3E0673 DairyScale Installer manual 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. Page 1 ...
DairyScale Installer manual 3E0673 INSTALLATION Planning the Installation During the planning of your DairyScale installation, you need to determine the location and installation requirements for the following components: Power Supply Provides the 12V supply to the Scale and Panel Reader. 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. 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. Weighing Platform set Composed of two platforms, Lead‐on and Main. 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 ...
3E0673 DairyScale Installer manual 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 Install the Power Supply in a cool dry place, close to a power point. 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. Connect the cable to the Power Supply. Temporarily terminate the power cables at the Scale end, ready to be connected later. Page 3 ...
DairyScale Installer manual 3E0673 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. Page 4 ...
DairyScale Installer manual 3E0673 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 Attach the Lead‐on Rail LHS (Left Hand Side) to the Crossmember Complete Assembly, using 3 x M12 x 25mm galvanised bolts. 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. Page 6 ...
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3E0673 DairyScale Installer manual 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. 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 Attach the Scale Main Rail to one of the Crossmember Complete Assemblies using 3x M12 x 25 galvanised bolts. Page 7 ...
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DairyScale Installer manual 3E0673 Attach the second Crossmember and attach to the Main rail using 3 x M12 x 25 galvanised bolts. Attach the second Main Rail using 6 x M12x25 galvanised bolts. Place the frame assembly on a flat surface ensuring that the rails are parallel and fully tighten all of the bolts. Page 8 ...
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3E0673 DairyScale Installer manual Step 3 ‐ Installing the Foot Assemblies This procedure describes how to create and install a crossmember foot assemby and load cell foot assembly. Procedure 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. Repeat this a further 7 times, so there are eight assemblies. Two of these assemblies form the Lead‐on foot assemblies. Put these to one side. 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 Attach the 2 Lead‐on foot assemblies to the Lead‐on Crossmember. Attach 2 of the Load cell foot assemblies in to the load cells in the Crossmember Complete Assembly. Page 9 ...
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DairyScale Installer manual 3E0673 Tighten the adjuster boss securely on to the load cell. Main Scale Frame Foot Assembly Attach the 4 remaining Load cell foot assemblies to the load cells in the Main Scale Crossmember. 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. Page 10 ...
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3E0673 DairyScale Installer manual Step 4 ‐ Mounting the Frames Procedure Take the Scale Mounting plate assemblies and place under the feet of both the Lead‐on frame and the Main frame. 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. When satisfied with the positioning of the Frame assemblies, fix the mounting plates in to position using the M10x60 Excalibur bolts. Adjust the feet so the frames are evenly supported at all corners. When satisfied with the levelling of the feet, tighten the M14 half Nuts on the feet, so they prevent the feet from moving. Page 11 ...
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DairyScale Installer manual 3E0673 Step 5 ‐ Inserting the Saddles and Slabs Procedure Place 5 Slab Saddle assemblies evenly on the main frame and 1 centrally on the Lead‐on frame as shown. Carefully place the Slabs into position between the saddle assemblies. Page 12 ...
3E0673 DairyScale Installer manual 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 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: T he 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. 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 Page 13 ...
DairyScale Installer manual 3E0673 Scale head installation Procedure Release the catches on the front of the Scale head and open the case. Slide the Scale head onto the Scale bracket. Connect the Scale power supply cable. 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. Page 14 ...
3E0673 DairyScale Installer manual CONNECTING CABLES TO THE SCALE Once all required components are individually installed, you can connect the components to the Scale. Procedure 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. Page 15 ...
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DairyScale Installer manual 3E0673 Connect the Panel Reader data cable into the COM 2 port on the Scale. 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). Page 16 ...
3E0673 DairyScale Installer manual TESTING THE DAIRYSCALE COMPONENTS Once all required components are installed you can test each component is functioning. Checking that the Load cells are functioning Use the following procedure to test that the Load cells are functioning correctly on both the Lead‐on and Main Weighing Platforms. Before you start Clear all debris from on and under the Weighing Platforms. Ensure the Weighing Platform cables are correctly connected to the Scale. Refer to Connect cables to the Scale (p 15). Procedure Change auto weighing Access the menu option. Refer to Change auto weighing (p 25). Note: The values shown above may vary depending on your installation. Write down the values for the following fields: Entry weight Leading weight Trailing weight Stand on, or place a weight on, the trailing edge of the Lead‐on platform Auto Weighing Configuration and look at the screen on the Scale. Entry weight Did the value increase from the value you wrote down? If yes, the Load cells on the Lead‐on platform are functioning correctly. ...
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DairyScale Installer manual 3E0673 If yes, the leading edge Load cells on the Main platform are functioning correctly. If no, the leading edge Load cells on the Main platform are malfunctioning. See below for details on identifying the problem. Stand on, or place a weight on, the trailing edge of the Main platform and Auto Weighing Configuration look at the screen on the Scale. Trailing weight Did the value increase from the value you wrote down? If yes, the trailing edge Load cells on the Main platform are functioning correctly. If no, the trailing edge Load cells on the Main platform are malfunctioning. See below for details on identifying the problem. Malfunctioning Load cells If you have found malfunctioning Load cells check the following: Check wiring in Junction box. Clear all debris from on and under the Weighing Platforms. Ensure the Lead‐on and Main platforms are not touching. Check all cables for damage. Check all Amphenol plugs are clean and correctly connected. Then complete the procedure again. Contact your supplier if you have continuing problems. Page 18 ...
3E0673 DairyScale Installer manual Calibrating the Scale head to the Weighing Platform Each time you connect a new Scale to the Weighing Platform, it must be calibrated to ensure it weighs accurately. Span Loadbars Menu Description Zero count Starts at zero and increases to a value between 31700 and 33700. Leading Load Bar This is the raw Analogue to Digital value from the count Leading edge Load cell on the main platform. The value displayed depends on the test weight used to calibrate the Scale. Trailing Load Bar This is the raw Analogue to Digital value from the count Trailing edge Load cell on the main platform. The value displayed depends on the test weight used to calibrate the Scale. Span weight During the calibration process the Scale uses the above values to estimate the test weight. The estimated weight is displayed in this field. Correct the displayed weight as required to calibrate the Weighing Platform. Defaults to 200 kg. Before you start Clear all debris from on and under the Weighing Platform set. Ensure the Weighing Platform cables are correctly connected. Refer to Connect cables to the Scale (p 15). Check that all Load cells are functioning. Refer to Checking the load cells are functioning (p 17). ...
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DairyScale Installer manual 3E0673 Zero count The option flashes until the appropriate number of samples are captured. A value is then displayed. This should take between 5 and 30 seconds. Note: If not enough clean samples (noise free and stable) are captured the Scale can not be calibrated to the Weighing Platform. See Fixing calibration problems (p 21) for more details. Place the known weight on the leading edge of the Main Weighing Platform. Press the green Weigh button. Leading Load Bar Count The option flashes until the appropriate number of samples are captured. A value is then displayed. This should take between 5 and 30 seconds. Note: If not enough clean samples (noise free and stable) are captured the Scale can not be calibrated to the Weighing Platform. See Fixing calibration problems (p 21) for more details. Place the known weight on the trailing edge of the Main Weighing Platform. Press the green Weigh button. Trailing Load Bar Count The option flashes until the appropriate number of samples are captured. A value is then displayed. This should take between 5 and 30 seconds. Note: If not enough clean samples (noise free and stable) are captured the Scale can not be calibrated to the Weighing Platform. See Fixing calibration problems (p 21) for more details. Span Weight The Scale then updates the value with the weight it thinks is on the Main platform. Span Weight Check the value. Span Weight Is the ...
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3E0673 DairyScale Installer manual Example: Centre soft Digit for change in span key weight value 1 10 0 100 50 1000 250 Span Weight Press the centre soft key to correct the displayed to the correct weight. 11. Once the correct weight is displayed, press the soft key to save Span Loadbars and exit the menu. Engineering Options 12. Press the soft key to exit the menu. Note: To exit without saving the changes, turn the mode select switch to another option without pressing . The Scale reverts to normal operation without saving the changes. Note: Once the calibration information is captured it is stored with the factory defaults. It is not lost if the factory defaults are restored Fixing calibration problems If there is too much electrical noise in the cable between the Weighing Platform ...
DairyScale Installer manual 3E0673 Setting maximum and minimum weights Refer to Change auto weighing (p 25) for details on the factory default settings for the maximum and minimum weights. Procedure Determine if you need to change the default maximum and minimum weights based on the animals you plan on weighing. Do you want to change the maximum and minimum weights? If yes, go to step 3. If no, end of procedure. Change auto weighing Access the menu. Refer to Change auto weighing (p 25). Min weight allowed Select the option. DIGIT The and soft keys display. DIGIT Press the button repeatedly, the label on the button changes from 1 to 10, 100, to 1000, to 10000 and back to 1. When the label is 1, each time you press the button, you add 1 to 10000 the limit. When the label is 10000, each time you press the button, you add 10000 to the limit. Min weight allowed Increase the value as required. 250 kg is the minimum weight allowed. You can increase this values if required. ...
3E0673 DairyScale Installer manual Testing the Scale Once the Scale has been calibrated, you need to test the Scale to confirm it is weighing correctly. Procedure Remove all objects from on the Main platform. Turn the mode select switch to . Check that the icon is displayed. Zero If it is not displayed press the blue button to zero off any weight (dirt or manure) left on the platform. Place the calibrated weight in the middle of the Main platform. The Scale displays the weight of the object. If the displayed weight correct? If yes, the Scale is correctly calibrated. If no, the Scale is not correctly calibrated. Re‐calibrate the Scale. Refer to Calibrating the Scale to the Weighing Platform. Testing the Panel Reader See the manufacturer's documentation for details on tuning the Panel Reader for optimal performance. Test with Electronic IDs and determine that the read range is acceptable for the herd. Page 23 ...
DairyScale Installer manual 3E0673 DAIRYSCALE ENGINEERING OPTIONS MENU The Engineering menu lets you change various options on the Scale. The following options are available in the Engineering menu: Change auto weighing Change span Change resolution Restore set up Accessing the DairyScale Engineering Options menu Engineering Options The menu is a hidden menu which enables you to change settings used to configure the Scale. Procedure Turn the mode select switch to . USER Press the and soft keys , as required, to select OPTIONS . SELECT Press the soft key. USER OPTIONS Once the view displays on the lower screen, press buttons in the following sequence. Green red blue blue red right hand soft key. ENGINEERING OPTIONS The menu displays in the lower screen. Change auto weighing Select the ...
3E0673 DairyScale Installer manual Change auto weighing This menu enables you to change the settings used in auto weighing. Change Auto Description Weighing menu Lead‐on weight This is the raw Analogue to Digital value from the Lead‐on platform Load cell. The data displayed updates every second and increases as weight is applied on the Load cells. In normal operations with no weight on the platform, the displayed value should be between 170 and 370. Note: The raw data displayed in this field is non‐linear due to the Lead‐on platform pivot action. Leading weight This is the raw Analogue to Digital value from the leading edge Load cells on the Main platform. The data displayed updates every second and increases as weight is applied on the Load cells. In normal operation with no weight on the platform, the displayed value should be between 31700 and 32700. Trailing weight This is the raw Analogue to Digital value from the trailing edge Load cells on the Main platform. The data displayed updates every second and increases as weight is applied on the Load cells. In normal operations with no weight on the platform, the displayed value should be between 31700 and 32700. Main platform gain Used when capturing raw samples to the computer. Min weight allowed 250 kg (minimum) Weights captured below this will be rejected and not stored. Max weight allowed 7500 kg (default) Weights captured above this will be rejected and not ...
DairyScale Installer manual 3E0673 Change resolution Important: Use this option only under instruction from Gallagher or your supplier. To change the static weight limits and steps for the Main Weighing Platform while in Manual mode complete the following steps: Note: The Weighing Platform does not need to be connected while you set the resolution limits and steps. Procedure Engineering Options Access the menu. See Accessing the Engineering Options menu (p 24). Change resolution Select the option. SELECT Press the soft key. DISPLAY RESOLUTION The screen displays in the lower screen. Press the soft key until the value you want to alter is highlighted. Alter the Limit or Step values as follows: Limit value Note: After you select a Limit value, the labelling of the three buttons DIGIT along the bottom of the screen changes to , and . DIGIT Use the ...
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3E0673 DairyScale Installer manual Use the and buttons to change the step value. You can set the step value to any of 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50 or 100. To save the changes, follow these steps. Navigate to the end of the resolution list. The labelling of the three buttons along the bottom of the screen BACK ACCEPT changes to and . Press the ACCEPT button. Note: To discard the changes, turn the mode select switch to any other position. Page 27 ...
DairyScale Installer manual 3E0673 Restore set up Factory calibration values are stored in a separate location in memory. Should the values be lost or corrupted in working memory, they can be recovered from the backup location through this menu option. Note: T he following information is stored with the factory defaults and is not lost when the factory defaults are restored: ‐ Calibration information ‐ Scale Model To restore the factory defaults, complete the following steps: Access the Engineering menu. See Accessing the Engineering Options menu (p 24). Restore set up Select the menu. SELECT Press the soft key. RESTORE DEFAULTS The screen displays in the lower screen. RESTORE DEFAULTS Load Factory Defaults Now ACCEPT CANCEL Do you want to restore the factory defaults? If yes, press the ACCEPT soft key. ...
3E0673 DairyScale Installer manual CONNECTOR WIRING RS‐232 port connectors Top 9‐pin Female DB9 D-SUB SOCKET EHR-7 SOCKET 7 6 5 4 3 2 1 (VIEWED FROM (VIEWED FROM CABLE SIDE OF SOCKET) REAR OF SOCKET) BROWN ORANGE YELLOW PRINTED CIRCUIT BOARD GREEN EARTH RS-232 PERIPHERAL DEVICE BLUE PURPLE ...
DairyScale Installer manual 3E0673 Scale power supply Weighing Platform connectors before December 2013 Left side of indicator Right side of indicator Page 30 ...
3E0673 DairyScale Installer manual SPECIFICATIONS Dimensions Scale head Dimensions Length 232 mm 9¼ inches Width 212 mm 8½ inches Height 90 mm 3½ inches Approximate weight 2 kg 4.4 pounds Weighing Platform dimensions Width Length Deck Height Lead‐on 686 mm 795 mm 111.5mm platform Main platform 686 mm 2280 mm 111.5mm Power supply specification Model Peak 7 Amps Output ...
DairyScale Installer manual 3E0673 Power Suppply Cable specification In order to correctly determine the cable requirements, use the following procedure. Output Voltage 12 V Current 4 Amps Max voltage drop 0.5 V Minimum cable resistance 0.125 Ohms Procedure To calculate the required cable resistance per metre use the following: Determine the exact distance from the Power supply to the Scale in metres. Determine the allowable resistance per metre using the following equation: Resistance per metre = 0.125 ohms Distance from Power Supply to Scale in metres Take the following information to your cable supplier and get a cable that meets the requirements. Distance from the Power supply to the Scale in metres, and Resistance per metre as per the previous calculation. Note: The cable used must have a resistance per metre of less than the calculated value. Scale power requirements Voltage 12 V Approximate consumption (without platform set) 65 mA Approximate consumption (with platform set) 115 mA Page 34 ...
DairyScale Installer manual 3E0673 DATE OF MANUFACTURE AND SERIAL NUMBER Scale date of manufacture and serial number The label detailing the date of manufacture and the serial number is on the inside of the fold‐out support stand. DATE OF SERIAL MANUFACTURE NUMBER Y Y W W D S S S Page 36 ...
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