Skov DOL 635 User manual

DOL 635 • DOL 639
Production Controller
Technical Manual
613241 • 2019-08-30 Software version 6.6
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http://docs.skov.com/1201

DOL 635 • DOL 639
Technical Manual 3
Product and Documentation Changes
SKOV A/S reserves the right to change this document and the product herein described without further notice.
In case of doubt, please contact SKOV A/S.
The date of change appears from the front and back page.
Note
• All rights belong to SKOV A/S. No part of this manual may be reproduced in any manner whatsoever without
the expressed written permission of SKOV A/S in each case.
• All reasonable efforts have been made to ensure the accuracy of the information contained in this manual.
Should any mistakes or imprecise information occur in spite of this, SKOV A/S would appreciate being noti-
fied thereof.
• Irrespective of the above, SKOV A/S shall not accept any liability with regard to loss or damage caused or
alleged to be caused by reliance on any information contained herein.
• Copyright by SKOV A/S.

DOL 635 • DOL 639
Technical Manual
1 Product description........................................................................................................................................6
2 Procedure........................................................................................................................................................7
3 Installation guide ............................................................................................................................................8
3.1 Technical menus.......................................................................................................................... 8
3.2 Selecting components.................................................................................................................. 8
3.2.1 Installation wizard ........................................................................................................................ 9
3.3 The installation menu................................................................................................................. 10
3.3.1 Feed weighers ........................................................................................................................... 11
3.3.1.1 Shared feed weigher.................................................................................................................. 11
3.3.1.2 Shared Silo ................................................................................................................................ 12
3.3.1.3 Electronic silo weighing.............................................................................................................. 13
3.3.2 Dry feeding................................................................................................................................. 14
3.3.2.1 Dry feeding - monitoring of feed chain ....................................................................................... 15
3.3.3 Water ......................................................................................................................................... 15
3.3.4 Light control ............................................................................................................................... 15
3.3.4.1 Light sensor ............................................................................................................................... 15
4 Connecting components .............................................................................................................................16
4.1 Menu for show connection ......................................................................................................... 16
4.2 Manual I/O allocation ................................................................................................................. 16
5 Adjustment....................................................................................................................................................17
5.1 Menu for Adjustment.................................................................................................................. 17
5.1.1 Feed weigher ............................................................................................................................. 17
5.1.2 Feed........................................................................................................................................... 18
5.1.3 Silo ............................................................................................................................................. 18
5.1.4 Water meter ............................................................................................................................... 18
5.1.5 Light control ............................................................................................................................... 18
5.1.6 24-hour clock ............................................................................................................................. 18
5.2 Select type of unit of measurements.......................................................................................... 19
5.3 View week number..................................................................................................................... 19
6 Calibration.....................................................................................................................................................20
6.1 The menu calibration ................................................................................................................. 20
7 Service information ......................................................................................................................................21
8 Testing...........................................................................................................................................................22
8.1 Testing basis components ......................................................................................................... 22
8.1.1 Testing Alarm............................................................................................................................. 22
8.2 Testing optional components: Manual control ........................................................................... 22
8.2.1 The menu Manual/Auto.............................................................................................................. 22
8.2.2 Testing Production Functions .................................................................................................... 23
8.2.2.1 Testing the Tip Weigher............................................................................................................. 23
8.2.2.2 Testing the feed demand sensor and cross auger sensor......................................................... 24
8.2.2.3 Testing the drum weigher .......................................................................................................... 24
8.2.2.4 Testing DOL 9940 ..................................................................................................................... 25
8.2.2.5 Testing of shared feed weight – drum weigher and DOL 9940 ................................................. 25
8.2.2.6 Testing the electronic silo weigher............................................................................................. 25
8.2.2.7 Testing light................................................................................................................................ 26
8.2.2.8 Testing the water meter and water supply ................................................................................. 26
8.2.2.9 Testing relay for 24-hour clock................................................................................................... 26
8.2.2.10 Testing feed relay, silo relay and silo auger............................................................................... 26
8.3 Testing network connection ....................................................................................................... 27
9 Settings .........................................................................................................................................................28
9.1 The menu Settings..................................................................................................................... 28

DOL 635 • DOL 639
9.2 Setting accept values for electronic silo and day silo................................................................. 29
9.3 Network settings ........................................................................................................................ 29
9.4 Backup ....................................................................................................................................... 30
9.4.1 Backup of historical data............................................................................................................ 31
9.5 UTC time.................................................................................................................................... 31
9.6 Display ....................................................................................................................................... 32
10 USB stick.......................................................................................................................................................33
10.1 Software update......................................................................................................................... 35
10.1.1 Preparing for a software update................................................................................................. 35
10.1.2 Carrying out the software update............................................................................................... 35
10.1.3 Check after software update ...................................................................................................... 37
11 Memory..........................................................................................................................................................38
11.1 Error log ..................................................................................................................................... 38
11.2 Operation log ............................................................................................................................. 38
12 Import data from replaced controller..........................................................................................................39
13 Resetting data...............................................................................................................................................40
14 Operation access..........................................................................................................................................41
14.1 Remote control via Service Access ........................................................................................... 41
15 Troubleshooting ...........................................................................................................................................42
15.1 Signal levels of the feed weigher ............................................................................................... 42
15.1.1 Feed weigher controlled by one production controller ............................................................... 42
15.1.1.1 DOL 9940 .................................................................................................................................. 42
15.1.1.2 Drum weigher............................................................................................................................. 42
15.1.2 Feed weigher shared by two production controllers .................................................................. 42
15.1.2.1 Feed weigher sharing signals .................................................................................................... 43
16 Technical data...............................................................................................................................................44
16.1 Dimensioned sketch................................................................................................................... 45
17 Functionality .................................................................................................................................................46
Technical Manual

DOL 635 • DOL 639
6 Technical Manual
1 Product description
DOL 63X is a series of one- and two-house controllers developed especially for pig houses. The controller se-
ries includes several variants. Each of them meets the different requirements for climate and production control
in connection with the production forms and geographical climatic conditions.
• DOL 634 climate controller
• DOL 635 production controller
DOL 634 is available in the following climate variants:
• LPV
• Tunnel
• Combi-Tunnel
• Basic
• Central exhaust
• Natural
DOL 635 includes complete production functionality, while DOL 634 includes the basic production features such
as light, water and 24-hour clock.
A combination of climate and production functionality can be achieved by combining DOL 634 and DOL 635
system software. This controller is called DOL 639.
The controller is operated via a large touch display with graphical views of the ventilation status, icons and
curves, among other things. Front views may be adapted in accordance with the user requirements so that the
most frequently used working procedures are easily accessible.
DOL 63X has two LAN ports for connection to FarmOnline and two USB ports.

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Technical Manual 7
2 Procedure
This technical manual deals with the installation of the controller and and is aimed primarily at the technicians
and electricians who will be mounting, installing and testing the controller.
The installation must be carried out by expert personnel and according to current national and in Europe also
EU regulations.
Note that electrical equipment may not be opened without removing the supply voltage and only competent per-
sonnel may carry out servicing and troubleshooting.
In the manual the menus are depicted as tables with primary menus and
sub-menus. The outline is used to give an overview of the setting options
as well as to see where in the menus a given setting can be found.
If a setting is only available in some variants or in specific setups, it is in-
dicated in the table.
The individual functions and settings are described in the following sec-
tions which are presented in the same order as the menus.
The following checklist indicates the main points of the work flow regarding set up of the house controller.
Mounting
1. House controller.
2. Emergency opening, if applicable.
Installation
1. Connect cables according to the wiring diagram for the emergency opening of the system.
2. Set voltage in the controller.
3. Connect mains voltage to the controller.
4. Select components in the house controller's Setup menu by reviewing all points in the Installation wizard.
5. Connect the individual components by means of the Show connection menu of the controller and the wiring
diagrams.
6. Customize the front view.
7. Adjust the system.
8. Test the system.
Start-up
1. Setting and calibration.

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8 Technical Manual
3 Installation guide
3.1 Technical menus
Technical Setup Installation
Adjustment
Show connection
Manual I/O allocation
Calibration Production
Service information Software information
CPU module
Main I/O
General I/O
Manual/auto Manual
Production
Alarm relay status
Production alarm relay status
Service Settings
USB stick
Memory
Import data from replaced controller
Reset
Use password
Front view configuration Configure front view
Load default front views Finishers
Gestating sows
Farrowing sows
Reset front view
SW version
3.2 Selecting components
There are two ways to carry out installation of the controller.
At the initial installation: Use the installation wizard which will guide you through all the options of the climate
functions.
At installation of production functions and adaptation of the existing installation: Use the menu Installa-
tion which enables you to go directly to the relevant function.
Select components in the installation menu of the controller.
(Technical | Setup | Installation wizard or Installation).

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Technical Manual 9
It is not possible to select more components than there is available I/O
for.
You must therefore be aware of whether the controller accepts your wish
to connect a component.
If missing I/O, you can:
• move some of the installed components around (see also section
Manual I/O allocation [}16]).
• uninstall components.
• install extra I/O modules (if these are available).
While functions are selected in the setup menus Installation and Show
connection, all alarms will be delayed. Thus, no alarms will be generated
until 2 minutes after the last change in the installation menu.
This is indicated as info in the alarm menu for as long as the delay is ac-
tive.
This does not apply to alarms from CAN bus communication (I/O mod-
ules).
3.2.1 Installation wizard
The installation wizard provides a structured step-by-step walk-through of selected general functions and all cli-
mate functions.
Thus it supports that necessary selections and settings are made in connection with the controller setup.
Choose between:
• a complete installation walk-through. Here the installation must be
completed for changes to be saved.
• installation of a specific function, for example, cooling. Here individual
changes can be saved.
Press the arrow buttons in the top right corner to move one step forwards
or backwards in the installation.
Press the return button in the top left corner to move back one step at
main level.
See also the section Procedure [}7] for an overview of the entire work-
flow when starting up the house controller.

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10 Technical Manual
3.3 The installation menu
I/O Modules
Main I/O configuration Main IO 11 in/2 out
9 in/4 out
7 in/6 out
Connected
Yes/No
Add. I/O modules Add. I/O module Type Address Con-
necte
d
Yes/
No
Silo weighing modules Weighing module None Address Con-
necte
d
Yes/
No
Only with 1-house DOL 1991 silo
DOL 1992 silo
Only with 1-house DOL 1993 silo
DOL 1994 silo
CAN Protocol Classic
CANOpen
Production
Feed
Feed control None
Dry feeding
Number of feed lines 1-2
Feed separation
shutter
Yes/No Not with drum
weigher and
DOL 9940
with shared
weigher
Feed weigher None
Drum weigher
DOL 9940
Tip weigher
Electronic silo weigher
Time controlled
Time-controlled with cross
auger
Feed counter
Weigher adjustment Stand-alone
Shared with shutter
Drum weigher/
DOL 9940
Weigher shutter Controlling/Not
controlling
Only for
shared
weigher with
shutter

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Technical Manual 11
Silos for feed
weigher
1-5 (Not with elec-
tronic silo
weighing)
Electronic silo sur-
veillance
1-4 (Not with elec-
tronic silo
weighing)
Shared Silo Silo 1-5
Empty silo sensor
1-5
Yes/No
Chain fault detection Broken chain detection 1-2
Chain 1-2 is not running
Yes/No
Water
Water meter 1-4
Water meter setup Water meter relay
Inspection pig weight
Inspection pig weight Yes/No
24-hour clock
24-hour clock 1-4 Yes/No
24-hour clock 1-3
follow week program
Yes/No
Light control
Main light None
Dimmer without relay
Dimmer
Relay
Light active at power
failure
Yes/No
Number of light sen-
sors
0-1
Light sensor type DOL 16 0-50 Lux
DOL 16 0-100 Lux
DOL 16 0-1000 Lux
Other Sensor
Production alarm relay
See the Circuit Diagrams and Cable Plans document for setup of main, I/O and silo weighing modules, and for
setup of CAN Protocol.
3.3.1 Feed weighers
3.3.1.1 Shared feed weigher
DOL 9940 or drum weigher
A feed weigher can be shared between two house controllers. One house controller is to be set up as the con-
trolling controller. This means that this production controller controls the distribution shutter of the weigher. For
this purpose, it uses a relay. Both house controllers use an input (sharing signal) and a relay (request relay) to
signal to each other whether or not they are currently using the feed weigher.

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12 Technical Manual
Uses the feed weigher Does not use the feed weigher
Controlling house controller Distribution shutter. Relay ON
Distribution shutter position: 10 V
Distribution shutter. Relay OFF
Distribution shutter position: 0 V
Request relay Always ON OFF
When feeding is required, turn on
the relay for 10 seconds every 2
minutes
Shared signal 0 V. If the second house wishes to
use the weigher, the signal will in-
crease to 10 V for 10 seconds ev-
ery 2 minutes.
The shared signal is 10 V
Signals for shared feed weigher
In addition, each controller has its own feed demand sensor, cross auger relay, cross auger sensor and silo
augers.
Furthermore, a number of silos are installed for each controller.
A shared feed weigher must be calibrated in both controllers (it is possible to copy the calibration value
from one controller to the other).
3.3.1.2 Shared Silo
The function Shared silo can only be used on farms where the production controllers are connected through a
LAN network and where the management program FarmOnline Explorer is used.
A silo that supplies feed to several houses should be regulated and divided by the production controllers in the
different houses.
When a silo is divided between different production controllers in such a way, the consumption/delivery for one
production controller is transferred to the others as a change in the current silo content.
The following common values apply:
1. Silo content The production controller automatically reduces the silo content with an amount corresponding
to the animals' feed consumption.
2. The user adds the amount of feed delivered to one of the house controllers manually and the other house
controllers update the silo content automatically. However, the value of the amount of feed delivered is only
available in the delivery log on the house controller it was entered on.
3. Tare. The user can change the current silo content. It can be set to any value, but the function is most often
used to ensure that the production controller records an empty silo as having a silo content of 0.
The production controllers should be on the same LAN network. In the management program FarmOnline Ex-
plorer, the production controller should be a part of the same configuration. This way they get access to data
from each other. See the section Network settings [}29] for the setup of the production controllers on a net-
work and see the FarmOnline Explorer Technical Manual for creating a configuration. The workflow is as fol-
lows:
1. Connect the production controllers to the LAN network.
2. Create a configuration in FarmOnline Explorer, where the controllers are included.
3. Create and name the shared silo in one of the controllers.
4. Select the silo in the other controllers.
The production controller can manage up to five silos, that can all be used as a shared silo. The setup of silos
should be carried out in all the connected controllers.

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Technical Manual 13
First select the number of silos and then, in the menu Shared silo, which silos that should be shared with an-
other controller.
Select the silo to be shared.
Set the silo to being shared (Create Silo).
This is done by naming it.
The name of a shared silo should be unique at the farm to make it possi-
ble to tell the silos apart.
When a shared silo has been created, is should be selected from the
other controllers to set up the connection between them.
The shared silo with the new name is displayed in the production menu.
Silo 1-4 cannot be shared, if electronic silo surveillance is activated.
3.3.1.3 Electronic silo weighing
Start by selecting Electronic silo weigher followed by the number of Silos for feed weigher.
Note that silo weighing boxes must be installed, before you can select electronic silo weighing, see the installa-
tion menu and technical user guide for silo weighing boxes.
On farms with several silos and only one physical silo auger, select Electronic silo weigher common auger.

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14 Technical Manual
3.3.2 Dry feeding
Example of dry feeding system.
1. Silo augers
2. Feed weigher
3. Feed demand sensor
4. Hopper station
5. Drive unit
6. Feed stop sensor
7. Automatic feeders
8. Wire/chain system
Setting the Startup time ensures that the feed stop sensor is free of the feed after start-up.
Set the time it takes for the feed to get from the last feeding dispenser to the feed stop sensor (6).
Dry feeding - with two feed lines and feed distribution shutter
Two feed lines are used in feed systems where it is necessary to increase the feeding system’s capacity or
where there are animals in different age groups, that requires different types of feed.
1. Silo augers
2. Feed weigher
3. Feed distribution shutter
4. Feed demand sensor
5. Hopper station
6. Drive unit
7. Feed stop sensor
8. Automatic feeders
9. Wire/chain system
The two feed lines start at the same time but stop based on the input from the feed stop sensors of the two feed
lines.

DOL 635 • DOL 639
Technical Manual 15
Different types of feed may be fed to the two feed lines in systems with
two feed lines and a feed distribution shutter located below the feed
weigher. The feed is delivered to feed line one or feed line two, according
to the position of the shutter.
If there is no distribution shutter, separate outlet feeding may be achieved
on the two feed lines by setting up a feed program for each feed line. See
also Feed [}18].
3.3.2.1 Dry feeding - monitoring of feed chain
The production controller can monitor the feed chain, as well as trigger an
alarm and stop the feeding if errors occur.
A 0-10 V input terminal is required for each type of monitoring.
Monitoring of feed chain errors
Errors are registered via an input provider.
Monitoring of feed chain ceases to operate
If the feed chain stops in the middle of a feed program, it can be regis-
tered via a pulse signal or an input provider.
3.3.3 Water
When selecting a relay for water meter water can be closed when there is
an alarm for high water consumption.
The relay cannot be activated in the event of power failure. In this case
the water will be switched on.
3.3.4 Light control
The main light can be fitted with a light dimmer.
3.3.4.1 Light sensor
When using a light dimmer, the light can be controlled by a sensor.
The light sensor is also used for alarming purposes.
Select which sensor type to use.
If Other Sensor is selected, it must be calibrated.
When installing light, you must decide how is should react in an emer-
gency situation.
Yes: In case of control failure, the light is on.
No: In case of control failure, the light is off.

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16 Technical Manual
4 Connecting components
The main part of the connection terminals is universal. Different components can therefore be installed using the
individual terminals.
When you select a component from the menu Technical | Setup | Instal-
lation the house controller allocates I/O on the basis of a list. This means
that the house controller selects the first available I/O on the list, and that
the components are allocated I/O in the order they are selected.
The same I/O allocation in several controllers – i.e. when the individual
components are connected to the same terminal numbers – is ensured
by saving the set-up on a USB stick and entering the set-up into several
controllers.
4.1 Menu for show connection
When you have selected all the components in the installation menu, the climate controller will show you where
to connect the individual components.
See the menu Show connection for where exactly the individual components are connected.
When a wiring diagram in the Circuit Diagrams and Cable Plans reads "See Show connection", it refers to this
menu.
4.2 Manual I/O allocation
If you want to decide the I/O allocation for one or more components yourself, you can change it manually under
the menu item Manual I/O allocation.
Select the menu Technical | Setup | Manual I/O allocation, and press
the component to be changed.
The current I/O allocation is shown in large bold type
Choose between the listed terminals:
Red: The terminal is currently allocated to another function.
Black: The terminal is not in use.
Press the required terminal.
If you use a terminal that is currently used by another function, the house controller will change the I/O alloca-
tion for this function.
Check in the menu Show connection that the house controller has moved the first allocated function to another
terminal.
The house controller will not change the I/O allocation until you approve
it.
If the I/O allocation can be changed, the house controller will accept it.
If the I/O allocation cannot be changed, the house controller will reject it,
and the I/O allocation will remain unchanged.

DOL 635 • DOL 639
Technical Manual 17
5 Adjustment
This section describes adjustment of the system, which is typically only done once, at start-up.
5.1 Menu for Adjustment
This section describes adjustment of the system, which is typically only done once, at start-up.
Adjustment
Production
Tip weigher Only for Tip weigher
Fill amount weigher Only with drum weigher/
DOL 9940
Feed Turn-on time 5:00 MM:SS
Stop feeding detection
time
12:20 MM:SS
Run in empty house Yes/No
Use separate feed pro-
grams
Yes/No
Max. runtime for cross
auger
12:05 HH:MM
Silo Silo Capacity
Name
Water Water meter
Water meter setup Name
Water meter’s part of sum
Water flushing line time
Water flushing setup
Light control Max. luminance
Main light Name
Light sensor controlled
Use boost
24-hour clock 24-hour clock Name
Timer
Unit of measurements Metric (°C)
US mode (°F)
View week number Yes/No
5.1.1 Feed weigher
Tip weigher Setting the tip weigher to the required number of kg per kip.
Provides an impulse for each portion of feed weighed.
Feed per second Setting the time-controlled feed weigher to the required number of kg per second.
Fill amount weigher Setting the max. quantity of feed per weighing (drum weigher and DOL 9940).
Factory-set values: 20 kg

DOL 635 • DOL 639
18 Technical Manual
Remember to change this to 40 kg if DOL 9940 is used.
5.1.2 Feed
Turn-on time Setting of the time it takes for the wire/chain system to reach the feed stop sensor
from the last feeding dispenser.
Stop feeding detection
time
Setting of the time for when there can be feed at the feed stop sensor before the
system shuts down.
Run in Empty house The feeding system will normally not run when the batch status is Empty house. In
houses where the feed system supplies feed to other sections, you can set the
system to run and the alarms to be active, even when batch status is Empty
house.
Use separate feed pro-
grams
With two feed lines and without feed separation shutter.
If feeding is required not to run at the same time for both feed lines, you should
use two feed programs.
Max. runtime for cross
auger
Setting the time for when the cross auger should run when no more feed is com-
ing from the feed weigher.
5.1.3 Silo
Silo 1 capacity Setting the maximum capacity of the silo. This is used in connection with graphic
read-outs in the FarmOnline Explorermanagement programme.
Name This is used to name a silo according to function, so that it can be recognised in the
menus and alarms.
5.1.4 Water meter
Water meter Setting the number of liters supplied by the installed water meter.
Water meter setup Naming of water meter according to function, so that it can be recognized in the
menus and alarms.
Select whether the individual water meter consumption should be included in the
figures for the total water consumption (Part of sum).
5.1.5 Light control
Max. luminance Setting luminance (Lux).
Name Naming of light source according to function, so that it can be recognized
in the menus and alarms.
Light sensor controlled Selecting the light sensor control, so that the light sensor adjusts the light-
ing level automatically.
Use boost This is used for light fixtures that cannot be switched on unless they start
at maximum power for a short period of time.
5.1.6 24-hour clock
24-hour clock Naming of 24-hour clock according to function, so that it can be recognized in the
menus.
Timer Select if the 24-hour clock is to regulate according to Stop time or ON time.
Stop time: Set the time for start and stop.
ON time: Set a time for start and how long the function will run.
These are set in the menu Production | 24-hour clock.

DOL 635 • DOL 639
Technical Manual 19
5.2 Select type of unit of measurements
Unit of measurements The controller and display units as either metric or US units.
5.3 View week number
View week number View of the week number in front view.
(Only broilers)

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20 Technical Manual
6 Calibration
6.1 The menu calibration
Production
Calibrate light
(only at Other sensor)
Manual calibration
Main light Performance - Illuminance
ON/OFF - Illuminance
Light color Light color calibration
Output/Light color
Calibrate light sensors Input calibration instrument value
Light sensor value too low to calibrate
Light sensor correction factor
Light sensor
Feed weigher Status feed weigher
Calibration weight
Start calibration
Empty feed weigher
Inlet shutter
Calibration
Calibration state Start calibration
Wait for weigher
Calibrate with weights
Calibrate empty weigher
Calibration finished
Silo Silo 1 Calibrate/Set tare
Silo 1 content
Calibration state
Calibration weight
Calibration tare amount
Current count
Calibration tare count
Calibration weight count
Weighing stable