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Installer Instruction
This is a not the first formal release - it replaces the following releases: Installer Instr'n Milfos ED200 12May08.doc Installer Instr'n Milfos ED200 10Feb09.doc You will find all significant changes (from previous 12May08 document) are on pgs 1 to 3, 7, 9 (Unmarked - Wiring diagram) and 11 to 16 only, with right margin change-bars. Any other change-bars are typo/format changes only. CONTENT Hyperlinks
1. Overview ................................................................................................... 2 2. Health & Safety ......................................................................................... 2 3. Milk Metering integration with Protrack .................................................. 2 4. ED200 Position on Platform ...................................................................... 2 5. Areas of Responsibility.............................................................................. 4 6. Bill of Materials ......................................................................................... 4 7. Parts and Functions................................................................................... 6 8. Pre Installation Work Required ................................................................ 7 9. ED200 Component Layout ........................................................................ 8 10. Recommended Install Process................................................................ 8 11. Installing Drivers for USB to 422 Converter ......................................... 10 12. Configuring Protrack............................................................................. 10 13. Testing ED200 Communications ........................................................... 11 14. Appendix A ED200 Receiver Unit Wiring Schematic.......................... 12 15. Appendix B Troubleshooting.............................................................. 12 16. Appendix C - FAQ .................................................................................. 15 17. Appendix D ED200 Technical Specifications...................................... 16
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Installer Instruction
1.
Overview
The Milfos Milk Meter system will integrate with the ED200 Receiving unit that communicates directly via COM port to the Protrack PC and stores the data for the round as the milk meter passes the receiving unit. Protrack stores this data and can display this information in reports, display information in the Dairy and populate groups based on the data. The ED200 may be retrofitted into existing systems i.e. where there is an existing Milfos Automatic Cup Removers, Milk Meters and IR gun. Or the ED200 may be installed into a new installation of Milfos Milk Meters. Not all Milfos Milk Meters can communicate with the ED200. This needs to be understood and confirmed by Milfos at the point of sale. Ideally both the Milfos representative and Protrack representative should be on site at the time of install, if however this is not practical the areas of responsibility should be understood.
2.
3.
4.
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6.
Bill of Materials
These parts will be required for the installation of Milfos ED200. LIC to Supply: a) ED200 Receiver Unit. b) Mounting Plate for Receiver Unit. c) 4 x Bolts for Mounting Plate. d) ED200 Termination Box. e) 8 x U bolts with Nuts and Washers. f) 2 x Mounting Pipes. This wont be required for some existing / new installations. g) 230Vac to 24Vdc Power Supply. This wont be required for New Architecture Install. h) USB to RS485/422/232 Converter. Installer to Supply: a) Conduit gland(s) and fittings. b) Cat 5E STP cable (same cable as in Installers Pack) c) Connectors. d) Bootlace ferrels. e) Silicon or something similar to seal extra glands on ED200 Termination box.
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7.
b) Milfos ED200 receiving unit is mounted at either the Cups Off or Cups On position, roughly in line with the Intel Scan Plus Units and as a suggestion this should not be placed more than the distance of the original cables and preferably less than half a meter away. This activates the Intel Scan Unit and prompts it to send milking information by transmitting via the Milfos ED200 Controller (Termination unit) to the PC. This unit comes complete with U-Bolts ready for mounting.
c) The Milfos ED200 Termination unit pictured below receives power from a 24VDC power supply and provides power to the ED200 Receiver. It then receives the milking information from the ED200 Receiver. Both these functions occur via the Yellow Red and Green wires in the above picture. It then sends the information via our screened Cat 5E STP cable to the dairy PC.
d) 24VDC Power supply. For Old architecture systems, the 24VDC Power Supply that is supplied by Milfos can be used. This is installed between a 230VAC power source and ED200 Termination unit. It has 3 core flex from power source (3 pin plug) then uses 2 pairs of the Cat 5E STP cable going to ED200 Termination unit. For New architecture systems, the 24VDC power can be run from the 24VDC power supply inside the top cabinet. The Milfos 24VDC power supply isnt required.
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8.
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9.
Office
PC
IR Communications
10.
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d) Remove one of the larger cable glands on the bottom of the ED200 Termination box and drill the hole out to fit a 20mm conduit gland. Fit gland and run conduit carrying the Cat 5 STP cable that the Electrician ran as part of the pre-installation work. Trim conduit to suit and support the conduit from the roof by cable tying to some steel framework or by installing some light chain between roof and bracket. Terminate the Cat 5 STP cable in the Termination unit, blocks and colours are clearly marked inside. Use appropriate bootlace ferrels on conductor ends. See Wiring Diagram below: e) Block the remaining glands in the Termination box off so no water can get inside. Silicon or something similar can be used. f) In the office mount the ADAM-4561 / ICP Con 7561 onto DIN rail either in the top cabinet (New Architecture or Vynco Vantage-V01 Systems) or on wall behind the PC (Old Architecture). If it is an Old Architecture system, some DIN rail will need to be attached to the wall. Use appropriate bootlace ferrels on conductor ends. Note: Dont plug the USB cable into the PC until instructed to do so. g) Wire the two pairs of the Cat 5E STP cable that carry 24VDC to the power supply. This supply in Old Architecture will be the 24VDC power supply unit that Milfos supplied. This Power Supply will need to be plugged into Mains power (preferably not off the UPS). If it is New Architecture or Vynco Vantage-V01 System then the 24VDC supply is from the DIN terminals in the top cabinets. h) The Cat 5E STP cable data pair from the ED200 Termination unit should then be terminated on the ADAM-4561 / ICP Con 7561 converter. i) Install Driver for the USB to 422 converter as outlined in the next section. j) Test that the ED200 is communicating with Protrack and the Milk Meters. k) Perform an Installer QA for the Milfos ED200.
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Milfos ED200 Installation 11. Installing Drivers for USB to 422 Converter
Turn the PC on and once it has started up refer to the appropriate driver installation document: Adam 4561 Driver Installation document. Installation and Configuration Guide for Protrack PCs document (ICP Con driver install refer Milfos Milk Meters (ED200) section). Please rename the COM ports according to the following conventions utilising the steps covered in the Installation and Configuration Guide for Protrack PCs document.
UPS Platform Reader Gallagher XDS5000 Tru Test XD3000 Milfos ED200 Draft Reader PLC Touchscreen 1 Touchscreen 2 Touchscreen 3 COM COM COM COM COM COM COM COM COM COM 1 2 3 4 5 6 7 8 9 10
12.
Configuring Protrack
a) Open PT Config and select the COM5 port for ED200 as determined by the previous section installation instructions.
b) Close PT Config (It will automatically save settings). Protrack will now be communicating with the ED200.
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c) The ED200 has a test mode that can be used to test the integrity of the communication link between the ED200 and the Protrack PC. To enable the Communications Test Mode remove the link in the ED200 Termination unit marked External Pushbutton. Normally this link is a short wire with crimped terminations, in the picture below it is shown as a loop of black wire. Note: A wiring diagram for the ED200 can be found in Appendix A. d) Removing this link will enable the ED200 Comms Test Mode which will send a special test message to the Protrack PC. When the Milfos ED200 Monitor is enabled in the Protrack Device Communications window, receiving the ED200 Comms Test Mode data packet will cause the message to be written to the log window containing the text: Received Valid Test Mode Packet as well as the raw packet data bytes in hex. Replace the link when communications has been successfully established. e) Spin the platform and every time a Milk Meter Unit passes the ED200, a packet of information should be displayed in the message screen. You should rotate the platform so each Milk Meter passes the ED200 and watch the logged messages on the Protrack Device Communications window at the ED200 position to check the each Milk Meter have been assigned the correct Bail Number and matches the Protrack Bail Numbers. If the milking clusters are to drop below the bridge then check that all clusters drop down before Milking starts. f) If the ED200 doesnt communicate or respond as expected, see Appendix B Troubleshooting section.
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Milfos ED200 Installation 14. Appendix A ED200 Receiver Unit Wiring Schematic
15.
Appendix B Troubleshooting
Issue 1: Ignoring Duplicate Data Packet for Bail is displayed in Device Communications (Milfos is displaying debug information) screen when platform is spinning. Reason: Bail IDs are all set the same (default is Bail 200) the in Milk Meter Units. Note: Also if the platform moves past the ED200 then backs up, it will see two duplicate data packets for the same bail. This will rectify itself once the platform spins under normal operating conditions.
03/11/2008 03/11/2008 03/11/2008 03/11/2008 04:26:38.312 04:26:38.390 04:26:38.437 04:26:38.437 r,PlatformReader,3,LA 00000 0 982 000116085013 r,PlatformReader,3,LA 00000 0 982 000116085013 O,TFAMilkMeter,,39755.1851670949,0,200,0,2,0,0,0,0,0,0 Err: OnOpDataMessage: Failed to Lookup Cow EID for Milk Meter on Bail: 200
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Fix:
Issue 2: Bail sequence is incorrect in Device Communications (Milfos is displaying Monitor information) screen with platform spinning the correct way. Reason:
05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009
Bail numbers incorrectly programmed in Milk Meter Units. See below for example.
L,21,,0,39849.2742191088,0,0,0,39849.2741273199 O,TFAMilkMeter,,39849.27453125,9.825,6,0,1,148,0,2.76,8.28,0,0 Msg: OnOpDataMessage: Store: TFAMilkMeter,982 000094247259,39849.27453125,9.825,6,0,1,148,0,2.76,8.2 Mon: ED200: Bail: 6 Yield: 9.825 Status: 1 Draft: 0 Peak Flow: 8.28 Duration: 236 Average Flow: 2.76 Time to r,PLC,1,@00RD00000254* r,DraftReader,1,A 00000 0 982 000094294607 Q,0,982 000094294607,0,0,0,0,0,0,D r,PLC,2,@00WD0053* w,PLC,3,@00RD0003000154* r,PLC,3,@00RD00000254* w,PLC,4,@00WD00030000000050* r,PLC,4,@00WD0053* E,22,,0,0,0,0,0,0 L,22,,0,39849.2743531134,0,0,0,39849.2742646704 Mon: SendCommand5: Request Draft Centre w,PLC,7,@00WD0005000452* r,PLC,7,@00WD0053* O,TFAMilkMeter,,39849.2746589236,8.421,8,0,1,140,0,2.04,5.22,0,0 Msg: OnOpDataMessage: Store: TFAMilkMeter,982 000094294768,39849.2746589236,8.421,8,0,1,140,0,2.04, Mon: ED200: Bail: 8 Yield: 8.421 Status: 1 Draft: 0 Peak Flow: 5.22 Duration: 264 Average Flow: 2.04 Time to r,PLC,1,@00RD00084258* r,PLC,2,@00WD0053* w,PLC,3,@00RD0003000154* r,PLC,3,@00RD00084258* w,PLC,4,@00WD00030000000050* r,PLC,4,@00WD0053* B,1,,0,0,0,0,0,0 E,49,,0,0,0,0,0,0 L,49,,0,39849.2744900116,0,0,0,39849.2743996588 O,TFAMilkMeter,,39849.2747979861,8.532,7,0,1,137,0,2.28,7.02,0,0 Msg: OnOpDataMessage: Store: TFAMilkMeter,982 000094294521,39849.2747979861,8.532,7,0,1,137,0,2.28, Mon: ED200: Bail: 7 Yield: 8.532 Status: 1 Draft: 0 Peak Flow: 7.02 Duration: 267 Average Flow: 2.28 Time to r,PLC,1,@00RD00000254* r,DraftReader,1,A 00000 0 982 000094294734 Q,0,982 000094294734,0,0,0,0,0,0,D r,PLC,2,@00WD0053* w,PLC,3,@00RD0003000154* r,PLC,3,@00RD00000254* w,PLC,4,@00WD00030000000050* r,PLC,4,@00WD0053* E,50,,0,0,0,0,0,0 L,50,,0,39849.2746220255,0,0,0,39849.2745348963 Mon: SendCommand5: Request Draft Centre w,PLC,7,@00WD0005000452* r,PLC,7,@00WD0053* O,TFAMilkMeter,,39849.2749428472,8.958,9,0,1,322,0,1.08,3.06,0,0 Msg: OnOpDataMessage: Store: TFAMilkMeter,982 000094295027,39849.2749428472,8.958,9,0,1,322,0,1.08, Mon: ED200: Bail: 9 Yield: 8.958 Status: 1 Draft: 0 Peak Flow: 3.06 Duration: 535 Average Flow: 1.08 Time to r,PLC,1,@00RD00000254*
06:35:15.937 06:35:19.500 06:35:19.500 06:35:19.500 06:35:27.187 06:35:27.203 06:35:27.203 06:35:27.234 06:35:27.234 06:35:27.281 06:35:27.281 06:35:27.343 06:35:27.593 06:35:27.593 06:35:27.593 06:35:27.593 06:35:27.656 06:35:30.531 06:35:30.531 06:35:30.531 06:35:39.125 06:35:39.171 06:35:39.171 06:35:39.234 06:35:39.234 06:35:39.296 06:35:39.296 06:35:39.296 06:35:39.296 06:35:42.546 06:35:42.562 06:35:42.546 06:35:50.796 06:35:50.796 06:35:50.796 06:35:50.843 06:35:50.843 06:35:50.890 06:35:50.890 06:35:50.937 06:35:51.484 06:35:51.484 06:35:51.859 06:35:51.859 06:35:51.906 06:35:55.062 06:35:55.062 06:35:55.062 06:36:02.265
Fix: Issue 3:
Milfos Program Bail numbers correctly. Some Milk Meter information not coming back through when platform is spinning.
Reason: Could be same as Issue 2. Could be that the ED200 is not communicating with all Milk Meter Units because it is out of range, misaligned, sunlight is interfering or Dirty lenses on ED200 / Milk Meter Unit. Fix: Try Moving ED200 to a better position or closer to the Milk Meter Unit (Make sure it wont catch anything when platform is spinning). If sunlight is a problem, block sunlight from Milk Meter Unit when it is with range of the ED200 unit. Check that Milk Meter Unit and ED200 lenses are clean.
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Fix: Check all data is coming back into Protrack. If not see Issue 3. If all the data is coming back, direct the issue back to the local Milfos dealer.
Issue 5: Clusters dropping down when going past ED200 (Clusters are not supposed to be dropped for this installation). Reason: Fix: Milk Meter Units incorrectly programmed. Direct the issue back to the local Milfos dealer.
Milk Yield coming back is incorrect (Also see Appendix D - FAQs). Milk Meters incorrectly calibrated (Also see Appendix D - FAQs). Direct back to the local Milfos dealer (Also see Appendix D - FAQs).
Issue 7: Reason:
MINDA Milk Yield report not showing any data. ED200 not communicating or MINDA report not correctly set up.
Fix: Check ED200 communicating with Milk Meters and fix if it is a problem. Check Milk Yield report set up and if problem persist, call 0508 Protrack.
Issue 8: Reason:
No data is coming back through from ED200 it has been working before. ED200 has lost power or lens on ED200 is dirty.
Fix: Check power supply and the switch on the side of ED200 Termination box is on (ED200 Receiver should have display lit up when power is on). Clean the ED200 lens.
Issue 9:
Reason: Comms wires have been incorrectly wired. The following Data has been captured in the log files.
29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 29/01/2009 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.969 14:53:07.985 14:53:07.985 14:53:07.985 14:53:07.985 14:53:07.985 Err: ED200RxChar: Discarding Invalid Start Mon: ED200RxChar: Received Data: AB Err: ED200RxChar: Discarding Invalid Start Mon: ED200RxChar: Received Data: FE Err: ED200RxChar: Discarding Invalid Start Mon: ED200RxChar: Received Data: BE Err: ED200RxChar: Discarding Invalid Start Mon: ED200RxChar: Received Data: B3 Err: ED200RxChar: Discarding Invalid Start Mon: ED200RxChar: Received Data: BA Err: ED200RxChar: Discarding Invalid Start Mon: ED200RxChar: Received Data: FF Err: ED200RxChar: Discarding Invalid Start Mon: ED200RxChar: Received Data: F9 Err: ED200RxChar: Discarding Invalid Start Err: ED200RxChar: Discarding Invalid Start Err: ED200RxChar: Discarding Invalid Start Mon: ED200RxChar: Received Data: FB FF Err: ED200RxChar: Discarding Invalid Start of Packet Byte: AB of Packet Byte: FE of Packet Byte: BE of Packet Byte: B3 of Packet Byte: BA of Packet Byte: FF of Packet Byte: F9 of Packet Byte: FB of Packet Byte: FF of Packet Byte: FF of Packet Byte: FF
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Fix: Check wiring of the communication wires they are most likely to have been reversed. Re wire to specification.
16.
Appendix C - FAQ
Q. Why isnt the data being displayed on Protrack after installation?
A. The Protrack Layout displays the information for the last completed platform revolution that the cow went around in the same milk cycle i.e. cow 123 would display nothing for the first two milk cycles after the integration occurred as there is no data to display. Example cow 123 displays 14.6 in the morning milking when she first comes onto the platform. That 14.6 reading was from the previous mornings milking. If cow 123 went around the platform twice that same milking then the second time around she will display the amount from the first time around the platform.
Q.
Not all of the cows are appearing on the Milk Yield report? Are the meters working properly?
A. The most likely reason is that there are Unknown or Unlinked cows on the platform. These yields are disregarded, as Protrack cant allocate them to a cow on the MINDA database. This data in the log file highlights an Unknown cow. The two commas in the yellow highlight is where a valid EID number should be, blank indicates an Unknown cow.
05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05:22:44.187 05:22:44.265 05:22:44.312 05:22:44.312 05:22:44.312 05:22:44.343 05:22:44.421 r,PlatformReader,3,LA 00000 0 982 000094294974 r,PlatformReader,3,LA 00000 0 982 000094294974 O,TFAMilkMeter,,39849.2241239815,5.79,18,0,1,64,0,1.56,4.68,0,0 Err: OnOpDataMessage: Failed to Lookup Cow EID for Milk Meter on Bail: 18 Mon: ED200: Bail: 18 Yield: 5.790 Status: 1 Draft: 0 Peak Flow: 4.68 Duration: 236 Average Flow: 1.56 Time to r,PlatformReader,3,LA 00000 0 982 000094294974 r,PlatformReader,3,LA 00000 0 982 000094294974
This data in the log file highlights an Unlinked cow. The data looks fine in the Log file, but the timing graph for the EID (green ellipse) reveals the cow is Unlinked.
05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 05/02/2009 06:34:15.906 06:34:15.906 06:34:18.875 06:34:19.906 06:34:18.875 06:34:25.968 06:34:25.968 E,16,,0,0,0,0,0,0 L,16,,0,39849.273521412,0,0,0,39849.2734303412 O,TFAMilkMeter,,39849.2738295718,9.141,1,0,1,216,0,1.62,4.5,0,0 Msg: OnOpDataMessage: Store: TFAMilkMeter,982 000094246918,39849.2738295718,9.141,1,0,1,216,0,1.62, Mon: ED200: Bail: 1 Yield: 9.141 Status: 1 Draft: 0 Peak Flow: 4.5 Duration: 360 Average Flow: 1.62 Time to r,DraftReader,1,A 00000 0 982 000094294925 Q,0,982 000094294925,0,0,0,0,0,0,D
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Q. After making a group of cows with low milk yield in MINDA there seems to be a large number of cows that are giving more than the threshold that I specified. Why? A. This is generally because a cow may have gone around the platform twice and milked out the first time and the cow cupped again the second time. Example: Cow 234 gave 12.3 the first time and had a Milking Behaviour Completed and went around a second time and gave 0.0 with Milking Behaviour Completed. The group looks for Milking Yields below the threshold. To resolve this issue, train staff cupping cows not to put cups on cows that have already been milked out properly.
Q.
A. There could be a number of reasons. What Protrack does is take the data from the Milk Meter and allocates it to the cow that Protrack has allocated to that bail. If the wrong cow is allocated to that bail, then the yields will vary, as it will have been allocated to the wrong cow. If this happens call 0508 Protrack for assistance. Also a Milk Meter may be incorrectly calibrated for that bail and yields for that bail would be lower than other bails. A MINDA custom report can be created to display this information. With Milk Meter Calibration queries please call your local Milfos dealer.
17.
Note: * Range as being defined as distance between ED200 Receiver and Milk Meter Unit when both units are parallel. - End of Instruction For continuous improvement purposes, please provide helpful comment/feedback on this document to - daker@lic.co.nz
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