pigtail cable and connection box 2 8 m long 4093506 See page 38 15 m long 4093506D RS485 Communication Cable Connects PC 3 lengths of junction spacing available 40 cm spac...

Page 24: ...97310C AfiMilk Pre wired Solenoid Assembly Vacuum Vacuum Operated AfiMilk vacuum shut off sweep solenoid and removal solenoid with connection cables for plugging the solenoids into the Plug in Connect...

Page 25: ...2 115 Power Cable Extension Kit Connects between power cable and power supply 20 m length 4097315 One per parlor RS485 Extension Kit Connects between RS485 communication cable and PC 20 m length 40973...

Page 26: ......

Page 27: ...n Box page 28 Wash Controller page 29 Wash Control Valve page 29 Optional external start button page 29 AfiFree Body Positioning Position the AfiFree Body as follows Below the milking platform Above t...

Page 28: ...ach AfiFree Body connects to other components through an AfiFree Connection Box or a Plug in Connection Box PICB During normal operation there is no need for access to the connection box It can be pla...

Page 29: ...h of the operator so that the button is easily accessible If the Controller is activated remotely or automatically it can be mounted higher up However the Controller remote activation button must be m...

Page 30: ...usually attached to the Generic Milk Meter Bracket which is itself welded to the stainless steel side of the milking curb Terminal 155i is usually attached to a metal plate that is itself fixed to a p...

Page 31: ...he use of a separate transformer and separate 24 VAC wiring for each side of the milking parlor for two reasons If one transformer fails the second side of the parlor remains operational Troubleshooti...

Page 32: ...mes a basic parlor installation AfiFree155i milk meters and cluster removal pistons without additional outputs Table 6 shows the required specifications for solenoid wiring and communication wiring to...

Page 33: ...g the Communication Cable page 47 Installing a Shut off Valve Using the Valve installation kit for AfiFree page 48 Mounting and Wiring the Wash Controller page 50 Mounting the Wash Control Valve page...

Page 34: ...lk meter bracket attach the generic milk meter bracket to the wall securely The generic milk meter bracket can be bolted or welded to the wall NOTE The AfiFree Connection box has molded mounting point...

Page 35: ...s not being used for installation of the shut off valve Left or right Attach the AfiFree Body bracket direct to the generic milk meter bracket or wall using two hexagon socket screws DIN912 A2 M6 x 20...

Page 36: ...t and level the bracket manually along the roll axis Figure 14 3 Place a spirit level on one bracket arm and level the bracket manually along the pitch axis Figure 15 4 Repeat steps 2 and 3 as necessa...

Page 37: ...th bracket locks 180 Figure 16 to lock the unit into place 4 Connect the milk outlet to the milk line and check the following Make sure that all connections are tight Make sure that the line connectin...

Page 38: ...y pigtail cable into the AfiFree body connection cable for available lengths and part numbers refer to Table 2 on page 21 2 Route the AfiFree body connection cable to the connection box 3 Wire the Afi...

Page 39: ...g and wiring Terminal 155i has the following parts Terminal 155i Bracket Mounting below Mounting the Terminal 155i page 40 Wiring Terminal 155i page 41 Terminal 155i Bracket Mounting The options for m...

Page 40: ...Terminal 155i bracket attached with bands to a pipe Bolting the Terminal 155i Bracket to a Cabinet Figure 20 Terminal 155i bracket bolted to a cabinet NOTE The current procedure explains how to affix...

Page 41: ...ngular holes of the mounting bracket 2 To make sure that the top clip is above the bracket while maintaining firm pressure slide the Terminal 155i up 3 While maintaining firm pressure slide the Termin...

Page 42: ...use the AfiFree Connection Box or the PICB you must install a 4A rated fuse in the phase line of the 24V power supply line Connect the power cable as follows Installations using AfiFree Connection Box...

Page 43: ...ree Connection Boxes see Wiring Solenoids to an AfiFree Connection Box below Installations using PICBs see Connecting Solenoids to a Plug in Connection Box below Wiring Solenoids to an AfiFree Connect...

Page 44: ...cable from the Cluster Removal Solenoid into socket 3 b Plug the cable from the Vacuum Shut off Sweep Solenoid into socket 4 Table 8 Wiring a Non AfiMilk Solenoid Color of Wire on Connection Cable P...

Page 45: ...the pulsator connection cable s yellow wire 2 Wire the blue and brown wires to the pulsator as described in Table 9 below 3 Plug the connector of the pulsator connection cable into socket 5 of the PIC...

Page 46: ...ox according to Figure 17 Connecting an AfiMilk Pre wired External Start Button Plug the external start button s cable into socket 12 of the PICB Connecting a Non AfiMilk External Start Button to a Pl...

Page 47: ...ire the communication cable to the connection boxes according to Figure 17 3 In the last connection box on the communication line install a 120 resistor across contacts 7 and 8 of the connection box T...

Page 48: ...ion Braid for AfiFree Communication Braid Extension Kit up to 20 m Red Black Red Black Red Black AfiCom1 Port 6 or 8 RS485 Plug in Connection Box Stall 2 10 P8 Connector Cable Green Red Use connection...

Page 49: ...and Figure 26 This stops the valve pressing against its holder Attach the shut off valve to the Generic Shut off Valve Holder using the two hexagon head bolts washers spring lock washers and nuts 3 C...

Page 50: ...arts Mounting the Wash Controller below Wiring the Wash Controller and Setting DIP Switches page 52 Mounting the Wash Controller The Wash Controller can be installed using mounting plates P N 4088016...

Page 51: ...No Quantity Allen screw M6 20 mm 9020383 4 Star washer 9010386 4 Nut M6 9020212 8 1 Determine the best location for the Wash Controller in accordance with Wash Controller Positioning page 29 2 Attach...

Page 52: ...ree155i bodies Connect wires and configure the DIP switch for the Wash Control Valves as in Table 12 Table 12 AfiFree Wash Controller Wiring and DIP Switch Positions Quantity of AfiFree155i Bodies Qua...

Page 53: ...d Lines to J8 Pins Jumper JP1 Pins Set DIP Switch DSW4 Automatic 24V AC DC 2 4 1 2 4 OFF Automatic Dry Contact 1 2 2 3 4 OFF Manual Wash Controller Activation Button No connections 1 2 4 ON Set the DI...

Page 54: ...ash Control Valve Figure 8 page 18 is supplied pre assembled 1 Use a saddle clamp with a female connector to connect the Wash Control Valve to the main vacuum line Figure 30 Detail 3 2 Connect the sol...

Page 55: ...in the vacuum line Detail C slightly off center from each AfiFree Body Ensure that the holes are in a uniform position on the line and relative to the AfiFree Body 4 Press the nipple Item 3 into the...

Page 56: ...lsator pipe single 5100001 3 Nipple on vacuum distribution line assembly 5200027 4 Tee PVC cemented 90 50 mm gray 1600C0007 5 Short Reducer PVC bush cemented 50 X 25 mm gray 5001520 6 Hose PVC glue co...

Page 57: ...May 2009 AfiFree Terminal 155i Installation Manual 57 Figure 31 AfiFree Wash Control Valve Vacuum Line...

Page 58: ...has the following steps 1 Configuring the AfiCom1 card see the AfiFarm Configuration Manual P N 9040148 2 Configuring the Parlor see below Configuring the Parlor 1 Make sure AfiSheep AfiGoat and AfiMe...

Page 59: ...Table 15 and Figure 32 the number of stalls in the parlor Figure 32 under Milk Meter Type Table 15 Parlor Type Icons Name of Parlor Icon Herringbone Polygon Rotary Entrance Identification Rotary Stal...

Page 60: ...type Select AfiFree milk meter icon Click here to move to next dialog box Number of stalls selected Figure 32 Parlor Configuration Dialog Box 6 Click The Ideal Setting dialog box appears 7 In the Ide...

Page 61: ...ust wait for one step to complete before progressing to the next one Configuration of AfiFree 155i milk meters connected to a flock management computer requires the following operations Assigning Iden...

Page 62: ...AfiFree155 milk meter is not assigned an identification number yet AfiFree Milk Meter Column AfiFree Milk Meter Icon ID assigned and in communication No ID or communication Figure 33 AfiMen Real Time...

Page 63: ...ware 0 6 Click OK The AfiMen Real Time window Figure 33 appears 7 Select the Track tab Figure 35 Figure 35 AfiMen Real Time Window Track Tab 8 Make sure the milk station is in session If the milk stat...

Page 64: ...33 the fill in the icon representing the milk meter changes from red to grey indicating that the AfiFree 155i milk meter has an identification number and communication is correct NOTE The cleaning cy...

Page 65: ...ification Number the Identification Number appears after Id for example Id23 If the stall has no identification number Id_ _ appears on the display NOTE When the Terminal 155i is in Settings mode if y...

Page 66: ...on is not in session click Continue to put it in session 4 Select the Milk tab 5 Click PARAMETER The Milk Parameters dialog box Figure 34 appears 6 Set the Automatic Load Software parameter value to 1...

Page 67: ...g Milk Meter Software below Manually Uploading Milk Meter Software 1 Open AfiMen The AfiMen Real Time window Figure 33 appears 2 Select the Milk tab 3 Click to enter Test mode 4 Select the Track tab 5...

Page 68: ...multaneously press and until Id appears on the display The Terminal 155i is now in Settings mode Id is short for Stall Identification Number It is the first item in the Settings menu NOTE When the Ter...

Page 69: ...em in the Settings menu NOTE When the Terminal 155i is in Settings mode if you press for four seconds the Terminal 155i saves the current settings and exits Settings mode 2 Use to scroll through the S...

Page 70: ...upplied by the parlor wash system The AfiFree Wash Controller alternately turns the Wash Control Valve s on and off The Wash Control Valve opens and closes the washing diaphragm of each AfiFree Body c...

Page 71: ...Table 17 Wash Controller Time Parameters Functionality Parameter DIP Switch Action To Set Parameter See Controller Valve AfiFree Body Time On DSW1 Supplies 24 V to valve Supplies air to AfiFree Body B...

Page 72: ...o double parameter values for DSW1 and DSW2 move the DSW4 switch 3 to OFF For example if switch 3 on DSW4 is set to OFF then 1 second becomes 2 seconds 2 seconds becomes 4 seconds etc Figure 38 DSW1 a...

Page 73: ...36 38 kPa 3 Check that the Wash Controller has been set up to local requirements 4 To verify that there is vacuum at all the washing diaphragms remove the vacuum line connection to the AfiFree155 body...

Page 74: ...ing b Verify that each AfiFree155i milk meter responds to all the button presses c Verify that all AfiFree155i milk meters send data to the computer d Verify that the data sent from the AfiFree155i mi...

Page 75: ...ulsation Stall 2 0 8 1 0 OFF PF Pulsation Frequency Constant Pulsation Frequency set Stall 3 30 180 1 p min 120 PR Pulsation Ratio Constant Pulsation Ratio set Stall 4 50 80 1 50 PTP Reverse pulsation...

Page 76: ...0 set outputs to work with pulsation control and strip IOC 1 set outputs to work with back flush and strip IOC 2 set outputs to work with pulsation control and diversion milk line IOC 3 set outputs t...

Page 77: ...ss for several seconds 4 To decrease the value do one of the following To decrease the value by the amount indicated in the Step column press and release To decrease the value by 10x the amount indica...

Page 78: ...lps to stimulate milk let down Three parameters control the stimulation function Stimulation Duration STD Stimulation Pulsation Frequency STF Stimulation Pulsation Ratio SR To allow automatic stimulat...

Page 79: ...istered The Milk Remainder parameter compensates by automatically adding a set amount to the quantity of milk recorded for each animal Sweep either under AfiSheep AfiGoat or in a standalone configurat...

Page 80: ...e different from the value in AfiSheep AfiGoat then AfiMen overwrites the value in the milk meters with the value in AfiSheep AfiGoat except for the G parameter This option is useful when replacing a...

Page 81: ...for an Individual Milk Meter 1 Weight the milk from the milk meter the Actual Amount 2 Calculate G for the milk meter as follows Actual Amount Amount recorded by AfiFree155i X 100 G value 3 Set the G...

Page 82: ...Type menu and select a new value 5 Click OK to accept the changes The Password dialog box appears 6 In the Password dialog box type afi and click OK to confirm the changes Uploading Parameter Values...

Page 83: ...ameter value on all AfiFree 155i milk meters 1 Open AfiMen The AfiMen Real Time window appears Figure 33 2 In the AfiMen Real Time window select 3 Click The Password dialog box appears 4 In the Passwo...

Page 84: ......

Page 85: ...21 Troubleshooting Guide Indication Probable cause Possible solutions Display panel is not illuminated Faulty connection of power supply 24 V cable to the control unit Check the power connection Insuf...

Page 86: ...er units are OK then check local vacuum line connection to AfiFree Body If other units have similar problems then check for problems in main vacuum line Defective diaphragm Check diaphragm and replace...

Page 87: ...lace Blocked air bleeder of the AfiFree Body Unblock the air bleeder The G parameter is inaccurate Change the G parameter to the correct value Alternating large weighing deviations Alternating over we...

Page 88: ......

Page 89: ...nt Parts List page 95 Washing valve rubber diaphragm on AfiFree body for part number see AfiFree Body Replacement Parts List page 95 Milk Pipe Section between shut off valve and AfiFree body P N 52355...

Page 90: ...1 Preparing the Computer below This step prepares the computer to Assign the original identification number to the new AfiFree155i unit Download the software including parameter values 2 Removing a M...

Page 91: ...into the replacement Terminal 155i Checking and Preventive Maintenance The checks listed below should be made from time to time and especially before the national cattle breeders association performs...

Page 92: ...llowing Check that the vacuum level is correct using the parlor gauges and a reference gauge a gauge brought from outside the parlor Make sure that the vacuum pumps have sufficient reserve for the num...

Page 93: ...155i Replacement Parts List page 96 Vacuum Shut Off Valve Installation Replacement Parts List The AfiFree155i milk meter controls a valve that shuts off vacuum to the cluster When an animal has finish...

Page 94: ...21 A2 9020769 3 Washer M6 DIN 9021 A2 9020769 4 Spring Lock M6 washer DIN 127 A2 M6 9020684 5 Nut M6 DIN 934 A2 9020683 6 Hexagon Head Bolt M6 x 20 DIN 933 A2 9020641 7 Washer M6 DIN 9021 A2 9020769 8...

Page 95: ...ames and part numbers Figure 43 AfiFree body Exploded View Table 23 AfiFree body Replacement Parts List No in Figure 43 Part Name P N Qty Complete AfiFree155 body 4299120 1 2 AfiFree body retaining cl...

Page 96: ...inal 155i Replacement Parts List Table 24 lists the replacement parts for Terminal 155i Table 24 Terminal 155i Replacement Parts List Part Catalog No Terminal 155i 4097335 Terminal 155i bracket 409734...

Page 97: ...onfigurations under AfiSheep AfiGoat or standalone Operating Mode Indicators Table 25 shows AfiFree155i s operating mode definitions on Terminal 155i Mode Milking Removal Cleaning Sub Mode Normal Mess...

Page 98: ...in Milking Mode Message Sub Mode in Removal Mode PC button pushing Removal Mode Message Sub Mode in Removal Mode Enter button pushing Removal Mode Message Sub Mode in Milking Mode PC button pushing Mi...

Page 99: ...e action of the following To confirm a changed value press the Enter button To keep the current value press the Cancel button Terminal 155i User Procedures This section contains the following sub sect...

Page 100: ...this procedure in the following cases Animal ID not detected Animal ID not correctly detected 1 On the Terminal 155i press the Edit Message mode button The message sub mode is activated 2 Press the An...

Page 101: ...l B 4 3 6 2 Animal ID field Animal IDs longer than six digits The Terminal 155i LCD displays no more than six digits of an animal ID If there are no alphabetical characters the last six characters are...

Page 102: ...ys from insemination fields A second code is displayed on the Peak flow field and a third code is displayed on the Momentary flow field c Do the appropriate of the following To enter or change a code...

Page 103: ...May 2009 AfiFree Terminal 155i Installation Manual 103 While the data is being processed the data updating icon flashes Following successful processing the message mode is deactivated...

Page 104: ...ld displaying Example Cleaning The Temperature inside of Milk Meter Body Celsius Fahrenheit Removal Hyphen before first milking or after reset Final milk yield at end of previous milking before reset...

Page 105: ...by average conductivity of last 3 sec Removal OFF before first milking or after reset The Maximum Conductivity of the milk at last milking in AfiFree conductivity units Milking The Maximum Conductivit...

Page 106: ...ted yield after identification OFF when no identification Milking Predicted yield after identification 6 Days in Milk field Mode Description Example Cleaning OFF Removal Days in milk after identificat...

Page 107: ...n no identification Milking after identification Days from insemination after identification 8 Momentary Flow field Mode Description Example Cleaning OFF Removal OFF Milking Current milk flow 9 Peak F...

Page 108: ...d of previous milking before reset Milking Time from start of current milking min sec When milking time reaches 20 min the counting restarts from 0 00 and the first character blinks 11 Pulsation field...

Page 109: ...oval Group number after identification OFF when no identification Milking Group number after identification 14 Infected Half icon field Mode Description Example Cleaning OFF Removal Milking After iden...

Page 110: ...ond code is displayed on the Peak flow field If an animal has three health codes the third code is displayed on the Momentary flow field In both those cases the icon of flow fields and flow bar are de...

Page 111: ...e cleaning fluid in AfiFree conductivity units updated every 3 sec end calculated by average conductivity of last 3 sec Removal OFF before first milking or after reset The Maximum Conductivity of the...

Page 112: ...in AfiFree conductivity units 4 Predicted conductivity field Mode Description Example Cleaning Removal Milking OFF 5 Predicted yield field Mode Description Example Cleaning Removal Milking OFF 6 Days...

Page 113: ...de Description Example Cleaning OFF Removal OFF before first milking or after reset Last milk flow peak at end of previous milking before reset Milking Last milk flow peak 10 Milking time field Mode D...

Page 114: ...Removal Milking OFF OFF ON OFF OFF ON ON ON 12 Stall number field Mode Description Example Cleaning Removal Milking Stall number 13 Group field Mode Description Example Cleaning Removal Milking OFF 1...

Page 115: ...D field Press simultaneously Cancel and 4 To disable enable Group field Press simultaneously Cancel and 5 To disable enable Peak Flow Current Flow and Flow bar fields Press simultaneously Cancel and 6...

Page 116: ...a code defined in AfiSheep AfiGoat as a Low level health code Before the milking Animal ID field and Health code field are blinking YES NO High conductivity The milk has conductivity high than alarm...

Page 117: ...ield is blinking and Animal ID field blinks with NO YES Diaphragm fault Diaphragm not open During the milking Stall number field is blinking and Animal ID field blinks with NO YES No Milk Meter The co...

Page 118: ...stem SAE Afikim recommends cleaning fluids with a maximum concentration of 10 Butyl Glycol or Butyl Cellusolve Follow all of the manufacturers recommendations including concentrations temperatures and...

Page 119: ...actors requiring additional liquid for cleaning Double size milk line is installed in the parlor Milk tank is far from the parlor Temperature and Cycle There are various cleaning systems and procedure...

Page 120: ...surfaces of the AfiFree155 bodies Performing an Acid Wash Perform an acid wash three times a week or more frequently when necessary The acid wash does not replace the daily cleaning routine NOTE Ther...

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