Feed Management System
Contents
1. IH HIRED HAND Feed Management System pu E Hired Hand Manufacturing Inc 1733 County Road 68 PO Box 99 Bremen Alabama 35033 Part No 4801 2998 Rev 6 04 Installation amp Operation Manual Feed Management System Table of Contents Section Title Page l Ratingsand Sp cifications stag er E TREE En EE EE EA 3 PONE Cie S LESE EM 3 J Eni W arrana m 4 A ATMO CU CHOU MET o E A EA E A ATE 5 4 1 Sye EMANS r a MM ERE UD 5 Ds VOOM Requined usine pu N II MI I MEM M MI I MEME I IMP MES 5 6 Feed Management I O Module Installation ett oorr rtr hee IER eb tuere dad b atesteaceeaeeedears 3 6 1 VO Module 1 940 90099 near en nn E Ree ener eon nee nen Sore decentes tati een oe ee nee iae eee 5 O2 talla eaa a O A A 5 7 Current Sensor Installation on Feed Augers or Egg Belts eese 6 Tes Sensor Connection to Motor Wires and Feed Management I O Modulle cccessssessessssesssssseseeens 7 Ge Feed Bevel Sense Tis Can Ose te ec A asa i a eat ene i aca ec a aes EL cer aa ana a 7 8 1 Feed Leveksensor WIEMIS i omescteten eh niat teo ett sau teh eben eoe i an rents tte ba reb pitt 7 82 JBeedb vel Sensor VIOlDLIE Bees eot post teda tdg te hardest et tutta NO N od UT Eo ditas eus om MEM t a Id Ue 8 8 3 Feed Level Sensor Wiring to the Feed Management I O Module ss 10 9 Feed Management Software Programtimlfig ose rh E ar a UEM E Uu Up t iD A M EpL AU UE 11 9 1 Current2. 16 ON OFF STAGES 49 644 10 DIAGNOSTICS4 17 VARIABLE STAGES je eee Feed Level Module Setup 1 Bin 1 2 Diameter 6 ft 3 Cap Angle 30 4 of Rings 1 5 Ring Height 2 67ft 6 Feed wt 00 lb 7 Bin ht 9 07 ft 8 Bin 2 9 Diameter 6 ft 10 Cap Angle 30 11 of Rings 1 12 Ring Height 2 67ft 13 Feed wt lb 14 Bin ht 9 07 ft the installer easy setup The NAVIGATOR Current Conditions Target Conditions Minimum Vent JAN Stage Conditions Historical Data Back Up Status Alarm Status Network Status Program Setup The user enters the Bin Diameter 6 7 9 or 12 the Cap Angle 30 or 40 degree the of Rings 1 5 and the Ring Height which should typically be 2 67 2 8 The Ring Height can be used to adjust any errors in calculation that the controller might make The EV will then calculate the Bin ht Bin Height You can verify this by measuring from the top of the boot to the top of the cap excluding the lid ring Refer to Figure 10 If the Bin ht is incorrect adjustments can be made to the Ring Height for correction In addition Feed wt displays the estimated weight of the feed currently in the bin based on a feed density of 40 Ibs cu ft EROS T o Dead Zone al OC NM Top Angle Number of dii Rings Ring Bin Height Height Figure 10 Diameter gt Part No 4801 2998 Rev 6 04 FEED
3. 6 Feed Management I O Module Installation IMPORTANT Controller software Version 0 20 or higher must be installed in the EV3000 EV3001 to allow compatibility with this kit 6 1 I O Module Kit 6407 6035 Feed Management I O Module Ribbon Cable 6 2 Installation The I O Module must be mounted to the inside of the Evolution 3000 3001 enclosure and connected by ribbon cable to PCB 170 WARNING Disconnect and ensure that all power is removed from the Evolution 3000 3001 controller before proceeding with installation 1 Loosen the Front Panel Screw and open the Evolution controller front panel 2 Connect the ribbon cable to the Feed Management I O Module as shown in Figure 1 3 Refer to Figure 1 for I O Module mounting placement and clean the enclosure surface with alcohol and ensure the surface is completely dry Part No 4801 2998 Rev 6 04 FEED MANAGEMENT SYSTEM Page 5 of 15 l ez i i i Feed Management O Module F I Standoffs amp Double Sided Tape Ribbon Cable Holder I l l l l l l l l l l l l l l l I l l l 4 Remove the paper backing from the standoff double sided tape attached to the I O Module and apply the I O Module to the inside left side of the enclosure as shown in Figure 1 Ensure that the I O Module is not placed excessively low which will prevent ribbon cable removal OR excessive high which may contact the front panel circuit boards and interfere with
4. level sensors are used to monitor the feed inventory in the feed bins The current sensors are used primarily to monitor the runtime of the cross fill auger motors The following screen shows the Evolution controller 100 day Feed History that is generated through the use of these sensors The Usage column shows the daily estimated usage in lbs or kg The Augerl and Auger2 columns display the daily runtimes for the current sensors hours minutes Notice that the first row indicates the present status of the current sensors 1 Day 5 Status 41 40 35 2 Usage 2100 1b 2000 1b 1500 1b 1000 1b 150 lb 3 Auger1 On 4 10 3 00 3 00 4 Auger2 On 9 10 8 00 8 00 In addition to the history capabilities the addition of the current sensors adds two new alarm features The alarms allow you to place a runtime limit on each current sensor to help the user detect feed spills or protect against running out of feed The updated Alarm Status screen is shown below Proceed to Detail Screens TEMPERATSR PRESSURE 5 Low Pres Part No 4801 2998 Rev 6 04 1 High Temp 2 Low Temp 3 Cycle Press 4 High Press S WATER ALARMS 6 High Rate 1 7 Low Rate 1 6 High Rate 2 7 Low Rate 2 LIMIT 85 0 65 0 LIMIT 0 04 0 15 0 03 STATUS LAST ALARM Off 08 09 07 Off 07 22 01 Off 07 13 06 LIMIT STATUS LAST ALARM 100 hr OK 01 01 12 25 hr OFF 01 0
5. of 15 4 Introduction 4 1 The Feed Management System is the latest technology in the Evolution family This technology adds the capability for monitoring feed levels in bins run times of feed augers egg belts or any AC Motor pulling between 35A and 100A Beyond monitoring it also adds alarm features to help prevent feed spills or running out of feed The Feed Management I O module adds the inputs to the Evolution control The Current Sensor is used to monitor runtimes of Feed Augers or Egg Belts for recording history and Alarm features The ultrasonic Feed Level Sensors are used to monitor the feed inventory in the feed bins System Limitations The ultrasonic Feed Level System is intended to provide a low cost alternative to load cell systems for tracking feed inventory It is not an accurate way to track feed consumption or to accomplish restrictive feeding This system will provide an estimated daily consumption although it is simply estimated There are many factors which will cause day to day errors in this estimate These factors include coning and inaccurate feed density It is important to understand that errors in level will occur from time to time due to coning These errors should be limited to damp starter feed therefore the system should provide accurate readings in almost all cases 5 Tools Required 7 16 Wrench Flat head screwdriver Wire Strippers 74 Drill Bit 7 16 Ratchet Small Flat head Screwdriver
6. pair 20 AWG minimum HHI P N 1503 2427 must be ordered separately Breaker Box Feed Auger Belt Other Motor Figure 3 x S Feed s c Current Management Sensor I O Module 8 Feed Level Sensor Installation The Feed Level Sensor is an ultrasonic sensor designed to monitor the feed level inside a feed bin 8 1 Feed Level Sensor Wiring Wiring Requirements A customer supplied shielded 3 conductor 20 AWG minimum cable must be used to run from the top of the feed bin to the Evolution controller HHI P N 1503 2963 cable must be ordered separately 1 Loosen the enclosure bottom screw and open the enclosure cover Observe the orientation of the 3 pin connector and remove the connector from the PCB header Refer to Figure 4 3 Loosen the dome shaped nut from around the existing sensor cable and run the customer supplied cable first through the supplied cable sleeve then through the dome shaped nut and into the enclosure Use care to prevent damage to existing sensor wire connections NOTE The cable protection sleeve must be placed over the 3 conductor cable at this point although will remain loose until the Feed Level Sensor is mounted and secured in the Feed Sensor Mounting section 4 Strip the three conductor cable wires 4 5 Insert the three wires into the 3 pin connector slots and tighten the three screws securely by hand Do not over tighten 6 Place the 3 pin connector onto the PCB header in the
7. 1 12 100 hr OK 01 01 12 25 hr OFF 01 01 12 NAVIGATOR STATUS LAST ALARM Current Conditions OK 08 15 10 36p OK 08 10 03 36p LEUR o ET ES Minimum Vent AN Stage Conditions Historical Data Dx Back Up Status P Alarm Status 36p Network Status Program Setup 00a 00a 00a 00a NOTE The High and Low temperature reading is taken from the Sensors for Display in Sensor SYSTEM STATUS STATUS LAST ERROR Setup of the Program Setup 10 Tunnel Ventb OK 07 12 02 36p q 11 Growout Day OK 07 31 05 36p creen 12 Local Network OK 07 27 05 36p 13 Back Up Limits OK 07 31 05 36p 14 Sensor 1 OK 07 27 05 36p 14 Sensor 2 OK 06 10 09 36p 14 Sensor 3 OK 06 11 01 36p 14 Sensor 4 OK 06 13 06 36p 14 Sensor 5 OK 06 13 03 36p 14 Sensor 6 OK 06 21 03 36p 14 Sensor 7 OK 06 17 02 36p 14 Sensor 8 OK 06 13 10 36p 15 Outside OK 07 13 02 31p FEED MANAGEMENT SYSTEM Page 11 of 15 For the Ultrasonic Feed Level sensors we have created a Setup Wizard that allows following screen shows the Feed Level Setup Wizard screen FREQUENTLY ADJUSTED SETTINGS 1 1 GENERAL SETTINGS 3 STATIC PRESSURE 2 SENSOR SETUP 4 PROGRAMS amp SECURITY4 INITIAL SETUP 5 TEMP TIMERS RAMP 12 TUNNEL SETUP 6 FEED CLOCK SETUP 13 ON OFF STAGES 1 164 7 LIGHT CLOCK SETUP 14 ON OFF STAGES 17 324 8 STAGE PROPERTIES 15 ON OFF STAGES 33 484 9 NATURAL VENT
8. Conditions Screen on the Evolution 3000 3001 Controller sess 14 10 gt AWitrasomie Sensor LED Iidi6a3toEs ient b b apu aad tensed bea nate enu ad ies esos 14 Mle SUS cet an neat esata c ETT KERN 15 Part No 4801 2998 Rev 6 04 FEED MANAGEMENT SYSTEM Table of Contents 1 Ratings and Specifications HHI Part a 6407 6036 Feed Bin Level Sensor 12Vdc 100mA 0 F thru 130 F 0 thru 30 67 ft 6407 6070 1 5 Vdc 120 mA 18 C thru 54 C 35 thru 100A AC 2 Warnings Warning Only a certified electrician should install or maintain electrical connections Warning Proper safety equipment must be used during installation of Feed Level Monitor Warning Do not install or maintain equipment during a lightning storm Warning Maximum operating temperature of Feed Level Sensor is 18 to 54 C 0 to 130 F Warning When this system is used in a life sustaining application where failure could result in loss or injury the user should provide adequate back up or accept the risk of such loss or injury Part No 4801 2998 Rev 6 04 FEED MANAGEMENT SYSTEM Page 3 of 15 3 Limited Warranty All products are warranted to be free from defects in material and workmanship for a period of one year from the date of purchase if installed and used in strict accordance with the installation instructions Liability is limited to the sale price of any products proved to be defective or at manufacturer
9. MANAGEMENT SYSTEM Page 12 of 15 One other setting has to be verified by going to the Diagnostic screen DIAGNOSTICS For Qualified Technician Use Only 1 Power Ventilation Auxilary SWX 2 Ignore Inlet 1 Auxiliary SWX 3 Ignore Inlet 2 Auxiliary Swx 4 Natural Ventilation Auxiliary SWX 5 Ignore Unit 1 Auxiliary SWX 6 Ignore Unit 2 Auxiliary Swx 7 Feed Level Sensor 8 Maximum Range 26 00 ft 10 GPAD12 115 GPAD14 98 11 Soft Resets 12 Voltage Resets 13 Hard Resets Under Feed Level Sensor you will find the term Dead Zone This refers to the area that the sensor is hanging into the feed bin Figure 11 shows how to measure the Dead Zone Figure 11 Dead Zone The measurement should be taken from the top of the cap excluding the lid ring to the bottom of the sensor probe This measurement is the Dead Zone that should be entered Part No 4801 2998 Rev 6 04 FEED MANAGEMENT SYSTEM Page 13 of 15 9 1 Current Conditions Screen on the Evolution 3000 3001 Controller The current environmental conditions of the building are shown here Below is a table describing the variables that can appear in the Current Conditions status screen The numbers in brackets e g 1 refer to the descriptions below the sample screen displays A Feed Level The Feed level is shown in number of feet from the bottom first then the percentage of feed remaining in the feed bin is shown inside Two feed bins may be mon
10. The ultrasonic sensor will sense a distance up to 30 8 The Max LED flashes when 30 8 is sensed Typical feed bins will not reach this height therefore the Max LED should not be used Figure 12 WINDOW LIMIT A POWER S5IGHAL E ud MAX Itu Rte 2 Mu B POWER SIGNAL MIN MAX Part No 4801 2998 Rev 6 04 FEED MANAGEMENT SYSTEM Page 14 of 15 11 Parts HHI Part Number NENNEN FU ee MENMMgS Se c 6407 6035 Feed Management I O Module E 6407 6036 Feed Bin Level Sensor 1503 2963 i jg Cable 20AWG 3C PVC M3273 6407 6070 Current Sensor 35 100 A Feed or belt runtimes 1503 2427 Cable SJT 18 2 Yellow Sensor i o yyy gts Part No 4801 2998 Rev 6 04 FEED MANAGEMENT SYSTEM Page 15 of 15
11. closure of the control front panel NOTE The standoff tape is difficult to remove once applied to the enclosure surface Ensure the I O Module is positioned properly before making contact with the enclosure 5 Route the ribbon cable through the ribbon cable holder and connect the remaining end of the ribbon cable to PCB 170 in the orientation shown in Figure 2 Ensure the ribbon cable is placed and secured so that it can not be pinched during closure or opening of the front panel HET Sea bo Su ipo ke a Hn PCB 170 5 Figure 2 I O Module Connection 6 Ensure all wires are out of the front panel hinge and closure areas close the front panel and secure with the front panel screw 7 Current Sensor Installation on Feed Augers or Egg Belts The Current Sensor is designed to provide an ON OFF indication of current flow Current levels above 35 Amps turn the switch ON This Current Sensor is recommended only for applications with a continuous operating current above 35 Amps The Current Sensor will not turn completely ON if the application has a current level below 35 Amps Part No 4801 2998 Rev 6 04 FEED MANAGEMENT SYSTEM Page 6 of 15 7 1 Sensor Connection to Motor Wires and Feed Management I O Module The current sensor must be within 9 feet of the control The sensor may be placed inside the control or breaker box The wires from the Current Sensor to the Feed Management I O Module should be shielded twisted
12. ither side of the Cover 6 Position the Cable Sleeve as shown in Figures 6 7 amp 8 7 Secure the cable sleeve to the Mounting Bracket using cable ties as shown 8 Position and secure the sensor 3 conductor wiring to the back side of the feed bin to prevent damage during feed replacement The wiring should be secured to prevent excessive wind movement Sharp edges should be avoided to prevent cable damage Outside View of Feed Bin Flange LE 7 4 20 x 7 2 1 Bolts 4 20 Nuts 14 20 x V2 Bolts EK Cable Sleeve Figure 7 Figure 8 Part No 4801 2998 Rev 6 04 FEED MANAGEMENT SYSTEM Page 9 of 15 8 3 Part No 4801 2998 Rev 6 04 Feed Level Sensor Wiring to the Feed Management I O Module Evolution 3000 or 3001 Controller l Feed Management I O Module Circuit Board E W Feed Level Sensor Mounted on top of the feed bin Shield inside View Cable from the feed bin to the controller Figure 9 Feed Management I O Module Exploded View Analog 1 Connections for Feed Bin 1 Analog 2 Connections for Feed Bin 2 Front Panel ew 1l BE s a THEE eo E e ar CEC ETO JUE e m ee ee FEED MANAGEMENT SYSTEM Page 10 of15 Feed Management Software Programming This section introduces the Feed Management software The Evolution controller software allows the use of two ultrasonic feed level sensors and two current sensors The feed
13. itored Bin 1 amp Bin 2 EVITE VEU Mon 14 Jun 2004 5 00 p mu Current Conditions Vent Mode Minimum Growout Day 40 Room Temp Target Outside Pressure Target Humidity Airspeed Water Consumption g 240 10 hr zc 280 10 hr A Feed Levels 1 11 2ft 60 2 5 0ft 23 Cooler Temp 77 0 LEUCA Tee LETS THES Minimum Vent JAN Stage Conditions Historical Data Back Up Status Alarm Status Network Status Program Setup Y Sensor 1 Y Sensor 3 71 Sensor 5 Sensor 7 Y Sensor is enabled Sensor used in Room Temp Calculation Y Sensor 2 71 2 Sensor 4 Sensor 6 Sensor 8 E NOTE In this manual Reference numbers refer to descriptions given in text These numbers do not appear on display 10 Ultrasonic Sensor LED Indicators The ultrasonic Feed Level Sensor includes LED indicators to display the sensor status Refer to Figure 12 Power LED Indicates power is ON Signal LED Red Indicates that the sound waves are being received back to the module NOTE Ifthe distance from the end of the ultrasonic sensor to the solid feed level surface is between 8 and 30 8 both Min and Max LED s will be ON solid If the distance is at the Minimum or Maximum point the Min or Max LED will flash Min Flashing Yellow Indicates that the feed level is FULL and the ultrasonic sensor is sensing a level of 8 or less from the top Max Flashing Yellow
14. ng feed replacement 1 Select the location for mounting the Feed Level Sensor The mounting location should be 45 to either side of the feed bin cover hinge Refer to Figure 5 2 Carefully hang the Feed Level Sensor over the feed bin flange as shown in Figure 6 Mark the location for the top bolt hole and remove the sensor Use a 4 drill bit and drill the marked hole location through the feed bin cover flange Part No 4801 2998 Rev 6 04 FEED MANAGEMENT SYSTEM Page 8 of 15 CAUTION Extreme Care must be taken to avoid dropping tools or parts into the feed bin If parts or tools are dropped into the feed bin contact qualified personnel for procedures and assistance DO NOT ATTEMPT RETRIEVAL without proper procedures and assistance 3 Mount the Feed Level Sensor to the feed bin flange using the supplied 4 20 x 1 2 bolt and 4 20 nylon lock nut Tighten the top bolt and nut securely Refer to Figure 6 4 Measure 2 downward from the top bolt and mark the location for the bottom bolt hole Use a 1 4 drill bit and drill the marked hole location through the feed bin cover flange and sensor mounting bracket 5 Install the supplied 4 20 x 2 bolt and 4 20 nylon lock nut in the bottom drilled hole Tighten the bolt and nut securely Figure 5 Figure 6 F E Top View of yi Feed Bin Flange Top View of E Feed Bin e 7 4 20 Bolts Hole Cable Ties X Feed Level Sensor Mounting Locations 45 to e
15. s option to the replacement of such products upon their return No products are to be returned to the manufacturer until there is an inspection and or a return goods authorization RGA number is issued All complaints should be directed first to the authorized distributor who sold the product If satisfaction 1s not obtained or the name of the distributor is not known write the manufacturer that appears below directed to the attention of Customer Service Manager This limited warranty is expressly in lieu of any and all representations and warranties expressed or implied including any implied warranty of merchantability or fitness for a particular purpose The remedy set forth in this limited warranty shall be the exclusive remedy available to any person No person has authority to bind the manufacturer to any representation or warranty other than this limited warranty The manufacturer shall not be liable for any consequential damages resulting from the use of our products or caused by any defect failure or malfunction of our products Some areas do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights that vary from area to area Warrantor Hired Hand MFG Inc 1733 County Road 68 PO Box 99 Bremen Alabama 35033 Part No 4801 2998 Rev 6 04 FEED MANAGEMENT SYSTEM Page 4
16. same orientation as removed while taking some of the slack out of the 3 conductor cable Do not stress the wires or connector by pulling wires or cable excessively tight 7 Tighten the dome shaped nut securely around the cables 8 IMPORTANT Record the wire colors to each of the 3 connections Gnd Sig amp Vdc and retain for connections to the Evolution controller s Feed Management I O Module Part No 4801 2998 Rev 6 04 FEED MANAGEMENT SYSTEM Page 7 of 15 9 Close the enclosure cover place the rubber seal and tighten the enclosure bottom screw securely by hand Do not over tighten sensor Cable BN Dome Shaped Nut La Figure 4 I T 4 Strip wires 4 and place inside appropriate slot Enclosure bottom screw Tighten screws onto bare conductors 8 2 Feed Level Sensor Mounting Tools and Parts Required For This Section 7 16 Wrench 14 20 x 4 Bolt Qy 2 Ya Drill Bit 7 16 Ratchet Ya 20 Nylon Lock Nut Qty 2 A WARNING e Proper safety equipment must be used during installation of Feed Level Monitor e Do not install or maintain equipment during a lightning storm Failure To Follow These Instructions May Result In Property Damage Serious Injury Or Death Mounting Requirements The Feed Level Sensor should be mounted approximately 45 away from the feed bin cover hinge as shown in Figure 5 Sensor placement and securing the 3 conductor cable should help prevent accidental contact duri
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