IDeal TM Afi Identification System Product number 4022900H/L Installation Manual Kibbutz Afikim, 15148, ISRAEL +972-4-675-4811 ¬ +972-4-675-1862 market@afimilk.co.il http WWW.afimilk.co.
ii IDeal Installation Manual P/N 9040380
Certificate of Approval This is to certify that the Quality Management System of S.A.E. - COMPUTERIZE DAIRY SYSTEMS. has been audited by SII and found to comply with the Quality Management Standard: SI ISO 9002 The Certificate is granted in accordance with SII’s Rules for the Certification of Quality Systems (SII procedure-002) which requires the continuous maintenance of the Quality System to the above Standard, as testified by the periodic audits conducted by SII.
iv IDeal Installation Manual P/N 9040380
Approvals and Declarations European Standards: CE COMPLIANCE IDeal System 4022900H/L The above product passed tests which comply to the following European Community standards: * Radio, SRD: EN-300 330-2 V1.1.1, ERC/REC 70-03E:05/03 Annex 9 * Electromagnetic Compatibility: • EMC for radio: EN 301 489-3V 1.31 (SRD).
WARNINGS USE OF THE IDeal SYSTEM SHOULD BE UNDER THESE CONDITIONS: 1. OPERATING THE SYSTEM WILL COMPLY WITH THE DECLARATION OF CONFORMITY, THE T.C.F. AND THE TEST REPORTS IN THESE DOCUMENTS. 2. The 230/24 VAC 50Hz (OR 120/24 VAC 60 Hz) SUPPLY TRANSFORMER FOR IDeal SYSTEM MUST COMPLY WITH EITHER VDE & CE (89/366/EC) OR UL DIRECTIVES.
USA Standards: FCC COMPLIANCE The responsible party for this device compliance is: Company name: Address: S.A.E. Afikim USA Inc. 6520 Platt Ave. #804 West Hills 91307-3218 USA This device (IDeal, model number 4022900H/L) complies with part 15 of FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
High voltage transients, surges, and other power irregularities can cause extensive damage. It is the user's responsibility to provide a power protection system. WARN ING It is the user's responsibility to install, operate, and maintain the system in accordance with all applicable codes, regulations, and safety measures. The device is intended for indoor installation only. CAU TION A readily accessible disconnect device shall be incorporated in the building installation wiring.
Specifications Working temperature 0-400C Power input voltage range 24 ±2.
Table of Contents Introduction ...................................................................................................................1 Chapter 1: IDeal Components ......................................................................................3 IDeal Controller.........................................................................................................4 The IDeal PCB ......................................................................................................
Introduction The “IDeal” controller is the unit responsible for active identification sequence in Afi systems such as “AfiAct”, “AfiMilk”, “AfiSort”, and other dairy systems from S.A.E. Afikim. The “IDeal” interfaces between the AFI system in which it is installed and the identification system’s sensors - the antennas. The main operations of this unit are: • Receiving an identification request from the computer. • Selecting the appropriate antenna to activate.
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Chapter 1: IDeal Components The “IDeal” identification system consists of an IDeal box (the controller box) and antenna input to the box. The system is connected to a computer, through an AfiCom1 or AfiCom communication card, to AfiFarm herd management software. Antenna input may consist of: • One or two antennas connected directly to the IDeal box (a “2 Antenna” system).
IDeal Controller The IDeal controller unit is a plastic box containing a printed circuit board (PCB). A display panel is on the front cover of the box, as pictured. Box dimensions are: • Width: 28 cm (11”) long. • Height: 19 cm (7½”). Including hinges and grommets height is 22 cm (8¾”), • Depth: 8.5 cm (3½”) thick. • Net weight: 1.7 Kg. (3 lb. 12 oz.) Shipping weight: 2.7 Kg. (5 lb. 15 oz.) The IDeal controller (P/N 4022900H/L)* consists of: • A plastic enclosure (P/N 7000070). Top (P/N 7000011).
* IDeal systems operate on one of two frequencies throughout the world: HI or LOW. The part number reflects the frequency setting of the IDeal when shipped. 4022900H designates an IDeal shipped at a high frequency. 4022900L designates an IDeal shipped at a low frequency. (Low frequency systems [blue antennas and tags] are used in Western Europe. High frequency systems [orange antennas and tags] are used in the U.S.A. and other countries.
The IDeal PCB This section describes the printed circuit board (PCB) of the IDeal controller, and The printed circuit board consists of three electrical circuits - a power supply circuit, a micro-controller circuit and an RF transmission/reception unit. The power supply circuit is fed by 24 ±2.4 VAC, supplying 5 and 12 volts for the micro-controller circuit, as well as by Tx (Transmission) power and frequency. The Tx power level determines the effective identification range of the system.
The following variables must be defined in each IDeal controller: • Type of system: – “2 Antenna” (only one or two antennas are connected directly to the IDeal), – “Switch Boxes” (three or more antennas are connected indirectly, through one two or three switching boxes. Up to 16 antennas can be connected to each switching box.) • Frequency settings – The IDeal box can be set to operate in a high frequency or in a low frequency. Frequency setting depends on the location of installation.
8 IDeal Installation Manual P/N 9040380 IDeal printed circuit board: layout of set up components, connectors, and test points Settings of the IDeal Controller
Adjustable Components of the IDeal PCB Jumpers and connection points JMP1 JMP2 JMP3 JMP4 JMP5 JMP6 JMP7 JMP10 J12 JMP13 JMP14 JPT1 Hi or Low frequency Hi or Low frequency Communication type Hi or Low frequency Hi or Low frequency Communication type C.L. communication type with “P3” connector Hi or Low frequency Not used, must remain OPEN. Not used, must remain OPEN. Not used, must remain OPEN.
Settings of the IDeal PCB Setting on PCB Type of system Switch number 5 on dipswitch panel SW2 (near the center of the board): (Dipswitch panel SW2 is located near the center of the PCB.) • “2 Antenna” system; if one or two antennas are SW2 connected directly to the IDeal, set switch 5 of SW2 to 2 ANT. (Default setting) SW. BOX 2 ANT RUN TEST • “Switching Box” system; if antennas are connected to the IDeal indirectly, by way of switching box(es), set switch 5 of SW2 to SW. BOX. 2 ANT SW.
to operate in the Current Loop communication type. (JMP3 is not utilized.) • RS232 communication type (optional comm. type): To set the IDeal to operate on RS232 communication, set jumpers as illustrated: * On Jumper JMP6, plug pins 3-4 and 7-8. Jumper JMP7 * Ensure that on Jumper JMP3, pins 1-2 and 5-6 are plugged. (Jumper JMP3 is preset to this position.) • RS485 will be available in the future. Ensure that pins 1-2 and 9-10 of jumper JMP7 are plugged.
• To set the IDeal to operate in a low frequency, jumper the right two pins of jumpers JMP1, JMP2, JMP4, and JMP5, and unplug jumper JMP10, as illustrated. Antenna reception Two regulation potentiometers influence working ranges of antennas: • P1, located near the center of the board, is used to adjust reception sensitivity. The IDeal’s reception circuit is calibrated before leaving the factory, so P1 should not be touched.
J1, J2 Antenna connectors: These 7-pin connectors are located along the right edge of the PCB. These connectors are used for direct connection of antennas to the board, in systems where only one or two antennas are required. Connector J1 supports antenna number 1 and J2 supports antenna number 2.
+5 V +12 V TX_Power GND Test Points JTP1 Four test points are located at the upper right corner of the PCB, at JPT1. These test points are used for testing the power supply circuit in cases of malfunction and/or for adjustment purposes. • GND - Ground signal for all other test points. • TX_Power This is the transmission power supply level for the antennas. The level of this power determines the identification range. Therefore this voltage level is checked whenever an adjustment is required.
The IDeal Display Panel A display panel is on the back side of the IDeal PCB. A 7 segment display, and eight LED indicators are visible through the clear front cover of the IDeal box. IDeal Box case The main display indicates the antenna number currently activated (transmitting a signal). Two pairs of gate indicators (Left entry and exit gates; right entry and exit gates) glow whenever the corresponding gate is closed. Entry and exit #1 should correspond to the gates on the left side of the parlor.
The Tx indicator (above the Rx Data gates indicators) reflects the IDeal’s transmission sequence. The Tx indicator blinks when identification request is sent. This indicator is a red LED. The Rx Data indicator reflects the IDeal’s reception status. When there is a positive reception of an identification signal, this indicator blinks brightly. A weak flicker indicates interference from an external source.
The Antenna Switching Box Each IDeal box can support as many as 48 antennas. In systems using more than two antennas, antenna switching boxes are required. An antenna switching box is a connection board, with a switching relay for each antenna. One box can support up to 16 antennas, and up to three boxes may be cascaded into the IDeal controller. Switching Box Board The switching box board, contains antenna connectors and serves as a buffered interface between the IDeal and antennas.
Switching Board Connectors The switching board contains four types of interface connectors: • Connector J1 receives the antenna select signal from the IDeal card. • Connectors J2 and J3 carry the antenna transmission and reception signals from/to the IDeal main board. Switching units are connected in parallel. The cable entering J2 may exit via J3, carrying signals to the next switching box. • Connectors 1 to 16 are the antenna connectors.
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Chapter 2: System Configurations This chapter illustrates, in more detail, configurations of the IDeal identification system. Two configurations are illustrated on the following pages.
Configuration The IDeal controller supports two working modes: • A “2 Antenna” mode uses only one or two antennas. Switching boxes are not required for this mode. This mode is used in systems such as “AFIACT,” “AFISORT” and “Entrance Identification” systems. • A “Switching Box” mode; where three or more antennas are connected to one or more switching boxes. The drawing below depicts a “2 Antenna” IDeal system in a milking parlor.
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The drawing below shows a “Switching Box” IDeal system in a herringbone parlor. In this configuration the antennas are connected to a switching box. (Switch No. 5 of dip switch array SW2 is set to SW. BOX).
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Chapter 3: Mounting the IDeal Box and Switching Boxes This chapter explains the mounting of the IDeal box. Location of the IDeal Box Mount the IDeal box in a location that meets the following criterion: • Mount the IDeal box on a wall or at any location from which it can be seen from everywhere in the parlor, (or other facility where it is used, such as a sort weigh system). • Maximum length of the cable running between the switching units and the IDeal is 15 meters.
Mounting the IDeal box Each Ideal box is provided with two support plates on its back, as illustrated. The box can hang from the support plates. Or, the support plates can be attached to the box “upside-down”, and the plates can support the box above the point of attachment to the wall or beam. The latter method is advantageous in mounting the box on a beam with little overhead clearance. The support plates protrude 6.5 cm (25/8”) from the edge of the box.
Chapter 4: Laying Cables This chapter describes the cable layout and wire connections of the IDeal identification system. Lay cables as illustrated and described on the following pages.
Laying Cables Lay cables as described below, and as illustrated on the following pages. • Communication Cable [4-wire, shielded, 22AWG (0.3 mm²)] Lay the communication cable between the IDeal box and the computer. • Antenna Select Cables (only in systems with switching boxes) [7-wire, 22AWG (0.3 mm²), shielded] Lay antenna select cables between the IDeal and antenna switching boxes. Note: Maximum length of the Antenna Select cable is 15 meters.
The drawing below depicts connections of a “Switching Box” IDeal system (supporting up to 48 antennas). Antenna cables 6 X 0.3 mm² (22 AWG) Tx Rx antenna signal cable 6 X 0.3 mm² (22 AWG) Tx Rx antenna signal cable 6 X 0.3 mm² (22 AWG) 15 meter max. length Antenna 2 15 meter max. length 7 X 0.3 mm² (22 AWG) Antenna 1 Communication cable 4 X 0.3 mm² (22 AWG) IDeal box Power cable 3 X 0.
The drawing below depicts connections of a “2 Antenna” IDeal system (supporting one or two antennas). Antenna 2 Antenna cables 6 X 0.3 mm² (22 AWG) Antenna 1 Communication cable 4 X 0.3 mm² (22 AWG) IDeal box Power cable 3 X 0.75 mm² 24 V AC Transformer (18 AWG) AfiCom1 or AfiCom communication card Ground the IDeal box to a metal structure. Power supply to this unit must be 24 ±2.4 VAC1 75VA, from Note: an isolating transformer.
Chapter 5: Wiring This chapter details wiring of the IDeal identification system. Inserting Cables into the IDeal Box After laying cables, insert them into the IDeal box. IDeal boxes, and antenna switching boxes, are provided with color-coded grommets. Each cable is inserted through its appropriate grommet. Insert cables as described on the following page. Green grommets – Antenna cables 6.5 mm (¼”) diameter (P/N 5001764) Red Grommet – Communication cable 5.
Insert cables as follows: 1. Using a small screwdriver, or any pointed object, puncture a hole on a side of the desired plugs. Pull loosened plugs from the grommet. Remove plugs only where a cable will replace it. If grommet holes are left open, the box will not be waterproof, and components may be damaged. Warning 2. Unscrew the nut and remove grommets. 1 3. Insert cables through the nut, and then insert cables through grommet holes. Allow slack for wiring inside the box. 2 4.
Wiring Cables to Connectors Wire cables as described in this section. Connecting the Communication Cable Connect the communication cable as described below. See the AfiCom 1 or AfiCom communication card installation manual for more details on connections to the AfiCom 1 or AfiCom card. In most situations, the Current Loop communication type is used. If using C.L. connect a “P3” communication cable to Connector J4, on the left edge of the IDeal board.
Connecting Antenna Cables Each antenna is connected individually to the IDeal, or to the switching box in a “Switching Box” system. In the IDeal box, wire colors are printed next to each connector. In switching boxes, one pattern of color connections is printed on the board. 16 antenna connectors are in each switching box. See illustrations on pages 27 and 28. In normal operation: • The brown and white wires are connected together, to the “Wht/Brn” pin.
Connect Antenna Select Cables (in systems with switching boxes) Connect antenna select cables as described below, and as illustrated on page 28 (On the switching box PCBs, wire colors are printed at connectors): • Connect J11 (Box select 1) in the IDeal box to J1 of Switching box No. 1. • Connect J10 (Box select 2) in the IDeal box to J1 of Switching box No. 2. • Connect J9 (Box select 3) in the IDeal box to J1 of Switching box No. 3.
Connecting the Power Supply After all other lines are connected, connect the power supply to the IDeal box. The IDeal unit is powered by a 24 ±2.4 VAC. The power line coming from the transformer is a three-wire cable, connected to connector J3. Do NOT connect the IDeal to the same power supply that is used for the milk meters. The ground of the main power supply must NOT be connected to the IDeal box.
Chapter 6: Testing After the installation and/or when an identification fault occurs, test for identification range. There is more than one way to carry out this procedure, but the sequence of actions is always the same: • Initiate an identification request in the antenna. • Test antenna range with a test tag. • If necessary, adjust the Tx voltage, or replace the faulty antenna. To initiate an identification request of an antenna, you may use an “AFI” program (i.e.
The IDeal identification system has a mechanism to prevent the same cow from being identified at two stalls: Note If a cow is identified by an antenna, And then the same cow is identified in the next stall, Then the IDeal signal request returns to the original stall where the cow was first identified. Because of the mechanism described in the note above, two normal tags are needed to advance the IDeal search from one stall to another. Testing of ranges is done with the test tag.
Note If you want to recheck the previous stall, then the IDeal signal request must be returned to the previous stall. In order to return the signal request to the previous stall, place the same tag you used to advance the signal request beside the next antenna. • At the next antenna, the IDeal will receive the test tag signal (withot returning to the previous antenna). 6. Repeat the mapping procedure for antenna 2 (as described in steps 3 and 4). 7. Use Tag 2 to advance the I.D. request to antenna 3.
6 Open Open Closed Open Same as 5, though for stalls 17 to 32. 7 Closed Open Closed Open 8 Closed Closed Closed Closed Scanning stalls 1 thru 16 and 17 thru 32 simultaneously. Scanning antennas 1 thru 48 and returning to 1 again. Adding a Resistor to Reduce Transmission Range If a reduction of transmission range is required, a resistor may be added at the connector of each antenna. Connect resistors as follows: 1. Separate the black and the blue wires. 2.
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