Page 1 Milk Meter Installation Manual  Kibbutz Afikim, 15148, Israel  +972-4-675-4811 Fax +972-4-675-1862 market@afimilk.co.il http:// www.afimilk.co.il Product P/N 4199400 Manual P/N 9040322 Version: 1.1, May 2009...
Page 2 Without limiting the rights under copyright law, this publication, or any part thereof, may not be reproduced, stored, or introduced into a retrieval system, or transmitted in any form, or by any method, for any purpose, without the prior written permission of SAE Afikim. This publication describes the state of this product at the time of its release, and may not reflect the product at all times in the future.
Page 3 Revision History Version Date Pages Description Writer First version Avi ben Jonathan 2009 Joya Matt Referenced Documents Document Title 9040150 AfiCom 1 Installation Manual 9040646 AfiWash Installation Manual AfiPass64 Installation Manual 9040610 4022900 IDeal Installation Manual AfiShepherd (AfiSheep, AfiGoat) User Manual AfiFarm 3 Configuration Manual 9040148 May 2009...
Page 4: Table Of Contents
Table of Contents Chapter 1 System Objectives and Functions ............ 11 Purpose ........................11 AfiFree155i in a Computerized Flock Management System ......11 AfiFree155i Stand-Alone System ..............12 Principle of Operation and Installation ..............12 AfiFree Body ..................... 14 Terminal 155i ....................15 AfiFree Wash Controller and Wash Control Valve ..........
Page 5 Wash Controller Configuration ................. 71 Testing AfiFree155i Performance ................73 Configuring AfiFree 155i Parameters ..............74 Introduction to the AfiFree 155i Parameters ............. 74 Notes to Parameter Table .................. 76 Setting Parameters from Terminal 155i ..............77 Reading and Setting Parameters ................ 77 Central Activation of Milking/Cleaning Mode ..........
Page 6 Chapter 6 Corrective Maintenance ..............89 Maintenance Policy ....................89 Silicone and Rubber Component Replacement ............. 89 Replacing AfiFree155i Bodies ................89 Removing a Malfunctioning AfiFree body ............89 Installing a Replacement AfiFree body ............. 90 Replacing a Terminal 155i ..................90 Preparing the Computer ..................
Page 7 Figure 34: Milk Parameters Dialog Box ..............62 Figure 35: AfiMen Real Time Window - Track Tab ........... 63 Figure 36: AfiFree 155i Software Files ..............67 Figure 37: AfiFree Cleaning System ................70 Figure 38: DSW1 and DSW2—DIP Switch Options for ........... 72 Figure 39: DSW3—DIP Switch Options ..............
Page 8 Table 8: Wiring a Non-AfiMilk Solenoid ..............44 Table 9: Wiring a Non-AfiMilk Pulsator ..............45 Table 10: Wiring a Non-AfiMilk External Start Button ..........46 Table 11: AfiFree Wash Controller Hardware ............51 Table 12: AfiFree Wash Controller Wiring and DIP Switch Positions ....... 52 Table 13: Wash Controller Activation –...
Page 9 AfiFree Body, Terminal 155i, and Wash Controller system. The manual follows the sequence of procedures for installation and configuration of the system. The appendices contain information regarding how to use AfiFree 155i, and especially Terminal 155i. How this Manual Is Organized System Objectives and Functions –...
Page 10 Conventions Used in this Manual Important information is highlighted in a frame, as explained below: Actions requiring special attention to avoid a possible hazard to personnel. For example, working with high voltage components. W AR NI NG Actions requiring special attention to avoid possible damage to equipment or livestock.
Page 11: Chapter 1 System Objectives And Functions
(automatic cluster removal)  Monitoring the quantity of milk provided by a specific animal Figure 1 (below) illustrates AfiFree 155i connected to AfiSheep/ AfiGoat. Figure 1: Terminal 155i units connected to AfiSheep/ AfiGoat May 2009 AfiFree Terminal 155i Installation Manual...
Page 12: Afifree155I Stand-Alone System
Releasing the cluster when milk flow drops below a predetermined rate (automatic cluster removal) Figure 2 (below) illustrates AfiFree 155i not connected to AfiSheep/ AfiGoat. Figure 2: Terminal 155i units not connected to AfiSheep/ AfiGoat Principle of Operation and Installation AfiFree155i has the following main components: ...
Page 13: Figure 3: Typical Afifree155I Layout
Figure 3: Typical AfiFree155i Layout May 2009 AfiFree Terminal 155i Installation Manual...
Page 14: Afifree Body
AfiFree Body The AfiFree Body (Figure 4) measures the volume of milk in real time as the milk flows through it. It has a milk chamber and an electronics compartment.  The milk chamber collects, measures and transfers the milk to the receiver vessel. ...
Page 15: Terminal 155I
Terminal 155i The user operates the AfiFree155i milk meter with the buttons on Terminal 155i. Terminal 155i also displays data about the animal being milked, such as health codes, conductivity, and milk yield. Inputs and outputs The inputs are as follows: ...
Page 16: Figure 5: Terminal 155I Panel
Figure 5: Terminal 155i Panel Figure 6: Terminal 155i LCD Display ‎ C hapter 1 System Objectives and Functions P/N 9040322...
Page 17: Afifree Wash Controller And Wash Control Valve
AfiFree Wash Controller and Wash Control Valve The parlor washing system cleans the AfiFree155i bodies via the AfiFree Wash Controller (below) and Wash Control Valve (page 17). AfiFree Wash Controller During milking the AfiFree Body operates with a continuous flow of milk through the unit.
Page 18: Connections Boxes
Figure 8: AfiFree Wash Control Valve Connections Boxes There are two alternative types of connection boxes for wiring AfiFree:  AfiFree Connection Box (below)  Plug-in Connection Box (PICB) (page 19) AfiFree Connection Box The AfiFree Connection Box (Figure 9) is a watertight junction box with terminal blocks for connecting power and communication wires.
Page 19: Figure 9: Afifree Connection Box
Figure 9: AfiFree Connection Box Plug-in Wiring System The Plug-in Wiring System is an improved alternative to wiring cables to a standard AfiFree Connection Box. It saves time and wiring errors. Wiring connections are made as follows:  The components of AfiFree155i connect to the Plug-in Connection Box (PICB— see Figure 10) entirely by means of ready-wired plugs and sockets.
Page 20: Valve Installation Kit For Afifree
Available spacing = 40 cm / 75 cm / 115 cm Cable Plug-in Plug-in Plug-in Connection Box Connection Box Connection Box for stall 1 for stall 2 for stall 3 Figure 12: Extension Tail Spacing on Power/Communication Cable AfiFree Valve Installation Kit for The valve installation kit for AfiFree contains all the parts necessary for mounting the shut-off valve and connecting it to the AfiFree Body.
Page 21: System Components
System Components  Table 1 shows the main components for installing the AfiFree Body and Wash Controller system.  Table 2 shows accessories for AfiFree connection box wiring.  Table 3 shows components of the Plug-in Wiring System (see page 19 for an explanation of the Plug-in Wiring System).
Page 22 50 wall. Plate The AfiFree Wash Controls 5099010 Control vacuum/clean air page 17 Valve Communication adapter between PC, AfiFree 155i, and AfiCom1 identification system AfiCom1 Plus Port 4098550 (includes AfiPort, P8 Installation Complete Manual Connector Cable, and Termination Resistor)
Page 23: Table 2: Accessories For Afifree Connection Box Wiring
Table 2: Accessories for AfiFree Connection Box Wiring Name Picture Function Catalog No. Details AfiFree Interconnection of cables 40973800 Connection Box page 18 AfiFree Body Connects 2.8 m 4093506 Connection between long page 38 AfiFree155 Cable body pigtail 15 m 4093506D cable and long...
Page 24: Table 3: Plug-In Wiring System
2 m length 4097310 One per Connection Cable 155i stall 5 m length 4097310B 10 m length 4097310C AfiMilk Vacuum/ AfiMilk vacuum shut off 1.5 m length 4197020 One per Pre-wired Vacuum sweep solenoid and stall Solenoid Operated removal solenoid with Assembly...
Page 25: Minimum Requirements
Name Function Length/ Catalog Quantity Extension Tail Spacing Power Cable Connects power supply 40 cm extension tail 4097313-40 spacing 75 cm extension extension tail 4097313-75 tail per spacing stall 115 cm extension tail 4097313-115 spacing RS485 Communication Connects PC 40 cm Cable extension tail 4097312-40...
Page 27: Chapter 2 Site Preparation Requirements
Chapter 2 Site Preparation Requirements This chapter contains the following sections:  Component Positioning Requirements (below)  Physical Infrastructure Requirements (page 30)  Physical Interfaces to Components (page 30)  Electrical Requirements (page 30)  Computer Requirements (page 32) Component Positioning Requirements This section explains the positioning requirements for the following components: ...
Page 28: Terminal 155I Positioning
Terminal 155i Positioning Terminal 155i is mounted on a bracket, which can be fixed to a suitable wall or pipe. Position Terminal 155i according to the following guidelines:  Where it is convenient for the milker to use the buttons and see the display ...
Page 29: Wash Controller Positioning
Wash Controller Positioning Position the Wash Controller as follows:  On a wall or other location where its LEDs can be seen clearly from the parlor floor  Shaded from direct sunlight (all hours of the day) and protected from water (e.g., rain and leaking pipes) ...
Page 30: Physical Infrastructure Requirements
Physical Infrastructure Requirements The following physical infrastructure is required for operation of AfiFree155i:  Milk Line  Vacuum Line  Washline Milk Line A stainless steel milk line is required to transport the milk to the milk tank. Vacuum Line A separate OD 50 mm PVC vacuum line is required in the parlor for the operation of the AfiFree Wash Valve.
Page 31: Power Supply Requirements
If one transformer fails, the second side of the parlor remains operational  Troubleshooting is easier In installations using the Plug-in Wiring System, AfiMilk recommends using one 1,000 VA transformer for up to 18 stalls. Table 5: Power Cable Specifications and Minimum Power Requirements...
Page 32: Wiring Requirements
 Must supply power only to the AfiFree155i milk meters and to outputs operated by the AfiFree155i milk meters  Do not connect either the secondary winding of the transformer or any of the loads to ground Wiring Requirements The power cables must be of sufficient size to carry the load without causing a voltage drop from the first to the last milking point.
Page 33: Chapter 3 Mounting And Wiring
Chapter 3 Mounting and Wiring This chapter contains the following procedures:  Checking Jumpers in the Plug-in Connection Box (below)  Mounting the Connection Box (page 34)  Mounting and Wiring the AfiFree Body (page 34).  Mounting and Wiring Terminal 155i (page 39) ...
Page 34: Mounting The Connection Box
Mounting the Connection Box The AfiFree Connection box has molded mounting points on its back. Two or more of these can be drilled through as required for screws or bolts. NO T E Before mounting a Plug-in Connection Box, make sure its jumpers are configured correctly (see Checking Jumpers in the Plug-in Connection Box, page 33).
Page 35: Figure 13: Mounting The Afifree Body Bracket With A Valve Installation Kit
3. Mount the AfiFree body bracket as follows: When valve And when the See: Do this: installation kit AfiFree Body is for AfiFree … being installed with its milk inlet positioned on its … Left Figure 13 Attach the generic shut-off being used for installation of valve bracket and the AfiFree...
Page 36: Leveling The Afifree Body Bracket
AfiFree Leveling the Body Bracket 1. Slightly loosen both leveling screws (Figure 14). 2. Place a spirit level on both arms of the bracket and level the bracket manually along the roll axis (Figure 14). 3. Place a spirit level on one bracket arm and level the bracket manually along the pitch axis (Figure 15).
Page 37: Mounting The Afifree Body
AfiFree Body Mounting the The AfiFree Body has a groove on each side (Figure 4, page 14) that fits the bracket arms. 1. Make sure that the bracket locks are open on both sides of the bracket arms (Figure 16). Yellow Pointer Lock Yellow Pointer...
Page 38: Figure 17: Afifree155I Wiring
AfiFree Wiring to an Connection Box 1. Plug the AfiFree Body pigtail cable into the AfiFree body connection cable (for available lengths and part numbers refer to Table 2 on page 21). 2. Route the AfiFree body connection cable to the connection box. 3.
Page 39: Mounting And Wiring Terminal 155I
Connecting to a Plug-in Connection Box 1. Plug the AfiFree Body pigtail cable into the AfiFree body plug-in connection cable (for available lengths and part numbers see Table 3, page 21). 2. Route the AfiFree body plug-in connection cable to the PICB. Plug the AfiFree body plug-in connection cable into socket 9 of the PICB.
Page 40: Figure 19: Terminal 155I Bracket Attached With Bands To A Pipe
Mounting the Terminal 155i Bracket with Bands to a Pipe 1. Determine the best location for Terminal 155i bracket in accordance with Terminal 155i Positioning (page 28). Attach the Terminal 155i bracket to a pipe with suitable bands, as shown in Figure 19.
Page 41: Mounting The Terminal 155I
1. Determine the best location for Terminal 155i bracket in accordance with Terminal 155i Positioning (page 28). 2. Mark the two horizontal holes to be drilled in the cabinet, as shown in Figure 20. 3. Drill the holes, using a 6.5 mm. drill bit. 4.
Page 42: Wiring The Power Cable
18 extension tails each. Where there are more than 18 milking points, use more than one length of power cable. AfiMilk recommends using one 1,000 VA transformer for up to 18 stalls. Connect the power cable as in Figure 22. ‎...
Page 43: Wiring The Solenoids
Connecting Solenoids to a Plug-in Connection Box When connecting solenoids to a PICB, use the appropriate procedures of the following:  For installations using AfiMilk solenoids—see Connecting AfiMilk Solenoids to a Plug-in Connection Box (page 44)  For installations using non-AfiMilk solenoids—see Wiring Non-AfiMilk Solenoids...
Page 44: Wiring The Pulsator
AfiMilk Wiring Non- Solenoids to a Plug-in Connection Box Wire a non-AfiMilk Cluster Removal Solenoid or non-AfiMilk Vacuum Shut-off Sweep Solenoid, as follows: 1. Cut off the solenoid connection cable’s yellow wire. 2. Wire the blue and brown wires to the solenoid (Table 8).
Page 45: Connecting The Pulsator To A Plug-In Connection Box
Connecting the Pulsator to a Plug-in Connection Box When connecting solenoids to a PICB, use the appropriate procedure of the following:  For installations using AfiMilk solenoids—see Connecting an AfiMilk Pulsator to a Plug-in Connection Box (below)  For installations using non-AfiMilk solenoids—see Wiring a Non-AfiMilk...
Page 46: Table 10: Wiring A Non-Afimilk External Start Button
Installations using AfiMilk Pre-wired External Start Buttons with PICBs—see Connecting an AfiMilk Pre-wired External Start Button (below)  Installations using non-AfiMilk external start buttons with PICBs—see Connecting a Non-AfiMilk External Start Button to a Plug-in Connection Box (page 46) AfiFree Wiring to an...
Page 47: Wiring The Communication Cable
Wiring the Communication Cable Connect the communication cable as follows:  Installations using AfiFree Connection Boxes—see Wiring to an AfiFree Connection Box (below)  Installations using PICBs—see Connecting to a Plug-in Connection Box (page Wiring to an AfiFree Connection Box 1.
Page 48: Connecting To A Plug-In Connection Box
 In sub-zero temperatures the water might freeze. AfiMilk recommends that the shut-off valve be installed vertically. Where vertical installation is not possible because of a physical limitation (such as a low milking platform) the shut-off valve can be installed at an angle of up to 90° from the vertical.
Page 49: Figure 25: Mounting Shut-Off Valve For Afifree Body-Milk Inlet On Left
Install the shut-off valve and holder as follows:  When the AfiFree Body has its milk inlet on the left—see Figure 25  When the AfiFree Body has its milk inlet on the right—see Figure 26 1. Attach the Generic Shut-off Valve Holder to the generic shut-off valve bracket using the two hexagon socket screws.
Page 50: Mounting And Wiring The Wash Controller
Vacuum NO Operated Washer Spring Lock Shut-of f Valve M6 DIN 9021 Washer Washer Bolt Washer Hexagon Socket Generic Shut-of f Generic Shut-of f Screw Valve Holder Valve Bracket Air/Vacuum NC Operated Shut-of f Valve Figure 26: Mounting Shut-off Valve for AfiFree Body—Milk Inlet on Right Mounting and Wiring the Wash Controller Mounting and Wiring the Wash Controller has the following parts: ...
Page 51: Figure 27: Mounting Wash Controller
To Mount the Wash Controller The Wash Controller is supplied with mounting hardware (Table 11). Table 11: AfiFree Wash Controller Hardware Description Catalog No. Quantity Allen screw, M6, 20 mm 9020383 Star washer 9010386 Nut, M6 9020212 1. Determine the best location for the Wash Controller in accordance with Wash Controller Positioning (page 29.) 2.
Page 52: Wiring The Wash Controller And Setting Dip Switches
Wiring the Wash Controller and Setting DIP Switches NO T E Refer to the label on the inside of the lid for wiring and dipswitch settings. This section has the following parts:  Power Input (below)  Wash Control Valve Output (below) ...
Page 53: Figure 28: States Of Dip Switches Dsw1, Dsw2, Dsw3, And Dsw4
Table 13: Wash Controller Activation – Connection and Settings Activation Activation Connect the Jumper JP1 Pins Set DIP Mode Type (Input Command Switch Command) Lines to J8 DSW4 Pins Automatic 24V AC/DC 2, 4 4 – OFF Automatic Dry Contact 1, 2 4 –...
Page 54: Mounting The Wash Control Valve
Mounting the Wash Control Valve The Wash Control Valve (Figure 8, page 18) is supplied pre-assembled. 1. Use a saddle clamp with a ¾‖ female connector to connect the Wash Control Valve to the main vacuum line (Figure 30, Detail 3). Connect the solenoid to the vacuum wires in the Switch Box.
Page 55: Installing The Vacuum Line For The Wash Control Valve
Installing the Vacuum Line for the Wash Control Valve All references in the following explanation refer to Figure 31 and Table 14. 1. Position the vacuum line (Item 1) above the milk line. Maximum length of the pipe (Item 2) is 50 cm (19‖). 2.
Page 56: Table 14: Afifree Wash Control Valve Vacuum Line Parts List
Table 14: AfiFree Wash Control Valve Vacuum Line Parts List Reference No Part Name (Figure 31) Pipe Meridor Ø50 mm PN16 PVC 5000377 Pulsator pipe (single) 5100001 Nipple on vacuum distribution line (assembly) 5200027 Tee PVC cemented, 90°, 50 mm, gray 1600C0007 Short Reducer, PVC bush cemented,50 X 25 mm, gray 5001520...
Page 57: Figure 31: Afifree Wash Control Valve Vacuum Line
Figure 31: AfiFree Wash Control Valve Vacuum Line May 2009 AfiFree Terminal 155i Installation Manual...
Page 58: Chapter 4 System Configuration
System configuration has the following steps: 1. Configuring AfiSheep/AfiGoat (below)—only necessary when AfiFree 155i milk meters are connected to a flock management computer 2. Configuring Milk Meters (page 61) 3.
Page 59: Table 15: Parlor Type Icons
5. In the Parlor Configuration dialog box (Figure 32), select:  the parlor type (Table 15 and Figure 32)  the number of stalls in the parlor (Figure 32)  under Milk Meter Type Table 15: Parlor Type Icons Name of Parlor Icon Herringbone Polygon...
Page 60: Figure 32: Parlor Configuration Dialog Box
To select number of stalls Number of stalls in parlor, move pointer selected To select parlor Select AfiFree type, click Name of selected milk meter icon appropriate icon parlor type Click here to move to next dialog box Figure 32: Parlor Configuration Dialog Box 6.
Page 61: Configuring Milk Meters
– refer to Configuring Milk Meters in a Computerized Flock Management System, below.  When AfiFree 155i milk meters are used as stand-alone units (not connected to flock management computer) – refer to Configuring Milk Meters in a Stand- alone System, page 68.
Page 62: Figure 33: Afimen Real Time Window - Milk Tab
2. Open AfiMen. The AfiMen Real Time window (Figure 33) appears. Red fill inside a blue AfiFree155 milk meter icon indicates that the AfiFree155 milk meter is not assigned an identification number yet. AfiFree Milk Meter Icon AfiFree Milk Meter ID assigned and in No ID or Column...
Page 63: Figure 35: Afimen Real Time Window - Track Tab
8. Make sure the milk station is in session. If the milk station is not in session, click Continue to put it in session. The system is now ready to assign identification numbers to the AfiFree 155i milk meters. May 2009...
Page 64 In the AfiMen Real Time window (Figure 33) the fill in the icon representing the milk meter changes from red to grey, indicating that the AfiFree 155i milk meter has an identification number and communication is correct. The cleaning cycle is not performed at this time. Cleaning mode is the default mode that the AfiFree 155i milk meter enters after it has been assigned an identification number.
Page 65 Manual Identification Number Assignment If there was a malfunction during automatic identification number assignment, or one or more identification numbers were incorrectly assigned, you can assign identification numbers manually. NO T E The highest possible stall identification number is 64. 1.
Page 66 AfiSheep/AfiGoat from its default before uploading to the milk meter, see Entering a Parameter Value in AfiSheep/AfiGoat, page 81. For a description of the parameters, see Introduction to the AfiFree 155i Parameters, page 74. 1. In AfiSheep/AfiGoat, make sure that Auto Program is enabled (see To enable Auto Program: page 80) 2.
Page 67: Figure 36: Afifree 155I Software Files
At the conclusion of software upload, each AfiFree 155i milk meter automatically enters Cleaning mode and the display shows followed by the stall number. Recovering from a Malfunction during Data Upload There are two options for recovery:  Wait at least 5 minutes.
Page 68: Configuring Milk Meters In A Stand-Alone System
Do not give the same identification number to different milk meters. To assign an identification number: 1. Turn on the power supply to the AfiFree 155i milk meter. The display shows CL--. 2. On the Terminal 155i, simultaneously press...
Page 69: Table 16: Abbreviations For Animal Types
Configuring the Animal Type Each AfiFree milk meter can be configured for milking one of the following animal types:  Buffalo   Goat  Sheep Make sure that each milk meter is configured for the type of animal to be milked in the parlor, by doing the following: 1.
Page 70: Setting Up The Wash Controller
Setting Up the Wash Controller For parlors where the washing process is controlled by AfiWash, see NO T E AfiWash Installation manual P/N 9040646. This section contains the following parts:  Wash Controller Principles of Operation (below)  Wash Controller Configuration (page 70) Wash Controller Principles of Operation In milking mode, the AfiFree Body allows milk to flow through it freely.
Page 71: Wash Controller Configuration
The Wash Controller has two modes of operation:  Automatic mode - the main parlor wash system activates and shuts down the Wash Controller.  Manual mode - the Wash Controller is activated by a manual control button, and is turned off after a predefined time interval. Wash Controller Configuration Refer to the label on the inside of the Wash Controller lid for wiring and DIP NO T E...
Page 72: Figure 38: Dsw1 And Dsw2-Dip Switch Options For
Table 18: Wash Time Intervals Measurement Parameter Switch Time On DSW1 From the beginning of Cleaning Mode until the farthest AfiFree Body is filled with liquid Time Off DSW2 From the end of Cleaning Mode until the nearest AfiFree Body is empty ―Farthest‖...
Page 73: Testing Afifree155I Performance
Figure 39: DSW3—DIP Switch Options Check the current wash cycle duration by chemical testing and milk sampling. If the results are below standard, extend the wash cycle by increasing the Wash Duration parameter value. AfiFree155i Testing Performance AfiFree155i milk meters must be tested before beginning normal operation. If AfiFree155i milk meters have been installed as part of a system including antennas, parlor controls etc., the following tests are performed as part of the system tests.
Page 74: Configuring Afifree 155I Parameters
The value of the G parameter must be calculated and set to suit the characteristics of the parlor—see Calculating and Setting the G Parameter, page 81. The AfiFree 155i parameters are detailed in Introduction to the AfiFree 155i Parameters (below).
Page 75 Paramete Parameter Display view Default combi Units value description example nation Delay between Removal Vacuum closing and "F"+"3" Delay Removal Measureme Measurement "F"+"4" nt coefficient coefficient Milk Oddments milk "F"+"5" gram Remainder constant addition Duration of green Removal lights blinking before "F"+"6"...
Page 76: Notes To Parameter Table
Paramete Parameter Display view Default combi Units description example value nation Second Second Attachment Animal Attachment Premilk time ID +"8" Animal Dump Milk Dump Milk 9900 gram 0 (OFF) ID +"9" Allow cancel ACR "Group" Cancel ACR from AfiSheep/ 0 (OFF) +"4"...
Page 77: Setting Parameters From Terminal 155I
Setting Parameters from Terminal 155i The procedures in this section make use of the information in Table 19 (page 74). Some of these parameters can also be set from AfiSheep/ AfiGoat. Reading and Setting Parameters 1. On the Terminal 155i, press the appropriate key combination specified in Table 19 (page 74).
Page 78: Cluster Clearance
Cluster Clearance (either under AfiSheep/ AfiGoat or in a standalone configuration) Set parameter Cc to allow cluster clearance. CC parameter is the delay time desired (in seconds), between cluster removal and the lowering of the cluster. After setting this parameter, the milk meter is timed to lower the cluster (at the designated delay time) after cluster removal.
Page 79: Milk Remainder
Sweep (either under AfiSheep/ AfiGoat or in a standalone configuration) AfiFree 155i milk meters can be set to remove milk remaining in the milking tube after each milking by performing a sweep. The sweep pulse duration, number of sweep pulses, and sweep delay can be set individually in three parameters with those names (see Table 19).
Page 80: Auto Program
The parameters window appears. 3. Click the Milking Station icon in the Station pane. The AfiFree 155i parameters appear in the right hand pane (Figure 40). Figure 40: The Auto Program Check Box 4. Select the Auto Program check box (Figure 40).
Page 81: Calculating And Setting The G Parameter
AfiFree 155i Milk Meters, page 81. AfiFree 155i Setting Parameter Values for all Milk Meters There are two steps to setting the parameter values for all AfiFree 155i milk meters:  Entering a Parameter Value in AfiSheep/AfiGoat (below) ...
Page 82: Figure 41: Afisheep/Afigoat Parameters Screen
 Updating all parameter values including the G parameter value (below) To update all parameter values except the G parameter value on all AfiFree 155i milk meters: In the Parameters window, make sure the Auto Program check box is selected (Figure ‎...
Page 83 G parameter). If any milk meter has a parameter with a value different from the value in AfiSheep/AfiGoat, AfiMen overwrites the value in the milk meter with the value in AfiSheep/AfiGoat (except for parameter G). To update all parameter values including the G parameter value on all AfiFree 155i milk meters: 1. Open AfiMen.
Page 85: Chapter 5 Troubleshooting
Chapter 5 Troubleshooting This chapter contains the following:  Guidance on searching for the source of an electrical problem (below)  Troubleshooting Guide(below) For the meaning of lit or flashing LEDs on a Terminal 155i, see Table 25: Operating Modes and their Indicators (page 97) and Table 28: Alarm and Malfunction Indicators (page 117).
Page 86 Table 21: Troubleshooting Guide Indication Probable cause Possible solutions AfiFree155i measures very Diaphragm Stuck Vacuum leak—check other large milk quantity units:  If other units are OK, then check local vacuum line connections to AfiFree155 body  If other units have similar problems then check for problems in main vacuum line...
Page 87 Table 21: Troubleshooting Guide Indication Probable cause Possible solutions Under-weighing AfiFree Body is not level Level the AfiFree Body as described in Mounting and The amount displayed is less Wiring the AfiFree Body, page than the actual amount of milk. ...
Page 89: Chapter 6 Corrective Maintenance
Chapter 6 Corrective Maintenance This chapter contains the following sections:  Maintenance Policy (below)  Silicone and Rubber Component Replacement (below)  Replacing AfiFree155i Bodies (below)  Replacing a Terminal 155i (page 90) Maintenance Policy Upgrades and changes to the software should be carried out by SAE Afikim trained technicians only.
Page 90: Installing A Replacement Afifree Body
AfiFree body Installing a Replacement 1. Mount the new AfiFree body as in Mounting the AfiFree Body (page 37). 2. Connect the hoses to the new AfiFree body. 3. Connect the pig-tail of the new AfiFree body to the AfiFree body connection cable.
Page 91: Removing A Malfunctioning Terminal 155I
 Automatic address definition  Automatic Load Software  Automatic Load Tables A parameter is enabled when its value is 1. To accept the settings, press OK. Removing a Malfunctioning Terminal 155i 1. Unplug the Terminal 155i cable from the Terminal 155i. 2.
Page 92: Post-Milking Checks
 Check diaphragm is properly inserted into its seat. 5. Vacuum line to washing valve diaphragm of AfiFree155 body (including the line’s branches)—check for defects. 6. Main vacuum valve—check for defects. 7. AfiFree Wash Controller—check for faults. 8. Clusters, liners, and shut-off valves or diaphragms—check for defects and replace as necessary.
Page 93: Chapter 7 Parts Lists
Chapter 7 Parts Lists This chapter contains the following parts lists:  Vacuum Shut-Off Valve Installation—Replacement Parts List (below)  AfiFree Body—Replacement Parts List (page 95)  Terminal 155i—Replacement Parts List (page 96) Vacuum Shut-Off Valve Installation— Replacement Parts List The AfiFree155i milk meter controls a valve that shuts off vacuum to the cluster.
Page 94: Figure 42: Parts For Attaching Vacuum Shut-Off Valve
Figure 42: Parts for Attaching Vacuum Shut-Off Valve Table 22: Shut-Off Valve Installation—Replacement Parts List No. in Part Name Details Figure 42 Typical Vacuum NO Operated Shut-off Valve Washer M6 DIN 9021 A2 9020769 Washer M6 DIN 9021 A2 9020769 Spring Lock M6 washer DIN 127-A2 M6 9020684 Nut M6 DIN 934 A2...
Page 95: Afifree Body-Replacement Parts List
AfiFree Body—Replacement Parts List Figure 43 shows the replacement parts of the AfiFree body. Table 23 lists the part names and part numbers. Figure 43: AfiFree body Exploded View Table 23: AfiFree body Replacement Parts List No. in Part Name Figure 43 —...
Page 96: Terminal 155I-Replacement Parts List
Terminal 155i—Replacement Parts List Table 24 lists the replacement parts for Terminal 155i. Table 24: Terminal 155i Replacement Parts List Part Catalog No. Terminal 155i 4097335 Terminal 155i bracket 4097343 Terminal 155i cable 4000400 ‎ C hapter 1 P/N 9040322...
Page 97: Appendix A User Information And Instructions
Appendix A User Information and Instructions This appendix contains the following sections:  Terminal 155i Modes and Settings (page 97)  Terminal 155i User Procedures (page 99)  Terminal 155i Display Fields (page 104)  Terminal 155i Alarms (page 116) Terminal 155i Modes and Settings This section deals with modes and settings of the Terminal 155i, as follows: ...
Page 98: Terminal 155I Settings
Changing Operating Mode Table 26 shows how to change the operating mode of the Terminal 155i. Table 26: Changing Operating Mode Present Mode Action New Mode Terminal is OFF Power ON Cleaning Mode Cleaning Mode Cleaning button pushing Removal Mode Cleaning Mode Start/Stop button pushing Removal Mode...
Page 99: Terminal 155I User Procedures
Viewing and changing the Animal Type Use this procedure under standalone configuration. (Under AfiSheep/ AfiGoat, the animal type is set from within the flock management system.) While holding down the Animal ID button , press 0. The Animal ID field displays the current animal type, according to the following key: ▪...
Page 100: Displaying/Hiding Animal Identification Number
Displaying/Hiding Animal Identification Number  To display the animal identification number of the animal last identified in the stall, press for more than two seconds.  To hide the animal identification number after it has been displayed, press Message Sub-Mode Procedures (All of the procedures in this section are relevant under AfiSheep/ AfiGoat only.) You activate the message sub-mode by pressing the Terminal 155i Edit/ message mode button...
Page 101 2 or A or B or C example Key pressed Time pressed First 2 seconds Next 1 second Next 1 second Next 1 second Next 1 second Animal ID field The only valid position for an alphabetical character is the first (left-most) position. The best way for typing of number with the letter is to key in a letter first and just after that to type a numerous part of ID.
Page 102 Managing Health, DIM, Activity, and Days from Insemination Parameters Use this message for changing, entering or canceling one or more of the following parameters:  Health code  Days-in-milk (DIM)  Activity/ Days from insemination 1. On the Terminal 155i, press the Edit/ Message mode button The message sub-mode is activated.
Page 103 While the data is being processed, the data updating icon flashes. Following successful processing, the message mode is deactivated. May 2009 AfiFree Terminal 155i Installation Manual...
Page 104: Terminal 155I Display Fields
Terminal 155i Display Fields Display Fields under AfiSheep/ AfiGoat Display fields under AfiSheep/ AfiGoat connection 1. Milk Yield field Mode Milk Yield field displaying Example Celsius The Temperature inside of Milk Meter Cleaning Body Fahrenheit Hyphen (before first milking or after reset) Removal Final milk yield (at end of previous milking before reset) On-Line Milk Yield updated every 100mSec(?)
Page 105 3. Last Highest Conductivity Mode Description Example OFF if no fluid in a milk meter Cleaning The Current Conductivity of the cleaning fluid in AfiFree conductivity units (updated every 3 sec end calculated by average conductivity of last 3 sec) OFF (before first milking or after reset) Removal The Maximum Conductivity of the milk at last milking in...
Page 106 5. Expected Milk Yield field Mode Description Example Cleaning Predicted yield (after identification) Removal OFF (when no identification) Predicted yield (after identification) Milking 6. Days in Milk field Mode Description Example Cleaning Days in milk (after identification) Removal OFF (when no identification) Days in milk (after identification) Milking 7.
Page 107 Mode Description Example after Days from insemination (after identification) identification Removal when no identification OFF (when no identification) after Milking Days from insemination (after identification) identification 8. Momentary Flow field Mode Description Example Cleaning Removal Milking Current milk flow 9. Peak Flow field Mode Description Example...
Page 108 10. Milking Time Clock field Mode Description Example Cleaning OFF (before first milking or after reset) Removal Last milking duration (at end of previous milking before reset) Milking Time from start of current milking (min:sec) *When milking time reaches 20 min the counting restarts from 0:00 and the first character blinks.
Page 109 13. Group field Mode Description Example Cleaning Group number (after identification) Removal OFF (when no identification) Group number (after identification) Milking 14. Infected-Half icon field Mode Description Example Cleaning After identification OFF (if no infected half) When left half infected Removal Milking When right half infected...
Page 110 15. Health code field Mode Description Example Cleaning Health code (after identification) Removal Milking OFF (when no identification) If an animal has two health codes, the second code is displayed on the "Peak flow" field. If an animal has three health codes, the third code is displayed on the "Momentary flow"...
Page 111: Display Fields Under Standalone Configuration
Display Fields under Standalone Configuration 1. Milk Yield field Mode Milk Yield field display Example Celsius The Temperature inside of Milk Meter Cleaning Body Fahrenheit Hyphen (before first milking or after reset) Removal Final milk yield (at end of previous milking before reset) On-Line Milk Yield updated every 100 mSec Milking 2.
Page 112 Mode Description Example The Maximum Conductivity of the milk at current milking in AfiFree conductivity units Milking 4. Predicted conductivity field Mode Description Example Cleaning Removal Milking 5. Predicted yield field Mode Description Example Cleaning Removal Milking 6. Days from insemination field Mode Description Example...
Page 113 8. Current milk flow rate field Mode Description Example Cleaning Removal Milking Current milk flow 9. Peak milk flow rate field Mode Description Example Cleaning OFF (before first milking or after reset) Removal Last milk flow peak (at end of previous milking before reset) Milking Last milk flow peak 10.
Page 114 11. Pulsation field Description Mode Example Pulsation Output 1 Pulsation Output 2 Cleaning Removal Milking 12. Stall number field Mode Description Example Cleaning, Removal, Milking Stall number 13. Group field Mode Description Example Cleaning, Removal, Milking 14. Infected Half field Mode Description Example...
Page 115: Enabling And Disabling Display Fields
16. Icon PC Mode Description Example Message sub-mode OFF 17. Data Updating Icon Mode Description Example Enabling and Disabling Display Fields (either under AfiSheep/ AfiGoat or in a standalone configuration) Key Combination Display Result Press simultaneously "Cancel" and "F" To disable/enable LCD backlight Press simultaneously "Cancel"...
Page 116: Terminal 155I Alarms
Terminal 155i Alarms Alarm and Malfunction Indicators Terminal 155i indicates an alarm or malfunction by flashing or continuously lit LEDs (green and red). When Terminal 155i’s LEDs indicate an alarm, its display shows information about the alarm. Table 28 shows how to identify which alarm Terminal 155i is indicating. Activation Alarm name Alarm description...
Page 117: Table 28: Alarm And Malfunction Indicators
Activation Alarm name Alarm description Display timing Cluster Cluster Remover output failed Coincident "Stall number" field is Remover blinking and "Animal ID" output fault field blinks with Diaphragm Diaphragm not open During the "Stall number" field is milking fault blinking and "Animal ID" field blinks with No Milk The communication with milk...
Page 118: Appendix B Milking System Cleaning Guidelines
Appendix B Milking System Cleaning Guidelines This appendix provides guidelines and recommendations for cleaning the milking systems. It contains the following sections:  Cleaning Recommendations (below)  Performing an Acid Wash (page 120)  Always comply strictly with the instructions of the chemical manufacturers. Failure to comply with instructions can cause injury and damage to equipment.
Page 119: Chemical Dispensing Pumps
Chemical Dispensing Pumps To achieve accurate detergent dispensing, we recommend using chemical dispensing pumps. Vacuum Pump  The vacuum pump must operate throughout the cleaning cycle. A temporary stop of the vacuum pump while the sink is being filled can cause milk and cleaning fluid to seep out between the lid and the AfiFree155 body.
Page 120: Cleaning Exterior Surfaces
After warming up, the milking system must be brought into a closed circulation setup, detergent added, and the hot water and detergent circulated for 10-12 minutes. After being circulated in the milking system, the hot water and detergent must be drained away.

AfiMilk AfiFree 155i Installation Manual

Chapter 1 System Objectives and Functions

Chapter 2 Site Preparation Requirements

Chapter 3 Mounting and Wiring

Chapter 4 System Configuration

Chapter 5 Troubleshooting

Chapter 6 Corrective Maintenance

Chapter 7 Parts Lists

Appendix A User Information and Instructions

Appendix B Milking System Cleaning Guidelines

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