LD Sorting Gate - allflex.global · The Sorting gate comes in two different variations with the option to use Heatime, DFII or SenseHub monitoring systems. • Sorting to the Left

LD Sorting Gate Installation Guide

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Index

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1. AllflexLivestockIntelligence Sorting Gate

1.1Overview

ThisGuidehasbeendesignedtohelpusersandtechnicianswiththeinstallationandoperationoftheAllflexLivestockIntelligenceLDSortingGate.

PleasereadthroughthisguidefullybeforeattemptingtheassemblyandinstallationoftheSortingGate.

SortingGatesthatfilteroffcowsdirectlyaftermilkingareusefulinstreamliningdailyoperationswithin thedairy herd.Oneormore SortingGates canbe a very usefulenhancementtoanyHeatime®,DataFlow™IIorSenseHub™monitoringsystemsonfarm.

1. Allflex livestock intelligence

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1.2SortingGateFeaturesThe sorting gate enables the automatic separation of cows according to a set ofpredetermined criteria. Cows may be separated manually based on the farmer’sdecisionorautomaticallybasedonreportsgenerated.Automaticsortingeasesandsimplifieswork,savesprecioustimeandensuresacalmenvironmentforthecows.ThesortinggateidentifiesthecowspassingthroughitbyusingIRidentificationunitsandsortsthecowsdesignatedforseparation.TypicalsortinggatedecisionsincludetheseparationofcowsforAI,veterinarianinspection,orforgroupchanges.

Thegateitselfis6meterslongandcanbeeasilyassembledatthemilkingparlorexitoratanyotherlocationwherecowspassonaregularbasis.Thesortinggatemaybeconstructedwitheitheraleftorrightsortdependingontheholdingpenlocation.Athree-waysortinggateisalsoavailablethatsortstotwodifferentholdingareas,oneontherightandtheotherontheleftsideofthegate.

► HR LDN and cSense Flex Tag compatible. ► Heatime, SenseHub & DataFlow II integrated. ► Gate status indicator control panel. ► Pneumatic operation. ► Left or right sorting. ► Manual operation option. ► Two-way and Three-way sorting models available ► Modular Construction for easy Installation

KEY FEATURES


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1.3SortingGateLocationThere are 3 main requirements for the correct location ensuring the successfulinstallationofthesortinggate.Findingthecorrectsortinggatelocationiscriticalforitsproperandefficientoperation.Whenselectingthegate’s locationpleaseusethefollowingparameters:

• MAINS POWER AND AIR COMPRESSOR

Thesortinggaterequiresa230vMainsPowersupply&anAirCompressortofunction.Forthegatetoworksuccessfully,theAirsupplymustbebetween6to8barofpressuretoensurecorrectoperationisachieved.

• CONCRETE PATHWAY

Ideally,thesortinggateshouldbeinstalledonalevelconcretesurfacewithaminimalsizeofL6500mmxW1200mmxD100mm.Theconcretesurfacemustbegroovedtopreventcowsfromslipping.

• SHADING

Thegate’sidentificationsystemusestwoinfra-red(IR)IDunits.Forcorrectoperation,theseIDUnitsrequirethatdirectorreflectedsunlightwillnotshineontheIDunits.Ifthesortinggatecannotbeinashadedareaunderanexistingroof,aroofmustbeconstructedoverit.


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1.4SortinggateOperationTheSortinggatecomesintwodifferentvariationswiththeoptiontouseHeatime,DFIIorSenseHubmonitoringsystems.

• SortingtotheLeftorRight(2-Way)–Shownindiagramsbelow• SortingtoboththeLeftandtheRight(3-Way)

Theoperationisthesameforallmodelsofsortinggate.

1. ThecowenterstheraceandtriggersPhotocell1.ThecowisthenidentifiedbytheIDunits.Thecowcontinuesthroughtheraceandcoversthesecondphotocell.Ifthiscowistobeseparatedtheseparationgatenowopens.

2. ThecowproceedsthroughtheracepastPhotocell2.Ifthiscowisforseparation,thentheTexasGateclosesbehindthecow.ThereisalimitswitchsensorwhichtellsthesystemwhentheTexasgateiscompletelyclosed.TheTexasgatewillcontinuetocycle(openandclose)untiltheLimitSwitchsignalsthecompleteclosureoftheTexasgate.


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3. The cow is separated through the separation gate and as Photocell 3 isuncovered,theseparationgateclosesbehindthecow.

4. Thereislimitswitchfittedtotheseparationgatewhichtellsthesystemwhenthegatehascompletelyclosed.Onlywhentheseparationgateiscompletelyclosed,willtheTexasgatebeallowedtoopenforthenextcowtopass.

THE TEXAS GATE REMAINS OPEN ONLY BETWEEN COWS THAT ARE IDENTIFIED AND THAT ARE NOT TO BE SORTED.


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2.1 SortingGateFrameworkComponents

1xSupportFramewithHingesFRAME A

1xTexasGateAssemblyFRAME C

3xSupportFramesFRAME B

1xPairofStabilizerBarsFRAME D

2. Sorting Gateassembly

2. Sorting Gate Assembly

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2xLargeFramework(Length1775mm)

FRAME E

2xSmallFramework(Length940mm)

FRAME G

2xMediumFramework(Length1590mm)

FRAME F

2xSeparationGatesFRAME H


Forthe2-wayversion,the2ndSeparationgateisreplacedby1xextramediumsizedframework(FRAME F)andfittedusingtheextra4xBolta&4xBoltB

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2/3xAirRams(includingairconnectors,securingbrackets, couplingsand securingpins)fortheTexasGate&SeparationGates

2/3xSolenoids(includingairconnectors&pneumaticexhausts)fortheTexasGate&SeparationGates

2/3xLimitSwitchesfortheTexasGate&SeparationGates

6xPhotocellBracketsforthefittingofthePhotocellstotheframework


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2xrollsofAirPipestoconnecttheAirRamstotheRegulator&Solenoids

20mm&25mmBlackFlexibleConduitforneatlyconcealingallcablesonthegate

2xSteelPolesformountingoftheIDU510IDSensors

2xMetalTrunking(includingmetaljoiner)toholdcablingandAirPipesontopofthegate

16xPlasticEndCapstocoverallexposedinnerframework

1xrollof2coreblackpowercableforwiringintheLimitswitchesandSolenoids


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16x(3-way)/20x(2-way)80mmBoltsincludingwasher&nylocnut(Bolt A)

16x(3-way)/20x(2-way)90mmBoltsincludingwasher&nylocnut(Bolt B)

1x(2way)/2x(3way)150mmBoltsincludingwashers&nylocnut(Bolt C)

1x160mmBoltsincludingwashers&nylocnut(Bolt D)

20x80mmThunderboltsAnchors(Bolt E)

8x50mmMasonryscrews(Bolt F)

10x5.5x35mmTekScrews(Bolt G)


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2.2AdditionalComponents

1xDF1010ControlUnit

6xPhotocellsSensors

1xAirPressureRegulator

2xIDU510IDUnits

6xPhotocellCables

1xOutdoorSteelBox

1xPowerSupplyUnit

2xCrossedClamps


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FortheSenseHubversionofSortingGate-1xSenseHubSortGateControllerisrequired+ extra Ethernet cable for connection tothecustomersregularSenseHubController

ForHeatime/DFIIversionofSortingGate-1xDF800Mastercardisrequired+ExtraRS485CabletoreachfromtheDF1010totheDF800Mastercard(whichwillbelocatednexttothecustomerPC).

• SafetyGoggles• DustMask• 3-stepladder• RegularandPhilipsScrewdrivers• RangeofSpanners• SocketSet• AllenKeys• StringforLeveling• SpiritLevel(atleast60cmlong)• Wirecutters• MeasuringTape• WireStripper• ElectricGrinder/Hacksaw

• ElectricDrill• DrillBitsforMasonry• DrillBitsforMetal• StepDrillBit• Multimeter• LargeBlackPlasticCableTies• WhiteMaskingTapeforlabeling• ElectricImpactWrenchIncrangeofsockets• Mallet• Greaseforlubricatingthemovingparts• ARangeofHexNutDriverBits• CurvedFile

2.3 Installation tools


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2.4AssemblyofFrameworkForSafetyreasons,theLDSortingGateshouldalwaysbeassembledby2competentlytrainedpersonnel

FOR THE PURPOSE OF THIS ASSEMBLY GUIDE, A 3WAY SORTING GATE IS SHOWN

Tipsforboltingtheframeworktogether

PositiontheFrameworkso that all the fixingholesarealigned.Pushthe bolt through theframework until thethreadsarevisible.

Fit the washer to thebolt followed by thenylocnut

Using the spanner &ratchet / Impact driver,tighten the nut fullyso the framework issecurelyfittedtogether


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1. FindtheSupportFramewiththe4xHingesattached(FRAME A),standupandholdinanuprightposition.

2. Fit1oftheStabilizerbars(FRAME D)tothetopof the singleSupport Frame (FRAME A).This can be achievedby sliding the stabilizerbar inside the open corner of the supportframe.Thiscanthenbesecuredintoplacebyusingamallet

3. Take 1of theSupport Frames (FRAME B)andfit totheStabilizerBaras in thepreviousstep.Repeattheprocesswiththe2ndstabilizerbar(FRAME D)untilthissectioniscomplete(asinthepicture).Again,amalletcanbeusedtoensureallpiecesaresecurelyattached.

4. OncebothStabilizerbars(FRAME D)havebeensecuredintoplace,fixintopositionusing4 x BOLT G (1 at each corner). Thiswill stopthestabilizerbarsfrombecominglooseduringoperationofthegate


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5. Fitthe2xSmallpiecesofFramework(FRAME G)totheSupportFrameusing8xBOLT Aandtightentosecureinplace.

6. Carefullyandsafely,liftandplacetheTexasGateAssembly(FRAME C)intopositionagainstthesmallframework(FRAME G).

THE TEXAS GATE IS VERY HEAVY, USE CAUTION WHEN LIFTING


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Ensure the gate is fitted with the correct orientation (see picture) as incorrect fitting will mean the gate will not function correctly!

The Texas Gate will open away from the already constructed end of the race


HoldtheTexasGateAssembly(FRAME C)inpositionandforsafety,attachthe8xBOLT BsothereisnodangeroftheTexasgatebecominglooseandfalling

OPEN THE GATE IN THIS

DIRECTION

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7. Proceed to locate andfitthegreasenipplestothelocation on the Texas GateAssembly(FRAME C).EachHinge of the Texas gaterequires 1 x Grease Nippletobefitted.

8. Attachthe2xMediumSizedFramework(FRAME F)totheTexasGateAssembly(FRAME C)usingthe8xBOLT Busedinthepreviousstep.Thiscanbeachievedbyloosening1side(4xbolts)andthenre-fittingtheseoncetheFRAME Fisinposition.Tightenthenutsandboltstosecureinplaceandthenrepeatthisprocessfortheoppositeside.

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9. ThenextSupportFrame(FRAME B)cannowbeplaceduptothemediumsizedframework(FRAME F)andheldintoposition

10. Attach the 2 x Large Sized Framework (FRAME E) to the Support Frame using theremaining8xBOLT B

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11. ThefinalSupportFrame(FRAME B)shouldnowbefittedtotheraceusingtheremaining8xBOLT A

13. LifttheSeparationgateintopositionsothattheupperandlowercouplingslineupwiththehingesoftheframe.

The Separation gates should be fitted to the framework from inside the race. The sorting gate is designed so that the separation gates open inwards to the race when a cow is to be sorted.

12. Theseparationgates (FRAME H)cannowbefittedontothehingesoftheSupportFrame (FRAME A). Firstly, remove the rollpinsfoundinthetophingesoftheframe.


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16.Repeattheprocesstofitthe2ndSeparationgate.

For the 2-way version, the remaining piece of framework should be fitted to the side where no sorting of cows is required.

15. Place the separation gate onto thehingesensuringthatthesegatescanmovefreelywithoutanyresistance

14. Place the separation gate onto thehingesensuringthatthesegatescanmovefreelywithoutanyresistance


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17.Themetaltrunkingwhichwillholdthecabling(Photocells,Limitswitches,IDU510’s)andairpipescannowbefittedtotheassembledframework.Thiscanbemountedoneithersideofthesortinggatedependingonthelocationitisbeinginstalled.

18.Position1pieceofthetrunkingtoitsitsontopofthe1st&2ndsupportframes(FRAME B)attheentrancetothesortinggate

Trunking 1 Trunking 2

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19. Once the trunking is correctlypositioned, use the Tek Screws (BOLT G)to secure the trunking to the 2 x SupportFrames(FRAME B)

20. Slide the metal joiner inside the 1stpieceoftrunking.

21.,Takethe2ndpieceoftrunkingandlayitontopoftheTexasGateAssembly.Positionitsoitmeetswiththe1stpieceoftrunking

22. Proceed to connect the 2 pieces oftrunking together using the metal joiner.Once connected, secure the 2nd pieceof trunking to the top of the Texas GateAssembly (FRAME C) using 1 x Tek Screw(BOLT G)

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2.5SecuringthegatetothefloorNowthattheFrameworkhasbeencompleted,thegatecannowbesecuredtothefloor.PositiontheSortinggateatalocationwhichwillensureefficientcowflow

1.Onceinthedesiredlocation,checkthatthefeetofthegateareallinline.Youcancheckthatthegateisalignedcorrectlybyusingthelevellingstring.Tiethestringtothecornersof1sideofthegateandseeifthisistouchingeachfootalongthegate.Ifneeded,movetheframeworksoall5ofthefeetareperfectlyinline.

2.Withaspiritlevel,checkthecornersofthegatetoensureitsitsperfectlyupright.


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3.Thegatecannowstarttobesecuredtothefloor.TaketheDrill&8mmmasonrydrillbitandproceedtodrillpilotholesforthebolts.Startbydrillingtheholesandfittingthe10xmasonrybolts(BOLT E)to1sideofthegateonly(5feet),usingtheimpactdrivertosecuretheboltsintotheconcretesurface.Re-checkthealignmentofthegateaftereachapplicationtoensurenoshiftinghasoccurred.

4.Beforesecuringtheotherside,takeatapemeasureandensuretheinternalwidthis920mmateverypointatfloorleveloftherace.Again,useaspiritleveltochecktheframeisperfectlyupright.Proceedtodrillthepilotholes&fittheremaining10xmasonrybolts(BOLT E)tothe5feet.

5. Iffittingtoasurfacewithconcreteslats,drillingisnotpossibleasthismaycrackanddamagetheslats.Instead,usetheincludedadditionalclampingsystemtosecuretheSortingGatetothefloor.

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2.6FittingofthePhotocellsTip: Before Installation of the photocells, use a marker pen and mark all photocell cables (while still coiled) so that the location on the gate can be easily identified for wiring into the DF1010 - E1 (Emitter), E2, E3 & R1 (Receiver) R2, R3.

Important – The correct position of the Photocells is key to the successful operation of the Sorting gate. Always ensure the Specified measurements are

used when positioning the photocells on to the gate.

Photocell 1 Photocell 2 Photocell 3

Photocell 1–Thisshouldbepositioned1200mmfromPhotocell2.Thebottomofthebracketshouldbe900mmfromthefloor

Photocell 2–Thisshouldbepositioned500mmfromthecentreoftheTexasGateAssemblyFramework.Thebottomofthebracketshouldbe1160mmfromthefloor

Photocell 3–Thisshouldbepositioned900mmfromthecentreoftheTexasGateAssemblyFramework.Thebottomofthebracketshouldbe900mmfromthefloor


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1. Fitthe6xPhotocellbracketUClampstotheoutsideoftheraceframeworkasintheimagesabove(3toeachsideoftherace).TheUClampsshouldbefittedoverthepipeworkandthemetalplateplacedinside.

2. Slide the Photocell bracket through theU Clamps. Tighten the screw slightly tohold the bracket in position. Use the tapemeasureandspiritleveltocheckthepositionofthebrackettoensureallPhotocellswillbeperfectlyaligned.


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Ensure the correct Photocells are fitted. 1 pair of Photocells will contain 1 x Emitter & 1 x Receiver.


3.Fitthe6xPhotocellbracketUClampstotheoutsideoftheraceframeworkasintheimagesabove(3toeachsideoftherace).TheUClampsshouldbefittedoverthepipeworkandthemetalplateplacedinside.

4.FeedtheYellowPhotocellCablethroughthebracketandattachtothePhotocellEmitterensuringthe4pinsinsidetheconnectorarealigned.

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5. Position thePhotocellEmitterandsecure to thebracketusing the2xscrewsprovided.Repeatthisprocessuntillall3xEmitters&3xReceiversareallsecurlyfittedintothephotocellbrackets. Ensureall theEmitters&Receiversarefitted to the samesideof thebracketsasincorrectplacementwillresultinmisalignmentofthephotocellbeams.

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2.7FittingoftheIDU510IDUnits


1.Takethe2xSteelpoleswhicharesuppliedwiththeframeworkandfittothesortinggate.This canbe achievedby sliding thepoles through the loops found at the topof the 2ndSupportFrame(FRAME B)andTexasGateAssembly(FRAME C)

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3. Take1ofthemetalCrossedClampsandholdinpositionon1ofthesteelpoles.Start to feedthepurplecable throughtheholesof thecrossedclampuntilall thecable isthrough.

2. Securethe2polesintopositonbyfixingthe4xsecuringscrewsprovided

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4. FitthemetalbodyoftheIDU510intothecrossedclamp.Oncefitted,looselyfixintopositionbytighteningthescrewfoundontheundersideoftheclamp.Repeattheprocesssothatthe2ndIDU510isfittedtotheothersteelpole.

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5. Position the IDU510’s so that the 1st sensor is 800mm from the TexasGateAssembly(FRAME C).Fitthe2ndSensor850mmfromtheTexasGateAssembly.Oncethepositioniscorrect,fullytightenupthesecuringscrewsofthecrossedclampssobothoftheIDU510’sarelockedintoplace.

6. MeasurethedistancefromtheIDU510sensorstothepointwherethecablescanenterthemetaltrunkingandcut2piecesofthe25mmflexibleconduittothissize.

FeedtheIDU510’spurplecableallthewaythroughthelengthofconduit.Repeatthisforthe2ndIDU510andproceedtofitthe2piecesofconduitsnuglyoverthemetalbodyofthe2xIDU510units.Neatlysecuretheconduittothesteelpolesusingcabletiessoallcablingisprotectedandhiddenaway.

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2.8FittingoftheAirRams


For the 3-way sorting gate, there are 3 Air Rams which are used to power the Texas Gate and the 2 separation gates.

For the 2-way sorting gate, there are 2 Air Rams, 1 for the Texas Gate & 1 for the Separation Gate.

Separation Gate Ram(Connectoronside)

Texas Gate Ram(Connectorontop)

1. Unpacktheramsandproceedtoattachtheblueairconnectors(2perram).Thiscanbeachievedbyremovingtheredprotectivecovers&screwingtheconnectorsintotheramandtightenwithaspannertoensureanairtightfitisachieved.

Thesecuringbracketcannowbefittedtotheendoftheramsbyusingthe4xHexheadboltsprovidedwiththem.TheTexasgateramandseparationgateramsneedtohavethebracketfittedatdifferentpositionsasintheimagesabove.

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2.Screwthecouplingontotheendofalltheramsandlockintoplace.TheRamsarenowreadytofittothegate.

3.TaketheLargeAirRamandplaceontothetopoftheTexasGateAssembly(FRAME C)withtheairconnectorsfacingup.Positionthissothattherearbracketlinesupwiththefixingpointonthegate.

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4. Pack2ofthewashersunderneaththesecuringbracketoftheram.Useaspiritleveltochecktheramisperfectlylevel.Ifrequired,addmorewashersuntiltheramsitslevel.Feed1xBOLTDthroughthesecuringbracket&Framework.Fitthenylocnutandtightentosecureinplace.

5. ThePistonarmcouplingcannowbefittedtotheTexasGateframe.Lineupthecouplingto the frameand secure inplaceusing thepinprovidedwith the ram.Once fitted clipthepinontothearmoftheram.

6. TheAir pipes cannowbe fitted to thisRam by simply pushing the pipe into theconnector.Ensureeachpipeiswellconnectedandwillnotpullout.Neatlyfittheremainingairpipeintothemetaltrunkingtowhereallthepipesandthecablingwillexitthegate.

Placing the washers underneath the ram is critical as allows the ram to work freely without rubbing on the framework

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Thesmallerairramscannowbefittedtotheseparationgates.

7. Positionthesecuringbracketoftheramtothefixingpointfoundontheseparationgates.Again,severalwasherswillneedtobepackedunderneaththisendsotheramsitsperfectlylevel.

Oncethecorrectalignmenthasbeenachieved,place1xBOLTCthroughtheseparationgate&ram.Fixinpositionbyattachingandtighteningthenylocnut.

Caution – Do not allow the Air pipes to develop any kinks as this will severely affect the operation of the air rams

Placing the washers underneath the ram is critical as allows the ram to work freely without rubbing on the framework.

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8. Securethepistonarmstothemetalplatefoundontheframework(FRAME A)Thiscanbeachievedbyliningupthecouplingwiththeholeontheplateandsecuringinplacebyusingthepinprovided.Oncefittedsecurethepinbyclippingthistothearmofthecoupling.

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Please ensure enough excess is kept free so the separation gate can move freely without pulling out or damaging the pipes.

9. TheAirpipescannowbefittedtotheairrams.Insertthepipesintotheconnectorsensuringanairtightfitisachievedandthepipeswillnotcomeloose.

Fixthepipestotheframeworkusingcabletiesandproceedtofeeddownthelengthofthegate,firstlyinsidethestabilizerbar(FRAME D)andthenintothemetaltrunking.

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2.9FittingoftheLimitSwitches


For a 2-way Sorting gate – 1 x Limit switch for Texas Gate & 1 x for the Separation gate.

For a 3-way Sorting gate – 1 x Limit Switch for Texas Gate & 2 x for the Separation gates.

1. Takethelimitswitch/switchesfortheseparationgatesandproceedtolengthenthearms.ThiscanbeachievedbylooseningthescrewwithaPhillipsheadscrewdriver.Extendthearmssotheysitatthemaximumlengthpossible.

2. Theseparationgatelimitswitchescannowbeattachedbyfittingthemtoplatesateachcorner of the Support Frame (FRAME A).Mark the position and drill pilot holes into themountingplateontheframework.Fixthelimitswitchtotheplateusing2xTekscrews(BOLT G)Repeattheprocessandfitthelimitswitchtothe2ndSeparationGate.

SeparationGateClosedPosition SeparationGateOpenPosition

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3. Withthefinallimitswitch(TexasGate),completelyloosenthescrewsothatthearmcomesfree.Forthisswitchthearmneedstobepositionedata45-degreeangle.Oncecorrect,re-tightenthescrew.

4. MarkthepositionoftheswitchontotheundersideframeoftheTexasGateAssembly(FRAME C). The fixing points for this limitswitchneedtobe355mmfromtheedgeofthe TexasGate Frame.Drill pilot holes andproceedtofittheswitchtotheundersideoftheframeusing2xTekscrews(BOLT G)

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TexasGateClosedPosition TexasGateOpenPosition

5. AllLimitswitchescannowbewiredusingtheblack2-corepowercable.RemovethecoveroftheLimitswitchbylooseningthescrewwhichholdsthecoverplateon.

6. Withascrewdriver,pierceaholeintothewhiteplasticbungfoundattherearofthelimitswitchandproceedtofeedthecablethrough.Usingthewirestrippers,stripthecablebackandfittotheconnectionsinsidethelimitswitch.Oncewiredin,proceedtoneatlyfeedthecablesthroughtheTrunkingtowhereallthecableswillexitthegate.

MeasurethecablessotheyrunallthewaytotheDF1010controlbox.Cutthecablesandmarkeach1withthepositionoftheswitchonthegate.ThisissotheycanbeeasilyidentifiedforwiringintotheDF1010later.

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3. Installation of Air and Power Supply

1. EnsurethePowersupplyisnotconnectedtothemainssupply.RemovethecoverofthePower supply unit by loosening the screwslocatedateachcornerofthebox.

We Recommend locating the Power Supply & Air Supply close to theOutdoor Steel Boxcontaining theDF1010&Solenoids.Thiswill cutdownon the time taken to installand theamountofcablingrequired.

The Power Supply will need to be mounted within reach of a fully tested and working mains supply socket.

3.1InstallingthePowerSupply

3. InstallationofAir and Power Supply

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2. Locateasuitablepositionforthepowersupplytobemounted.Proceedtodillthroughtheplasticcaseateachcornerandintothewall.Fixtheboxtothewallusing4xmasonrysecuringscrews(BOLT F).

Replacethelidofthepowersupplyandtightenupthe4xsecuringscrews.

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1. UnpacktheRegulatorandproceedtofitthe2xbrassairfixingsbyscrewingthemintoeithersideoftheregulator.Useaspannertosecurethefixingsintoplace.

2. To mount the regulator to the wall, fitthemountingbracketbyremovingthelargeblack nut, placing the metal bracket ontotheregulatorandthensecuringinplacebyreplacingandtighteningthenut.Markandproccedtodrillpilotholesandfixtothewallusing2xmasonrysecuringscrews(BOLT F).

3. Fitthe2xAirconnectorstotheregulatorbyscrewingtheseintothebrassfixingsonthesides.Measureandcuttosize,enough8mmair pipe so that the customers compressorcan be connected to the left-hand side oftheregulator.Oncecut,fit theairpipe intothe connector ensuring an air tight seal isachieved.

4. Take the remaining 8mm air pipe andconnect to the right-hand side of theregulator.Runthisairpipeallthewayfromthe regulator to the position where thesteel box (containing the solenoids)will bemounted.

3.2InstallingtheAirSupply

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4. Installation of Electronics

4.1FittingoftheDF1010andSolenoids

4. InstallationofElectronics

1. Firstlyopenthesteelboxbyunlockingitwiththeblackplastickeysprovided.

2. FixtheMetalplatetothebottomoftheboxusing the8 x screws includedwith thebox.

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3. Take theDF1010andposition inside theboxas inthe imageabove.Ensureto leaveenoughroomsothatthe4xsecuringclipsontheoutsideoftheDF1010canbeaccessed.

4. Unclip the 4 x clips of the DF1010 tocarefullyremovethelidassemblyandplaceunderneaththemainhousing.

Check again the positioning of the DF1010insidethesteelbox.IfcorrectproceedtodrillthroughthecaseoftheDF1010andthesteelboxatthe3pointscircledhere.

SecuretheDF1010tothesteelboxusingthe3xnutsandboltsprovided.

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5. TheSolenoidscannowbefittedtothesteelboxintothepositionsshown.

Fora2-waysortinggate,2solenoidsareprovided.

Fora3-waysortinggate,3solenoidsareprovided.

6. Position1ofthesolenoidsintothesteelbox.Thesolenoidshave2holesinthebodywhichcanbeusedasfixingpoints.Takethedrillandplaceintheholeofthesolenoid.Drillthroughthesteelboxsothat2fixingpointshavebeenmade.

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7. Fitthesolenoidtotheboxusingthe2xnutsandboltsprovided.Repeattheprocessuntilallthesolenoidsaresecurelyfixedinsidethesteelbox.

8. AlltheexcesslengthofboltsfortheDF1010&Solenoidswillnowneedtoberemovedfromthesidesandbackofthebox.Usingagrinderorhacksaw,proceedtocutallexcessboltsoffensuringnosharpedgesareleft.

9. Using thedrill,metallicdrill bits& thenthestepdrillbit,proceedtomake4x25mmholes into the bottom plate of the steelbox, Fit the black conduit connectors intothese holes & secure in position using thenut included. Thiswill bewhere all cabling(runningthroughtheconduit)willenterthesteel box.

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10. Nowuse thedrill anda9mmdrill bitanddrillholes intothebottomplateof thesteelbox.Forthe3-waygate,drill7holes(3xairrams+Regulator)andforthe2-waygatedrill5holes(2xrams&1xregulator)Thisiswheretheairpipesoftheregulator&ramswillenterthebox.

11. TheSteelBoxcannowbemountedtothewall. Positionthesteelboxintothedesiredlocationandmarkthewallatthe4fixingpoints.

Proceedtodrillpilotholesintothewallandsecuretheboxinpositionusing4xMasonryscrews(BOLT F)

Use the round file to ensure no sharp edges are left as this may damage the air pipes

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1. RemovetheSenseHubSortinggatecontrollerandmetalmountingbracketfromthebox.

2. FittheSenseHubSortingGateControllertothemetalbracket.Positionontotheinnerdoorofthesteelboxensuringwhenthedooris closed, there will be plenty of clearancebetween theDF1010&Controller.Mark thepositionofthemetalbracketandproceedtodrillthroughthedoor.Fixthebrackettothedoorbyusingthe2xnutsandboltsprovided.Oncesecured,cutofftheexcessboltsfromthedoorusingahacksaw/grinderensuringnosharpedgesremain.

4.2FittingoftheSortingGateControllerFor Customers Using Heatime / DFII systems, The Sorting Gate Controller is not required and is replaced by the DF800 Mastercard (Section 4.3)

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Ensure the Sorting gate Controller is fitted to the lower part of the door so it will comfortably fit underneath the DF1010 when the door is closed.

An ethernet cable must be run between the Sorting gate Controller (attached to PD Port) and the regular SenseHub Controller (attached to PSE Port). The ethernet cable must be neatly secured ensuring it is not positioned to within 1 meter of high voltage cables when run parallel.

3. FittheSortinggatecontrollerbyslidingthisontothebracketandfixinginplacebytighteningthesilversecuringscrew.

4. Take the Extra Ethernet cable and fit 1 end into the PSE port of the regular SensehubController.RunthecableallthewaytothelocationofthesteelboxasthiswillrequiredforfittingtotheSenseHubSortinggateController.

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1. ConfirmthepositionoftheDF800soitcanbeeasilyconnectedtothecustomersPCviatheRS232seriallead.RemovethefrontcoveroftheDF800byunscrewingthescrewsfoundateachcornerofthebox.

ForCustomersusingHeatime/DFII,theDF800Mastercardmustbeused.TheMastercardwillneedtobeinstalledclosetothecustomersPC(runningtheHeatime/DFIISoftware)andwithaccesstoamainpowersocket.

DF800MastercardCompletewithPowerlead&RS232SerialCable

4.3DF800Mastercard

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2. Place the DF800 into the mountingposition and using a drill andmasonry bit,drill into thewall at the4points (1 ineachcorner). Fix in position using the screws &plugsthatareincludedtosecurelymounttheboxtothewall.

Wiring Schematic of the DF800 Mastercard. A larger copy can be found in section 6

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3. FeedthePower,RS485&RS232cablesintotheDF800.Thisisachievedbylooseningthe3securingnutsfoundatthebottomofthecaseandfeedingthecablesthrough.UsingtheWiringschematicforreference,fitthepowersupply,theNETRS485cableandtheRS232SerialcabletotheconnectionpointsoftheDF800.

4. Onceall connections are complete, replace the front coverof theDF800.Connect theRS232serialcabletothecustomersPC.

5. Neatlyandsecurely,runtheRS485cableallthewayfromtheDF800soitreachestotheDF1010locatedinsidethesteelbox.

An RS485 cable must be run between DF800 Mastercard and the DF1010 control box so communication between these can be achieved. The RS485 cable must be neatly secured ensuring it is not positioned to within 1 meter of high voltage cables when run parallel.

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4.4SolenoidsEachSolenoidwillneedtobewiredintotheDF1010controlbox.Airpipeswillalsoneedtobefittedtoeachsolenoidwith2xfeedscomingfromeachairramonthegateand1xfeedexitingthesolenoid.

1. Measurethe2xairpipescomingfromeachairramsotheywillcomfortablyreachthesolenoids.Cutthepipesandfeedthroughthe9mmholescreatedearlierinthesteelbox. Insertthepipesintothe2xairconnectorswhicharelocatedtogetheronthesolenoid.Repeatuntilallairpipesarefittedtoeachofthesolenoids.

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2. Thesolenoidsmustnowbe linked together.Measureandcut theairpipeandconnecttogetherusingtheT-sectionconnectorsasshowninthepictureabove.

3. TheremainingAirPipecomingfromtheRegulatorcannowbeconnectedtotheTconnector

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4. RemovetheblackconnectionplugfromtheSolenoidbylooseningthescrewandpullingtheplugawayfromthesolenoid.

5. Removethesealandtheconnectionblockfromthehousing

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6. Takethe2-corepowercableandfeedthroughthehousingof theplug.Usingthewirestrippers,stripthewiresback.

7. Fitthewiresintotheconnectionblockasshowninthediagram.

Onceconnected,re-fittheplugbacktogether.

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8. Re-connecttheplugtothesolenoidandsecureinplacebytighteningupthescrew.Onceconnected,measurethecableandcuttosizeso itwillcomfortablyreachtheDF1010controlbox.

9. Unwind the brass Pneumatic exhaustsuntil they are in a fully open position. Re-tightenby2fullturnssotheyarepositionedat an optimum level for powering the airrams.

10. RepeatuntilallthesolenoidsarecompletedandreadyforconnectingintotheDF1010.

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1. Measurethedistancefromtheexitofthemetaltrunkingtotheentranceofthesteelboxcontaining theDF1010. Cut 4 pieces of the 25mmblack flexible conduit ensuring theywillcomfortablyreachfromthetrunkingtothesteelbox.

4.5WiringoftheDF1010Wiring Schematic of the DF1010. A larger copy can be found in section 6

TheWiringSchematicshowingconnectionpointsforthePowerSupply,Photocells,IDU510IDUnits,Solenoids,LimitSwitchesandSenseHubSortinggatecontroller/DF800

Before commencing with the wiring of the DF1010, all cabling exiting the sorting gate must be neatly and securly fed through the remaining 25mm black flexible conduit and into the steel box.

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Groupthecablesasfollows:Limit Switch cables into 1 piece of 25mm conduitPhotocell cables into 1 piece of 25mm conduitIDU510 cables into 1 piece of 25mm conduitPower Supply & Sensehub Ethernet cable / DF800 RS485 cable into 1 piece of 25mm conduit

2. Usingthetape,tapeeachgroupofcablingtogetheratmultiplepointsdownthefulllengthofthecablesandproceedtofeedthesethroughtheconduit.Oncecompleted,feedthroughtheconduitconnectionpointsatthebottomofthesteelbox.

3. Attach the conduit into the connectionpoints at the bottom of the steel box.Continueuntil all 4 xpiecesof conduit areattached to the connection points and allcablingisinsidethesteelboxreadyforwiringintotheDF1010.

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4. Nowallthecablingispositioned,fixallairpipesandcabling(situatedinthemetaltrunking)inplaceusingthelargeblackcableties.Thiswillkeeptheseoutofviewandsafewhilstthegateisinoperation.

NeatlyCable tie all the flexibleblack conduit together so it isoutof viewand there isnopossibiltyofdamagebyanymeans.

5. OpenuptheDF1010byunclippingthe4xclipsfoundatthesideofthecase.Takeastanleyknifeandcarefullyremovethetopsfromallofthegreeninputgrommets.Thiswillmakeiteasierforinsertingthecabling.

Before cutting any cabling, ensure each individual cable is sufficintly marked showing the description of that part and the position it is found on the sorting gate.

Wiring the DF1010 in an incorrect manner will cause the Sorting Gate to malfunction.

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6. AttachtheEthernetcable(fromtheregularSensehubController)totheSenseHubSortingGateController.TheControllerlightswillbecomeactiveasthebootupprocessbegins.

7. InsertthecablesfromthePowerSupplyand the Sensehub Sorting Gate Controllerthroughthe2grommetsfoundattheright-handsideoftheDF1010

Wireintopositionasdescribedinthewiringschematic.

Ensure this ethernet cable is plugged into the PD Port on the Sorting gate Controller.

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8. Takethe2xpurplecablesoftheIDU510’sandfeedthrough2ofthegreengrommetsfoundattheleftandthenintothecaseoftheDF1010.MeasurethecabletotheconnectionpointoftheDF1010ensuringenoughcableisretainedsoitcanneatlyrundowninsidethesteelbox.Withthewirecutters,cutthecablebacktosize.Takethewirestrippesandstripthecablebacktoexposethewire.WireintothecorrectconnectionpointontheDF1010asshowninthewiringschematic.

9. Findthe2xcablesfromPhotocell1(E1&R1)andfeedthroughthegreengrommetsandintothecaseoftheDF1010.Measurethelengthandstripthecablesback.FittothecorrectconnectionpointsoftheDF1010asdescribedinthewiringschematic.

When wiring in the Photocell Cables, the white wire from the Photocell Emitters is not required. This can be secured away from the board by taping it to the yellow insulation of the photocell cable.

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10. RepeattheprocessforPhotocell 2 (E2 & R3) and Photocell 3 (E3 & R3)byfeedingthecablesthroughthegreengrommetsandintothecase.WireintotheDF1010asdesribedinthewiringDiagram.

11. FitthecablesforthelimitswitchesintotheDF1010.Wireontotheboardasdescribedinthewiringschematic.

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12. FitthecablesforthesolenoidsintotheDF1010.Wireontotheboardasdescribedinthewiringschematic.

13. Neatlygroupthecablestogetherandrunthemdownthesidesofthesteelbox,Cabletieallthecablessotheareneatlyandsecurelyplacedinsidethebox.

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4.6PoweringuptheSortingGate1. Turnon theAir compressorand immediatelycheck the regulator toensure thegate isreceivingtherightamountofpressureforcorrectoperation.Checkallconnectionsontheramsandsolenoidstocheckfornoleaks.

2. PluginthePowersupplytothemains.TheDF1010insidethesteelboxwillnowpowerup.

3. SwitchontheDF800MastercardlocatednearthecustomersPC.Thelightsonthefrontwillilluminateasitpowersup.

4. PuttheSortinggateintomanualmodebyclickingtheswitchonthefrontoftheDF1010.Makingsurenopersonorcowisinside/nearthesortinggate,commencetotesttheoperationofeachgatebyusingtheswitchesontheDF1010.Ifthegatesdonotoperatecorrectly,tryadjustingtheexhaustvalvesonthesolenoidstofinetunetheoperationoftheairrams

5. ChecktheoperationoftheIDU510’sbybreakingthebeamofPhotocell1.Oncethebeamisbroken,theIDU510’swillstarttoflashastheysearchforatag.

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5. General Maintenance and Troubleshooting

5.1Maintenance

• CheckAlignmentandpositionofallPhotocellbrackets• Cleanthe6xPhotocellswithadampclothtoremoveanydebris• Aftercleaningofthephotocells,checkthelightsofeachemittergooutwhenthebeamisbroken

• Cleanthe2xIDU510IDunitswithadampclothtoremoveanydebris• AftercleaningoftheIDU510’s,checkthelightsflashbybreakingthebeamofPhotocell1.• GreaseallmovingpartssuchastheTexasGate(nipples&slidemechanism)andhingesoftheSeparationGates.

• DraintheAirPressureRegulatortoremoveanymoisturebuildupinthesystem• ChecktheConditionofthefloortoensurethefeetarefirmlysecuredandnocrackingofthesurfacehasoccurred

• Checkallairpipestoensurenokinksorsplitsarepresent• CheckalltheFrameworkNutsandBoltstomakesuretheyarestillfirmlyinplace• Cleantheframeworkofthegatetoallowgeneralvisualinspection.

5. GeneralMaintenance& Troubleshooting

WEEKLY MAINTENANCE TASKS

MONTHLY MAINTENANCE TASKS

Please do not power wash, steam clean or jet wash any of the electronic components.

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5.2Troubleshooting1. One of the gates, (either the Texas or Separation gate) opens and closes repeatedly as if there was a cow blocking the complete closure of the gate (but no cows are present)

It ispossiblethattheLimitSwitchisnotdetectingthatgateiscorrectlyclosed.RefertotheWiringDiagramsandproceedtochecktheconnectionsintotheDF1010arecorrect.Re-checkallwiringintotheLimitswitchensuringthecorrectterminalshavebeenused(terminals21&22)

2. There are cows in the Sorted Cows Area that should not be there, these cows were sorted unnecessarily.

Ifaftercheckingallthereportsusedforsortingduringthisshiftandthereisstillnoreasonforthese“extra”cows,checkthepositionofallphotocells(asseeninsection2.6)andinadditionensurethatallphotocellsarecleanandfreefromanydebris.

3. There are cows missing from the Sorted Cows Area, these cows were required but not sorted.

Ifaftercheckingallthereportsusedtosortcowsandconfirmingtherequiredcowsappearinthesereports,checkthereadrangeoftheIDU510IDUnits.ThiscanbedonebycoveringPhotocell 1&usinganAllflexCSense tag,moving it slowly throughthegate.The IDU510’sshouldflashrapidlywhenthetagpassesfromPhotocell1andcontinuesuntilthetagreachestheTexasgateassembly.Thistestshouldberepeatedthroughoutthefullwidthoftheracetoensurenodeadspotsarepresent.Iftherangeisfoundtobeinadequate,pleasegotoquestion4.

Alsocheckthepositionofallphotocells(asseeninsection2.6)andinadditionensurethatallphotocellsarecleanandfreefromanydebris

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4. The cow moves through the race but the IDU510’s do not read the tag.

CheckthattheSenseHub/Heatimesystemisonlineandthatthereisaliveconnectionthesortinggate.ThiscanbecheckedbyseeingiftheIDU510’sbecomeactivatedwhenPhotocell1’sbeamisbroken.Ifthisdoesnotoccur,pleaseperformasystemrebootbypowercyclingthesortinggatepowersupply.TheregularSenseHubcontrollerwillalsoneedtobere-bootedbypowercyclingthePOEadaptor.IfusingaHeatime/DFIIsystem,powercycletheDF800Mastercardinstead.

5. As the Texas Gate / Separation Gates are activated, the air rams are not working or moving very slowly.

ChecktheAirpressureregulatorandnotetheoutputofthecompressor.Theidealoperatingpressureforthegateshouldbebetween6to8bar.Allairpipetoensurenoleakageisoccurring.Openthesteelboxandcheckallpneumaticexhaustsonthesolenoids(asinsection4.4)toensuretheyhavebeensufficientlyopened.

6. As the cow is passing through the Texas gate, the gate closes on the back end of the cow.

CheckthepositionofPhotocell2.Ifthepositioniscorrect,trymovingthePhotocellbracketcloser to theTexasGateAssemblyby50mm.Thiswillmean theTexasgatewill close laterensuringthecowhaspassedfreelyfirst.

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7. As the cows are passing through the sorting gate, the IDU510’s are only intermittently reading the tags

The read rangeof the IDU510’smaybeaffected.To increase the read range,unscrewandremovethecoverplateoneachIDunit.Takeoutthefilterpaper(foundonthebottomoftheinternalhousing)andcarefullyremovetheperforatedcentreonly.RefitthepaperbackintotheIDU510’sandreplacethecoverplate(Pleaseseepicturesbelow).ThiswillnowincreasethereadrangeoftheIDunits.

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6. Wiring Schematics


6.1DF1010ControlBoardSchematic(SenseHub™SortingGateController)

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6.1DF1010ControlBoardSchematic(DF800Mastercard)

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6.2DF1010LidSchematic

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6.3DF800MastercardSchematic


Documents

LD Sorting Gate - allflex.global · The Sorting gate comes in two different variations with the option to use Heatime, DFII or SenseHub monitoring systems. • Sorting to the Left