Gallagher DAIRY SCALE XDS5000 User guide

Installer Manual - ENG
DAIRY SCALE
XDS5000

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PUBLISHEDBY
GallagherGroupLimited
KahikateaDrive,PrivateBag3026
Hamilton,NewZealand
Copyright©GallagherGroupLimited2011
Allrightsreserved.PatentsPending.
DairyScaleInstallationManual
3E0673‐Edition11‐January2015
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DISCLAIMERWhilsteveryefforthasbeenmade
toensureaccuracy,neitherGallagherGroup
Limitednoranyemployeeofthecompany,shall
beliableonanygroundwhatsoevertoanyparty
inrespectofdecisionsoractionstheymaymake
asaresultofusingthisinformation.
InaccordancewiththeGallagherpolicyof
continuingdevelopment,designandspecifications
aresubjecttochangewithoutnotice.
DevelopedandmanufacturedbyGallagherGroup
Limited,anISO9001:2000CertifiedSupplier.

3E0673DairyScaleInstallermanual
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Contents
Introduction.........................................................................................................................1
ModelXDS5000................................................................................................................1
Installation..........................................................................................................................2
PlanningtheInstallation...................................................................................................2
Powersupplyinstallation..................................................................................................3
RaceandChicaneinstallation...........................................................................................4
WeighingPlatformsetinstallation...................................................................................6
PanelReaderinstallation................................................................................................13
Scaleheadinstallation....................................................................................................14
ConnectingcablestotheScale...........................................................................................15
TestingtheDairyScalecomponents...................................................................................17
CheckingthattheLoadcellsarefunctioning..................................................................17
CalibratingtheScaleheadtotheWeighingPlatform....................................................19
Settingmaximumandminimumweights.......................................................................22
TestingtheScale.............................................................................................................23
TestingthePanelReader................................................................................................23
DairyScaleEngineeringOptionsmenu...............................................................................24
AccessingtheDairyScaleEngineeringOptionsmenu....................................................24
Changeautoweighing....................................................................................................25
Changeresolution...........................................................................................................26
Restoresetup.................................................................................................................28
Connectorwiring...............................................................................................................29
RS‐232portconnectors..................................................................................................29
Scalepowersupply.........................................................................................................30
WeighingPlatformconnectorsbeforeDecember2013.................................................30
WeighingPlatformconnectorsfromDecember2013...................................................31
Specifications.....................................................................................................................33
Dimensions.....................................................................................................................33
Powersupplyspecification.............................................................................................33
PowerSuppplyCablespecification.................................................................................34
Scalepowerrequirements..............................................................................................34
General............................................................................................................................35
ScalePartslist.................................................................................................................35
Dateofmanufactureandserialnumber............................................................................36
Scaledateofmanufactureandserialnumber...............................................................36

3E0673DairyScaleInstallermanual
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INTRODUCTION
TheDairyScaleisspecificallydesignedtoaccuratelyweighlivedairyanimalsas
theywalkovertheWeighingPlatformset.Youmayalsoweighstaticloads.
Important
GallagherrecommendsyoureadthewholeInstallationsectionpriorto
planningeachDairyScaleinstallation.ThelocationoftheChicane,Weighing
PlatformsetandPanelReaderareinter‐related,andforeachinstallationyou
willneedtodeterminethebestconfiguration.
This manual
ThismanualdescribeshowtoinstalltheXDS5000GallagherDairyScaleintonew
andexistingDairysheds.
ModelXDS5000
TheXDS5000includes:
WeighingPlatformset,
Scalehead,
Powersupply,
Panelreader,
MyScaleProsoftware.
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INSTALLATION
PlanningtheInstallation
DuringtheplanningofyourDairyScaleinstallation,youneedtodeterminethe
locationandinstallationrequirementsforthefollowingcomponents:
1. PowerSupply
Providesthe12VsupplytotheScaleandPanelReader.
2. PurposebuiltChicane
TheChicaneisdesignedtoslowandseparatetheanimalssothatthe
weighingeventscanoccurattheoptimaltimespacing.
3. PanelReader
ThisautomaticallyreadstheElectronicIDtagattachedtotheanimaland
passesthatinformationontotheScaletobestoredwiththeweight.
4. WeighingPlatformset
Composedoftwoplatforms,Lead‐onandMain.
5. Scalehead
TheScalestoresallcollecteddata.ThedataintheScalecanbedownloaded
fromtheScaleontoacomputer.
TheScalecanalsoproducearealtimeoutputofEIDnumberandvalid
weightaseachanimalisweighed.
Installationconsiderations
Whileplanningtheinstallation,takethefollowingintoconsideration:
Cowsshouldbeweighedaftermilking.
ThePanelReaderneedstobemountedsoitcanreliablyreadtheherd's
ElectronicIDtagsastheywalkovertheWeighingPlatformset.Takecareto
ensurethePanelReadercannotreadtheElectronicIDtagsofanimals
passingnearby.
ConsiderthedrainagerequirementsaroundtheWeighingPlatformsetas
thisneedstobehoseddownregularly.
TheconcreteundertheWeighingPlatformsetshouldbeaslevelaspossible.
TheLead‐onplatformshouldbelocatedascloseaspossibletotheexitof
theChicane.
TheleadingedgeofthePanelReaderantennamustbemounted1100mm
fromtheleadingedgeoftheMainplatform.
NothingshoulddelaytheanimalfromexitingtheMainplatform.

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Powersupplyinstallation
TheGallaghersuppliedPowerSupplyprovides12Vtopowerthefollowing
components:
Scale
PanelReader.
TheWeighingPlatformsetispoweredfromtheScale.
RefertoPowerSupplyspecification(p33).
Procedure‐InstallingthePowerSupply
1. InstallthePowerSupplyinacooldryplace,closetoapowerpoint.
2. Runthe12VcablefromthePowerSupplytotheScale.
Gallagherrecommendsthatallcablingismountedwithinconduitorsimilar
toprotectitfrombeingdamagedbyanimals,UVlight,theweatherand
thedairyshedenvironment.
RefertoPowerSupplyspecification(p33)fordetailsonthemaximum
voltagedropallowed.
3. ConnectthecabletothePowerSupply.
4. TemporarilyterminatethepowercablesattheScaleend,readytobe
connectedlater.

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RaceandChicaneinstallation
ThepurposeoftheChicaneistoslowandseparatetheanimalssotheweighing
eventcanbecapturedreliably.
IfanimalsarepresentedattheMainplatformtoofast,eitherincorrectweights
willbecapturedorweightswillnotbecaptured.
Note:TheconcreteundertheWeighingPlatformsetmustbeaslevelaspossible.The
WeighingPlatformmustbelevelandbothplatformsmustbeeveninheight.
Chicanedimensions
Thefollowingisadiagramofanidealchicane.Usethisasabaseforthedesign
ofeachinstallation.
Note:TheLead‐onplatformmustbelocatedascloseaspossibletotheendofthe
Chicanetomaximiseitseffectiveness.
GallagherrecommendsthattheleadingedgeoftheLead‐onplatformisplaced
nogreaterthan200mmfromtheendoftheChicane.

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Chicane and Weighing Platform dimensions

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WeighingPlatformsetinstallation
TheWeighingPlatformiscomposedoftwoplatforms:
Lead‐on
ThisplatformalertstheScaleofanupcomingweighingevent.
Main
Thisplatformweighstheanimalasitwalksacross.
Procedure‐InstallingtheWeighingPlatformset
Warning:TheWeighingPlatformsetisdeliveredwiththecablescoiledunderneath.
Ensurethesecablesarenotdamagedduringtheinstallationprocess.
Materials
Dynabolts‐Galvanised,12mmx25mmifdirectontoconcreteor12mm
x100mmifspacersarerequired.
Electricdrillwithmasonrydrillbit
Step1‐AssemblyoftheScaleLead‐onFrame
Important:
WhenattachingeachpartwiththeM12x25mmgalvanisedbolts–ensurea
heavyflatwasherandaspringwasherisfittedinsidetherail.
Donotfullytightentheboltsintheassemblystage.
Procedure
1. AttachtheLead‐onRailLHS(LeftHandSide)totheCrossmemberComplete
Assembly,using3xM12x25mmgalvanisedbolts.
 
2. AttachtheLead‐onCrossmembertotheotherendoftheLead‐onRailLHS
asshown,using2xM12x25mmgalvanisedbolts.

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3. AttachtheScaleLead‐onRailRHS(RightHandSide)totheunattachedends
oftheLead‐onCrossmemberandtheCrossmemberCompleteAssembly,
using5xM12x25mmgalvanisedbolts.

4. Placetheframeassemblyonaflatsurfaceensuringthattherailsareparallel
andfullytightenallofthebolts.

Step2‐AssemblyoftheScaleMainFrame
Important:
WhenattachingeachpartwiththeM12x25mmgalvanisedbolts–ensurea
heavyflatwasherandaspringwasherisfittedinsidetherail.
Donotfullytightentheboltsintheassemblystage.
Procedure
1. AttachtheScaleMainRailtooneoftheCrossmemberCompleteAssemblies
using3xM12x25galvanisedbolts.

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2. AttachthesecondCrossmemberandattachtotheMainrailusing3xM12x
25galvanisedbolts.
 
3. AttachthesecondMainRailusing6xM12x25galvanisedbolts.

4. Placetheframeassemblyonaflatsurfaceensuringthattherailsareparallel
andfullytightenallofthebolts.

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Step3‐InstallingtheFootAssemblies
Thisproceduredescribeshowtocreateandinstallacrossmemberfootassemby
andloadcellfootassembly.
Procedure
1. TakeaM14HalfNutandaWeighScaleFootandthreadthenutalltheway
tothebottomofthefoot,butdonotfullytighten.

2. Repeatthisafurther7times,sothereareeightassemblies.
3. TwooftheseassembliesformtheLead‐onfootassemblies.Puttheseto
oneside.
4. Withtheremaining6assemblies,threadeachoneontoanAdjusterBoss,
butdonotfullytighten.These6assembliesformtheLoadcellfoot
assemblies.

Lead-on Frame Foot Assembly
1. Attachthe2Lead‐onfootassembliestotheLead‐onCrossmember.
2. Attach2oftheLoadcellfootassembliesintotheloadcellsinthe
CrossmemberCompleteAssembly.

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3. Tightentheadjusterbosssecurelyontotheloadcell.

Main Scale Frame Foot Assembly
1. Attachthe4remainingLoadcellfootassembliestotheloadcellsinthe
MainScaleCrossmember.
2. Tightentheadjusterbosssecurelyontotheloadcell.

Important:
Oncethefeetareinsertedintotheframeassemblies,beverycarefulnotto
lettheframesdropfeetfirstontotheground,asthismayresultindamage
oftheloadcells.

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Step4‐MountingtheFrames
Procedure
1. TaketheScaleMountingplateassembliesandplaceunderthefeetofboth
theLead‐onframeandtheMainframe.
2. Positiontheframescentrallyintheexitraceandpositionasshown,insuch
away,thatthecowsaretravellingontothelead‐onplatformbeforethe
mainplatform.Ensurethereis10mmclearancebetweenthetwoframes.

3. WhensatisfiedwiththepositioningoftheFrameassemblies,fixthe
mountingplatesintopositionusingtheM10x60Excaliburbolts.
4. Adjustthefeetsotheframesareevenlysupportedatallcorners.
5. Whensatisfiedwiththelevellingofthefeet,tightentheM14halfNutson
thefeet,sotheypreventthefeetfrommoving.

DairyScaleInstallermanual3E0673
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Page12
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Step5‐InsertingtheSaddlesandSlabs
Procedure
1. Place5SlabSaddleassembliesevenlyonthemainframeand1centrallyon
theLead‐onframeasshown.

2. CarefullyplacetheSlabsintopositionbetweenthesaddleassemblies.


3E0673DairyScaleInstallermanual
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PanelReaderinstallation
ThePanelReaderneedstobeabletoreadtheanimal'sElectronicID,priortothe
animalsteppingofftheMainplatform,toensuretheElectronicIDandthe
weightarestoredtogetherintheScale.
PanelReaderinstallationrequirements
Seethemanufacturer’sdocumentationforspecificinstallationinstructions.
MountingthePanelReader
1. MountthePanelReaderontheoutsideoftheracewiththeleadingedgeof
thePanelReaderapproximately1100mmfromtheleadingedgeofthe
MainWeighingPlatformand250mmabovetheground.
Note:ThemountingheightofthePanelReadermayneedtochange
dependingonthesizeofanimals.Thetallertheherd,thehigherthePanel
Readerneedstobemounted.
2. RunthepoweranddatacabletotheScalelocationandtemporarily
terminate.
Seethemanufacturer'sdocumentationfordetailsoncableshielding
requirements.

Panel Reader dimensions

DairyScaleInstallermanual3E0673
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Scaleheadinstallation
Procedure
1. ReleasethecatchesonthefrontoftheScaleheadandopenthecase.

2. SlidetheScaleheadontotheScalebracket.
3. ConnecttheScalepowersupplycable.

4. SetuptheScaleaspertheUsermanual.Youneedtosetupthefollowing:
SetthetimeanddateintheScale
SettheUserOptions
Assignthecommunicationsports(ThePanelReaderconnectstoCOM2)
Selectyourcountryofoperation
Selectmilkingstarttimes
Enterherdnames
Selectherdmilkingorders.

3E0673DairyScaleInstallermanual
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CONNECTINGCABLESTOTHESCALE
Onceallrequiredcomponentsareindividuallyinstalled,youcanconnectthe
componentstotheScale.
Procedure
1. ConnecttheWeighingPlatformcablestotheScale.


TheLoadcellassembliesareconnectedtotheJunctionboxusingthe
20munterminatedcablessupplied,whichareterminatedintheJunction
box.FollowthewiringdiagramonthelidoftheJunctionbox.Twoshort
tailsfromtheJunctionboxwillplugintotheScalehead.
MounttheScaleheadundercoverintheDairyshed,withtheloadcell
cablesroutedintotheshed.
Note:
TheyellowAmphenolConnectorisalwaysontheleftsideoftheindicator‐
andtheblackAmphenolconnectorisalwaysontheright.(Whichplatform
theyconnecttowilldependonwhichindicatorversionyouhave)
ItisimportanttomatchthewirecoloursontheAmphenolcableswiththe
writingontheinterfacePCB(2A0212LF‐1).Notethatthepinnumberson
theAmphenolconnectordonotnecessarilymatchthepinorderonthePCB
connector.

DairyScaleInstallermanual3E0673
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Page16
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
1. ConnectthePanelReaderdatacableintotheCOM2portontheScale.
2. ConnecttheScalepowersupplycabletotheScale.
Note:WarningmessagesaredisplayedontheScaleiftheWeighingPlatformsare
pluggedinincorrectlyorarenotpluggedin.
Thecomponentsthenneedtobeindividuallytested.RefertoTestingthe
DairyScalecomponents(p17).