Förster-Technik TAP5-VS2-50 Original Service Manual Download

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Original Service Manual

Automatic calf feeder

Type VARIO smart 2.0 Powder

TAP5-VS2-50

Program version 2.00 and higher

15. May 2018

Summary of Contents for TAP5-VS2-50

Page 1: ...Original Service Manual Automatic calf feeder Type VARIO smart 2 0 Powder TAP5 VS2 50 Program version 2 00 and higher 15 May 2018 ...

Page 2: ...ons 15 2 1 Intended use 15 2 2 Required qualifications 15 2 3 Residual risks 15 2 4 How am I warned of hazards 17 2 4 1 What are the components of a hazard description 17 2 4 2 Potentially fatal hazards or health hazards 17 2 4 3 Material damage 18 2 4 4 Safety signs 18 2 5 Safety devices 20 2 6 Structural alterations 21 3 Commissioning 22 3 1 Setting up the feeder 22 3 2 Electrical connection pro...

Page 3: ...nction keys 35 3 21 Animal list 35 3 22 Checking components 35 3 23 Calibrating feed components 35 3 24 Checking or setting cleaning settings 35 3 25 Cleaning 36 3 26 Reading in and creating transmitters 36 3 27 Registering animals 36 3 28 Entering correction days 36 4 Programming and control 37 4 1 Hand terminal 37 4 1 1 The keypad 38 4 1 2 The Auto LED 40 4 2 Offline mode 40 4 3 Automatic mode 4...

Page 4: ...e 63 5 4 6 Heating system 64 5 4 7 Boiler valve 64 5 5 Equipment 64 5 5 1 Mixer drain 64 5 5 2 Additive dispenser 64 5 5 3 Flushing agent 1 64 5 5 4 Flushing agent 2 65 5 5 5 Flushing agent sensor 65 5 5 6 Powder sensor 65 5 5 7 Circulation valve 65 5 5 8 Gully valve 2 65 5 5 9 Air valve 66 5 5 10 Mixer temperature sensor 66 5 5 11 Water meter 66 5 5 12 Supply and point electrode 66 5 6 Identifica...

Page 5: ...ering animals 79 7 2 1 Manual registration of animals 79 7 2 2 Automatically registering animals 80 7 3 Canceling animals or animal groups 81 7 3 1 Canceling individual animals 81 7 3 2 Canceling a group 82 7 3 3 Canceling weaned animals 82 7 4 Changing the registration of animals 82 8 Shutdown and recommissioning 83 8 1 Shutdown 83 8 1 1 Temporary shutdown 83 8 1 2 Permanent shutdown 86 8 2 Recom...

Page 6: ...d 104 9 3 Other faults and messages 105 9 3 1 Automatic feeder 105 9 3 2 Hand terminal 105 9 3 3 Boot loader 106 9 4 Service messages 107 9 4 1 Service work 107 9 5 Diagnosis 108 9 5 1 Checking valves motors 108 9 5 2 Checking the heating 109 9 5 3 Checking sensors 110 9 5 4 Calibration scales 111 9 5 5 Checking stations 111 9 5 6 Monitoring 111 9 5 7 Version 113 9 5 8 Setup 113 9 5 9 Software 113...

Page 7: ...all operating manuals and safety data sheets before starting up the automatic feeder for the first time or restarting it Observe all of the warnings and safety instructions in these operating manuals and safety data sheets at all times 1 1 Models The following automatic feeder versions are available Powder for the use of milk substitute MP Combi for the use of milk substitute and fresh milk Fresh ...

Page 8: ...3 Milk powder discharge 4 Water supply 5 Mixer beaker 6 Rod electrode 7 Hose connection from mixer to the feeding pump 8 Mixer motor 9 Wing nut for transport restraint 10 Water connection 11 Temperature sensor 12 Point electrode for 500 ml portion 13 Right door 14 Ground connection screw 15 Main switch 16 Hand terminal 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 9 ...

Page 9: ...side of the automatic feeder It contains information about the manufacturer type and number of the automatic feeder informa tion about connecting the feeder to the power supply as well as its certification An example of a name plate is shown below 1 Name and address of the manufacturer 2 Type and number of the automatic feeder 3 Information on the connection to the power supply 4 Certification of ...

Page 10: ...ump 2 acid 2 Mixer drain valve 3 Feeding box valves optional 4 Drain hose not shown here 5 Drain hose to gully 2 6 Hose connection from mixer to the feeding pump 7 Cleaning agent dosing pump 1 alkaline 8 Dosing device for liquid additives optional 1 2 3 4 5 6 7 8 ...

Page 11: ...r 6 Mixer 7 Valve unit optional 8 Hose connection between valve unit and teat 9 Mixer drain valve 10 Feeding pump 1 3 Technical data 1 3 1 Electrical connection Note The specifications for the electrical connection to your automatic feeder are on its name plate above the left side door on the outside see 1 2 3 Left side view of the automatic feeder 9 ...

Page 12: ...onnection NOTICE The water must be of drinking water quality Please bear in mind that high calcium iron and manganese concentrations can cause pre mature wear of the components In such cases it makes sense to install appropriate filtration systems The water pressure on site must be between 1 and 6 bar or between 100000 and 600000 Pas cal 1 3 5 Boiler The boiler holds approximately 7 ltr of water ...

Page 13: ...ng station max 30 Calves per device max 120 Optional A white plus sign on a black background indicates that optional functions or equipment are being described Abbreviation Meaning Call ltr t or Call t Call off today in liters Call ltr y or Call y Call off yesterday in liters abs absolute Adli Ad lib save amt Amount saved up feed pump Feeding pump out pause Dispensing pause sw off del Switch off d...

Page 14: ...temperature mix full Mixer full mixer cl Cleaning the mixer mixer dr valve Mixer drain valve n not No Number Clean teat Clean teat w o entitlement Without entitlement w o add or w o add Without additive P 1 5 Periods 1 5 R rationed feeding principle rel relative Drnk spd Drinking speed ho Hose clo close servo Servo control det pump Flushing agent pump Temp Temperature TR Feeding box fd sensor Feed...

Page 15: ...hey are able to assess the work assigned to them and detect potential risks on the basis of their technical training as well as their knowledge of the relevant standards They have knowledge of relevant accident pre vention regulations generally accepted safety regulations and country specific standards and provisions 2 3 Residual risks Hazards to health caused by the automatic feeder WARNING Dange...

Page 16: ...ng operation Carry out the recommended maintenance on the hoses The mixer and powder supply may start up unexpectedly if a calf which is entitled to feed approaches the unit This can crush or chop off fingers or hands Never reach into the area of the mixer or powder supply while the automatic feeder is in operation Use only the scrap er supplied to clean the powder discharge opening Poisoning Addi...

Page 17: ...of a hazard description A hazard description always consists of the following elements Hazard word danger warning caution attention Type of hazard what can happen Location of hazard where can it happen Actions necessary for preventing the hazard what should I do 2 4 2 Potentially fatal hazards or health hazards Depending on their severity and the probability of them occurring hazards that can caus...

Page 18: ...nsist of A pictogram in a yellow triangle illustrating the potential hazard What are prohibitory signs Prohibitory signs have a pictogram of the prohibited action in a red circle with a line through it See the adjacent example They graphically depict the prohibited ac tion In this example the hose with a line through it means that you may not use high pressure cleaners What are instruction notices...

Page 19: ...Important safety instructions 19 Burning scalding Health hazards caused by additives and cleaning agents Automatic startup No spraying Grounding symbol ...

Page 20: ...nd injuries caused by the powder con veyor starting up automatically The safety devices at the machine are an important part of the safety concept and help prevent accidents Do not remove or change the safety devices unless the corresponding safety instructions have been complied with Put the machine into service only once all safety devices have been fitted and are in the guard position Safety te...

Page 21: ... There is a risk of injury due to automatic start up Do not reach into the hazard area of the powder discharge opening The powder dosing can start up automatically at any time crushing or cutting off your fingers Always switch off the automatic feeder using the main switch and disconnect the mains plug Use only the scraper supplied to clean the powder discharge opening 2 6 Structural alterations T...

Page 22: ...t or suction hose heating made by Förster Technik Set up the automatic feeder in a location where the temperature cannot exceed 40 C and the humidity cannot exceed 80 If the end user intends to operate the automatic feeder outside of closed spaces inform the user that he she must protect the automatic feeder from rain and moisture for example with a roof Make sure that there is a drain where the a...

Page 23: ...form the end user that he she must provide the appropriate lightning pro tection e g lightning protection system for the entire building Comply with the local regulations and safety precautions Potential equalization To protect the animals and prevent electrical faults all metallic objects such as water pipes feeding station stand partition and automatic feeder must be grounded These locations are...

Page 24: ...iently large cross section Determine the number of points where water is simultaneously being extracted and adjust the cross section of the water pipe accordingly Make sure the water pressure is constant The water pressure must be at least 1 bar The maximum pressure must not exceed 6 bar If the water pressure drops below 1 bar you will have to install a pressure increasing device Lay the discharge...

Page 25: ... installed at a gradient to the automatic feeder see the illus tration NOTICE If no ActivityBoxes acre connected and hence no return hoses for the automatic suction hose cleaning are connected to the automatic feeder it is essential that the partition fittings are closed off with dummy plugs 3 4 2 Installing stand partitions Install the stand partitions where fitted in accordance with the manufact...

Page 26: ...situation in which feed for a calf outside of the feeding box is prepared but the calf does not receive it NOTICE There is a risk of malnutrition if calves do not receive any feed Malnutrition can cause impaired growth and development increased susceptibility to illness or even the death of your calves 2 Check the range of the aerials using the aerial test see 5 Setup 59 Note If 2 calves are ident...

Page 27: ...squelch values are based on experience and are set at the factory If the actual values differ the settings can be changed in the setup see 5 Setup 59 3 6 3 Connecting antenna cables Connect the antenna cable as follows 1 If necessary switch the automatic feeder off at the main switch 2 Connect the antenna cables to the connections provided 1 Antenna connections System Squelch default values Identi...

Page 28: ...ket on the feeder housing 1 Cylinder with Ethernet connection 4 Remove the plugs from the seal and open the screw connection of the cylinder 1 Seal in cylinder 5 Remove the cable sleeve from the cylinder and attach it at the location of the dummy plug in the feeder housing 6 Guide the end of the unattached Ethernet cable through the cable sleeve 7 Screw on the other end of the cylinder and pull ou...

Page 29: ...linder and tighten the cylinder and seals 10 Push the cylinder into the bracket into the housing of the automatic feeder 3 7 Installing the safety grid for the powder hopper attachment Install the safety grid as follows 1 Switch the automatic feeder off 2 Remove the bag with the small parts and hoses as well as the operating manual from the powder hopper 3 Insert the safety grid for the powder hop...

Page 30: ...he vapor barrier to 0 S1 switch for vapor barrier for powder discharge 3 9 Filling the powder container 1 When filling the powder container observe the occupational safety precautions CAUTION Beware of the health hazards caused by lifting heavy loads When filling the powder container make sure you do not strain yourself If necessary use appropriate lifting aids 2 Fill the powder container with mil...

Page 31: ... equipment NOTICE The cleaning agent container must be positioned so that it cannot be tipped over and so that calves unauthorized persons and children have no access to it The cleaning agent container can be freely selected To install it proceed as follows 1 In the cover of your cleaning agent container drill a hole ø20 mm for the cleaning agent lance 2 Feed the cleaning agent lance from below in...

Page 32: ...distort the cleaning agent container In this respect comply with the manufacturer s specifi cations and the national regulations 8 Position the cleaning agent container in the place provided for it Make sure that the suction tube is inserted cleanly and properly in the cleaning agent con tainer DANGER Danger of death if the cleaning agents are switched over This can result in the release of chlori...

Page 33: ...r by choosing The boiler will be filled with water 3 14 New installation During the initial startup and restart process for the automatic feeder the program software must be completely reconfigured reset This will remove superfluous data as well as outdated or incorrect settings from the memory Note Choosing Reinstallation deletes the Animal data group membership barn transfer date feeding days co...

Page 34: ...of the automatic feeder Note The automatic feeder will revert automatically to automatic mode 3 18 Setting portion NOTICE Feed temperatures that are too low can cause digestion problems in calves and feed tem peratures that are too high can cause gastritis in the abomasum The temperature of the feed in the mixer beaker must correspond to the mixing temperature specified by the MP manufacturer Keep...

Page 35: ...ist By default the key is assigned the animal list see 4 6 6 Animal list 50 Here is how you define which parameters are displayed in the two columns of the animal list 1 Navigate via Device data to the Animal list sub menu 2 In Column 1 or Column 2 select by using and to choose the parameter You can choose between Feed consumption in liters today or yesterday Drinking speed in Animal visits and Br...

Page 36: ...ty equipment 3 26 Reading in and creating transmitters During the initial startup process for the automatic feeder the transmitters have to be read and created once in the system When you do this each transmitter number is assigned one animal number of no more than six digits These animal numbers are then available and can be used to register the animals see 7 Transmitter and animal management 75 ...

Page 37: ...ss any buttons on the control panel during these initial routines You monitor and control the automatic feeder the feed pump for example directly via the keys of the hand terminal You monitor and change the settings of the automatic feeder and the values of calves via menus The menus and sub menus are arranged so that you can find the necessary settings quickly and easily With a click of a button ...

Page 38: ...ad With this key you open the Animal control menu or enter the number 1 With this key you open the Main menu or enter the number 2 With this key you open the Manual functions menu or enter the number 3 With this key you open the Search functions menu or enter the number 4 ...

Page 39: ... this key to delete warnings and alarms In the overview menu of automatic mode you use this key to bring warnings to the foreground With this key you can enter the number 9 You use this key to go backward within the menu structure You return to the starting menu by pressing this key multiple times You use this key to move the cursor upward and choose items from a list for example yes or no With th...

Page 40: ...our hand terminal goes out 3 Perform the desired action 4 3 Automatic mode You perform most routine tasks such as feeding in automatic mode In automatic mode the Auto LED lights up green You exit automatic mode by pressing and confirming the message Exit automatic mode by choosing After a prolonged period of inactivity the automatic feeder automatically returns to automatic mode This time period i...

Page 41: ...Arrows In automatic mode arrow heads are shown in front of menus A solid arrow head indicates that the menu contains sub menus An empty arrow head means that you can change settings here or start actions 4 4 1 2 Angle brackets Angle brackets around a menu or list mean that you can choose between menu options or list items For example you can select the appropriate calf from a list of animal number...

Page 42: ...eding plan The feed quantity remains constant for example in the middle of the feeding plan The feed quantity is continuously reduced for example at the end of the feeding plan f The calf is in the 40FIT period 4 4 1 7 Marking Marked calves are indicated by an asterisk to the left of the animal number 4 4 1 8 Alarms An exclamation mark to the left of the animal number indicates that a calf has tri...

Page 43: ...sary in order to dis play the full text on the screen 4 5 Menus 4 5 1 Animal control You can choose to open the Animal checking menu This menu contains all sub menus that the end user requires for daily calf monitoring The numbers next to the sub menus indicate the number of calves recorded in the sub menu concerned Animal list You will see a table that shows the calves sorted by different paramet...

Page 44: ...tic to manual mode The LED ex tinguishes and the automatic feeder is in offline mode You can actively switch the automatic feeder back to automatic mode Press until the mes sage Start automatic mode appears in the display Confirm this message with The au tomatic feeder will return to automatic mode The Auto LED lights up green You can control the following functions manually Extra portion Here you...

Page 45: ...of the risk of burns on feeding box valves optional During prolonged ad lib mode any feeding box valves that are fitted become hot You or the end user can burn your fingers or hand when touching these valves For this reason push the suction hose directly onto the mixer beaker spout and disconnect the connector from the feeding box valve 1 Device socket 2 Feeding box valve NOTICE Cleaning agent tha...

Page 46: ...ed in the mixer beaker must correspond to the mixing temperature specified by the MP manufacturer Keep to the feed temperatures recommended in this operating manual In this menu you make the following settings for the feed portion They set the set temperature of the feed in the mixer beaker They set the minimum temperature of the water in the boiler They set a pause between the dispensing of two p...

Page 47: ...avigate via Device data to the Portion sub menu 2 In Dispensing pause enter the required value in seconds from 1 16 The default value is 0 4 6 3 3 Portion output for entitlement less than 250 ml If the SynchroFeed functionality optional of the automatic feeder is used for technical rea sons the feeder cannot output any portions less than 250 ml In the event that an animal has drunk the contents of...

Page 48: ...olerance as follows 1 Navigate via Device data to the Portion sub menu 2 In the Tol Conc menu set the desired value and confirm with 4 6 3 5 Mixer draining Feed left over in the mixer must be pumped out This is done either via the mixer drain valve or the teat Alternatively you can choose not to pump out residual amounts at all NOTICE Leftover feed in the mixer can lead to an increased risk of inf...

Page 49: ...run on time of the mixer and activate or deactivate the mixing of milk portions Whether and how long the mixer should have a run on time depends on the solubility of the milk substitute 1 Navigate via Device data Portion to the Mixer run on time sub menu 2 In Mixer run on time enter the desired value 4 6 4 Drain time station parameters In the Feed menu you can define the drink out time for each fe...

Page 50: ... is assigned the animal list by default 4 2 The hash symbol stands for the key 4 3 The hyphen in the selection box is used to remove an assignment 4 6 6 Animal list In the Animal list menu you can list the calves in a table sorted by parameters The table is sorted in ascending order by the first column of the first parameter This means that the calf with the greatest need for monitoring is at the ...

Page 51: ...owing in the subsequent lines from left to right The animal number 1 The plan tendency 2 The group to which the calf concerned has been assigned 3 The last feeding box visited 4 Parameter 1 The current value today is in the column on the left 5 Yesterday s value is in the column on the right 6 Note The parameter for feed consumption is simply today s value or yesterday s value in liters to two dec...

Page 52: ...f the data is available NOTICE Data can be lost when the program version of the automatic feeder is updated You must also save the data of the automatic feeder manually for example to an SD card Otherwise calves may suffer from malnutrition if incorrect feed portions are dispensed Malnu trition can cause impaired growth and development increased susceptibility to illness or even the death of your ...

Page 53: ...nal data backup using an SD card During each backup a folder with the date of the backup is created on the SD card If data res toration is required a date stored on the SD card can be entered and selected using the num ber field The date of the last backup is always shown on the display When the feeder is delivered by default an SD card is fitted in the slot on the hand terminal The SD card should...

Page 54: ...Restore by choosing to perform a backup 2 1 If required enter the date from which you would like to restore the data into the Date menu and confirm this with 3 In the Date menu you can see when the last data backup was performed 4 6 8 Cloud This menu allows you to perform the relevant settings for the cloud 1 Navigate via Device data to go to the Cloud sub menu 2 In Finish you break off the connec...

Page 55: ...rtion settings for example 4 6 9 1 Only reinstall device data plans animal data or transmitter numbers Proceed as follows to reinstall device data plans animal data or transmitter numbers 1 Navigate via Device data to the Reinstallation sub menu 2 Confirm Device data by choosing 3 Confirm Reinstall device data by choosing 4 Confirm the security prompt Do you really want to restore the data to fact...

Page 56: ...P Manager or CalfCloud The options available for your equipment can be seen in the dealer area of Förster Technik s web site www foerster technik de 4 7 1 Software update via SD card The SD card update is performed using the SD card in the hand terminal and includes updating of all CAN participants If an update of the ActivityBox and the MultiReader detector is required this must be performed sepa...

Page 57: ...4 6 7 1 Internal data backup 52 2 Navigate via Device data Software Update to go to the Cloud sub menu 3 In Release official update the automatic feeder to the current software version 3 1 Confirm Start by choosing The automatic feeder will automatically seek out the current version 3 2 If there is a version available for the automatic feeder the message Feeder update available will appear Press E...

Page 58: ... data saved on the automatic feeder All the device data plans and medicine formulations will be reset to factory settings and all an imal data and transmitters deleted Perform a reinstallation as follows 1 Switch the automatic feeder off 2 Press and keep the key depressed whilst you switch the automatic feeder on and wait until the message Reinstallation appears in the display 3 Confirm with to co...

Page 59: ... as follows 1 Press and keep this key pressed when you switch on the feeder After a short time the Setup menu will appear in the display 2 If you want to change settings go to the relevant menu option and make the changes 3 Confirm the changes with 4 To exit setup repeatedly press until the message End setup appears Confirm with Note Also observe the operating manual for the automatic feeder ...

Page 60: ...dditive dispenser 1 yes no Additive dispenser 2 yes no Flushing agent 1 yes Equipment Flushing agent 2 yes no SP 1 sensor no rod Powder sensor yes no Circulation valve Valve no Gully valve 2 yes no Air valve yes no Mix sensor T yes Water meter yes Supply electrode yes Point electrode yes Identification Type Multi Tiris Ned Squelch 0 255 ID chip activated yes read Calibration scales activated yes n...

Page 61: ...rk configuration M M ECN IP 0 255 0 255 0 255 0 255 SN 0 255 0 255 0 255 0 255 GW 0 255 0 255 0 255 0 255 IP assignment DHCP static accept Cloud start Gateway MAC IP 0 255 0 255 0 255 0 255 SN 0 255 0 255 0 255 0 255 IP assignment manual autom Factory settings MultiReader No Version update MultiReader Temperature Read transponder type country no Squelch Resets Restarts Restart Restart SD card Feed...

Page 62: ... water mixtures Combi feeds fresh milk as well as MP water mixtures Milk feeds fresh milk only Leave the factory default value as it is NOTICE Even if you want a combined feeder to dispense MP feed only you must select Combi for the feeder type If you choose Powder the feeder will malfunction You set what liquid animal feed or which combination of liquid animal feeds only by Device data Operating ...

Page 63: ...t an address 3 Confirm your entry with Note If you select an address that has already been assigned the message Address already assigned will appear in the display 5 4 4 Feeder operating modes Please leave the factory set value SA StandAlone unchanged 5 4 5 Base size The set value determines The set quantity for calibrating the Water Boiler The standard portion size You define the size as follows ...

Page 64: ...drain valve The mixer drain valve is included as standard This is how to activate the mixer drain valve 1 In the setup menu open the Equipment menu item 2 In Mixer select yes 3 Confirm your entry with 5 5 2 Additive dispenser Up to two additive dispensers can be connected to the automatic feeder You activate the additive dispenser as follows 1 In the setup menu open the Equipment menu item 2 In Ad...

Page 65: ...is detected by a float switch mounted on a filling level rod set Rod If no flushing agent sensor is fitted set no 5 5 6 Powder sensor The powder sensor outputs a warning if the level of MP in the container is lower than the sensor If the sensor reports container empty for 10 portions in succession Warning top up MP will appear You activate the powder sensor as follows 1 In the setup menu open the ...

Page 66: ...or fitted otherwise choose no 3 Confirm your entry with 5 5 11 Water meter Please do not change the factory settings yes 5 5 12 Supply and point electrode You activate the electrodes as follows 1 In the setup menu open the Equipment menu item 2 In the Elec Supply menu select no and in the Elec Point menu select yes 3 Confirm your entry with 5 6 Identification Here you set the identification system...

Page 67: ...scales option 2 In activated choose yes if calibration scales have been installed 3 Confirm your entry with 4 In adjust press to adjust the calibration scales 5 The adjustment process begins with the taring of the calibration scales You will be informed of this in the message calibration scales are being tared 6 A menu appears where you need to enter the reference weight in grams that you require ...

Page 68: ...by default Note In a CAN bus system each address may only be assigned once You set the address as follows 1 In the setup menu choose the Terminal option 2 In Address select 1 3 Confirm your entry with 5 10 2 Contrast You set the contrast as follows 1 In the setup menu choose the Terminal option 2 In Contrast enter the desired value The default value is 60 3 Confirm your entry with 5 10 3 Sleep mod...

Page 69: ...W Gateway Here you can see the IP address of your gateway and if necessary change it IP assignment If you set the value here to DHCP your processor card will try to get its IP address from a DHCP server in your network If you select static here you will have to set the IP address of your processor card yourself in consultation with your IT specialist Note If after 10 seconds no IP address has been...

Page 70: ...re is automatically set then your gateway will try to get its IP address from a DHCP server in your network If you select manual here then you will have to set the IP address of your gateway yourself DHCP status only in connection with the automatic assignment of IP addresses This line gives you information about the internal status when getting the automatically assigned IP address There are five...

Page 71: ...t of the powder components milk substitute additives is determined If your automatic feeder does not have automatic calibration scales you must provide the fol lowing items for the calibration 1 Measuring cylinder with ml graduations capacity about 1 liter 1 scales weighing accuracy 1 g 1 vessel for collecting milk substitute 6 1 Calibrating without calibration scales You determine the actual valu...

Page 72: ...ner for the MP under the powder discharge 2 7 Confirm Start by choosing 2 8 Confirm Exit automatic mode by choosing This message will only be dis played if your automatic feeder is still in automatic mode Powder will be dispensed 2 9 Place the container with the collected MP on the scales 2 10 In the Actual menu enter the weighed quantity using the number keys 2 11 Confirm with 2 12 Date now shows...

Page 73: ...ows the amount of milk substitute MP to be dispensed by the auto matic feeder 2 3 Runtime shows the time in which the automatic feeder should dispense the MP 2 4 Date shows when MP was last calibrated 2 5 Confirm Start by choosing 2 6 Confirm Exit automatic mode by choosing This message will only be dis played if your automatic feeder is still in automatic mode 2 7 Place the calibration box into t...

Page 74: ... weighings without the user having to do anything and shows the result 2 9 Then the average value of these two control weighings is shown flashing in the dis played line Confirm with You then return to the calibration menu 2 10 Date now shows the current date 2 11 Remove the calibration beaker from the mixer beaker 2 12 Repeat the calibration to check your results 3 If the automatic feeder is equi...

Page 75: ...lars should never be in the bay They could push other animals out of the way and steal remaining amounts of feed Connection of transmitters and animal numbers The multi digit transmitter number is not well suited for the rapid location of individual calves For this reason a calf is issued an animal number along with the transmitter number The animal wears this animal number on an easily readable c...

Page 76: ...e that in Station you select the feeding box within which you have located the transmitter which you have identified 4 In order to allocate the newly read transmitter number to the displayed animal number con firm the security prompt Create new no xxx for animal xx by choosing 7 1 4 Manually entering transmitter numbers Instead of reading the transmitters you can also manually type in the transmit...

Page 77: ... transmitter so that the registration process of the transmitters and calves can take place completely automatically You set up automatic assignment of animal numbers as follows 1 Navigate via Animal management Transmitters to the New sub menu 2 Select the automatic option in No 3 In the Range menu define the part of the transmitter number that you would like to use as the animal number The animal...

Page 78: ...transmitter numbers as follows 1 Navigate via Animal management Transmitters to the Edit sub menu 2 Select the transmitter number to be deleted and confirm Delete by choosing Note You can only delete transmitter numbers of calves that are not registered status available 7 1 7 Deleting the transmitter number when canceling an animal Generally the collars or earmarks with the respective transmitters...

Page 79: ...s group The group to which you allocate the calves depends solely on the feed quantity and the con centration the end user wishes to dispense to the calves In this case it does not matter which station the calves consume their feed in or which bay the calves have been housed in 7 2 1 Manual registration of animals You register animals manually as follows 1 Navigate via Animal management Registrati...

Page 80: ...s When doing this you can specify that only calves whose transmitter numbers are already in the system can be reg istered If an available transmitter number is registered in the identification unit the correspond ing calf will be registered automatically Calves or transmitter numbers that have not yet been created in the system will trigger the Unknown transmitter number warning Proceed as follows...

Page 81: ...ng animals or animal groups Individual calves or a group of calves that are no longer being fed according to the plan must be removed from the pen compartment and their registration canceled The same applies to calves whose feeding plan has expired 7 3 1 Canceling individual animals You cancel an individual animal s registration as follows 1 Navigate via Animal management Cancellation to the Anima...

Page 82: ...g 7 3 3 Canceling weaned animals You can cancel the registration of weaned calves as follows 1 Navigate via Animal management Cancellation to the Weaned calves sub menu 2 Confirm Cancel by choosing if weaned animals are to be canceled 3 Confirm the security prompt Cancel animals with 7 4 Changing the registration of animals You can transfer calves registered at an automatic feeder to another group...

Page 83: ...matic feeder CAUTION Health hazards caused by lifting heavy loads Do not move the automatic feeder by yourself The automatic feeder must always be transported in an upright position To ensure that the automatic feeder does not become a breeding ground for germs which could endanger the health and life of the calves when you recommission the feeder you must thor oughly clean the automatic feeder be...

Page 84: ...en water expands and can damage automatic feeder components that contain water such as the solenoid valves 5 1 Close the water tap that supplies water to the automatic feeder 5 2 De pressurize the hoses by dispensing water into the mixer beaker 5 3 Press 5 4 Confirm Bo water start by choosing 5 5 Pour the liquid from the mixer into a container or the drain DANGER Fatal electric shock The electrica...

Page 85: ...e risk of infection To prevent infections use a new hose when recommissioning the unit 13 Disconnect the hose that runs from the drain channel to the mixer drain valve 14 Dispose of the hose NOTICE Beware of the risk of infection To prevent infections use a new hose when recommissioning the unit 15 Seal the cable gland of the Ethernet connection with a dummy plug and close the antenna connections ...

Page 86: ...ng to permanently shut down the automatic feeder you must dispose of it in ac cordance with the law To find out which regulations apply to you contact your waste disposal company or a waste disposal center listed in the yellow pages In the appendix of this manual you will find a list of the materials used in the construction of the automatic feeder see 10 2 Materials list 119 1 To shut down the fe...

Page 87: ... the water connector of the automatic feeder to the water tank using a clean new water hose 5 Proceed as follows to restore the cleaning agent supply optional to service 6 Install a new teat 7 Connect the teat to the feeding box valve rationed mode or the mixer beaker ad lib mode Use a new hose for this connection NOTICE The hose must be installed at a gradient to the automatic feeder without sagg...

Page 88: ... feeder Clean the hoses and the powder container By doing this you prevent germs that enter the automatic feeder from multiplying and infect ing your calves 18 Fill the powder container with milk substitute MP Use only milk substitute that is suitable for feeding calves NOTICE Make sure that no paper or other foreign bodies enter the powder container This could dam age the dosing mechanism or impa...

Page 89: ...the same steps as in commissioning see 3 Commissioning 22 4 Read the ID chip and check the setup settings see 5 Setup 59 5 In the Basic settings menu enter the desired language the current date and the current time of day This concludes the recommissioning process ...

Page 90: ...tomatically Some fault and warning messages can be deleted by pressing Some fault and warning messages can be deleted by confirming Delete fault or Delete warning with 9 1 Faults 9 1 1 Calibration scales If the calibration scales were not adjusted during setup you will see Fault calibration scales in the display You can correct the fault as follows 1 Confirm Calibration scales with 2 In Adjust pre...

Page 91: ...s filled with water If it is not filled feeder operation will be interrupted and the message Fault Boiler not filled will appear in the display Feeder operation will be interrupted Make sure that the end user provides the calves with feed using an alternative method as long as feed operation is interrupted You can correct the fault as follows 1 Confirm Fault boiler not filled by choosing 2 Check t...

Page 92: ... 1 Navigate via Diagnostics Sensors to the Elec point or Elec rod sub menu 2 In the right hand column check the status free or covered 3 Confirm Elec point or Elec rod with 3 1 In the Status menu check the status free or covered 3 2 Confirm Bo water start by choosing The electrode will be triggered if water is dispensed into the mixer beaker 3 3 Confirm Mixer draining by choosing to pump out the l...

Page 93: ...e boiler water The automatic feeder will operate in emergency mode the error message Calibr Bo wa terwill disappear You can correct the fault as follows 1 Repair or replace the water meter if necessary 2 Delete the water meter warning You will see the fault message Calibr Boiler water in the display 3 Calibrate water 4 Return to automatic mode 9 1 7 Emptying the mixer Fault mixer draining will app...

Page 94: ...ther the message empty or covered appears 7 2 Confirm in Mixer draining by choosing 8 Confirm Delete fault by choosing when you have fixed the fault 9 Remove cleaning agent remnants from components carrying feed by rinsing them with wa ter NOTICE Cleaning agent remnants that enter the feed can be hazardous to the health of calves Remove cleaning agent remnants before recommissioning the automatic ...

Page 95: ...s follows 1 Switch the automatic feeder off using the Main switch and disconnect the mains plug 2 Open the right side door of the automatic feeder 3 Remove the metal cover under which the safety temperature limiter is located 4 Press the reset button in order to reset the safety temperature limiter 5 Reattach the metal cover 6 Close the side door 7 Insert the mains plug again and switch the automa...

Page 96: ...user provides the calves with feed using an alternative method as long as feed operation is interrupted You can correct the fault as follows 1 Confirm Fault calibration by choosing 2 Calibrate all components shown in the display see 3 23 Calibrating feed components 35 9 1 11 ID chip The automatic feeder is equipped with an electronic name plate ID chip upon which the device number and other import...

Page 97: ...ted Make sure that the end user provides the calves with feed using an alternative method as long as feed operation is interrupted You can correct the fault as follows 1 Check all feeding box valves and the mixer drain valve for leaks 1 1 Clean leaky valves in order to remove any foreign objects that might have entered the system 1 2 Repair leaky valves or replace them 2 Check the rod electrode 2 ...

Page 98: ...ub menu 1 2 Confirm Bo water open by choosing to open the water valve The valve re mains open as long as you hold down 1 3 Check that the valve opens The valve opens when the water is dispensed 1 4 Repair the valve or replace it 2 Check the mixer drain valve 2 1 and press and hold until the mixer is filled with water 2 2 Navigate via Diagnostics to switch to the Valves sub menu 2 3 Confirm Mixer d...

Page 99: ... clogs and remove them NOTICE The hose which goes from the mixer drain valve to the drain channel must not be length ened 2 Check the feeding pump 2 1 Confirm Mixer draining warning by choosing 2 2 Confirm Feeding pump start by choosing The feeding pump will be actuated 3 Check the mixer drain valve 3 1 Confirm Mixer draining warning by choosing 3 2 Confirm Mixer drain open by choosing The mixer w...

Page 100: ...he right participant reports on the CAN address If this is not the case it is possible for the feeder and the participant to communicate but there will be no proper data exchange Warning Incorrect ID appears in the display You rectify the warning as follows 1 Check all CAN addresses 2 Switch the feeder on and hold the button until the setup menu appears on the display 3 Navigate to Setup Boxes and...

Page 101: ... reg istered You rectify the warning as follows 1 Confirm Unknown transmitters warning by choosing 2 In No check the unknown transmitter number 3 In Number you check how often the unknown transmitter number has been identified 4 In Time you check when the transmitter was last registered by the identification system 5 Confirm Delete by choosing if you wish to delete the transmitter number 6 Confirm...

Page 102: ...ser provides his her calves with feed using an alternative method as long as the calibration scales are not working DANGER Fatal electric shock The electrical components of the automatic feeder are live Always switch off the automatic feeder firstly with the Main switch and then disconnect the power plug before working on components of the feeder You rectify the warning as follows 1 Check that the...

Page 103: ... Open the flap on the back of the automatic feeder 4 Unplug the old ID chip from the main board see circuit diagram provided 5 Insert the new ID chip on the main board see circuit diagram provided 6 Close the flap on the back of the automatic feeder 7 Insert the mains plug and switch on the automatic feeder again using the main switch 8 Choose Setup ID chip to go to the Read sub menu 9 Activate th...

Page 104: ... s registration it will not receive any feed This can lead to malnutrition Malnutrition can cause impaired growth and development in creased susceptibility to illness or even the death of your calves The end user must use an alternative method to supply their calves with feed 2 Confirm delete warning by choosing You rectify the warning transmitter storage full as follows 1 Navigate via Animal mana...

Page 105: ...or the user interface Entry of the current date and time 9 3 2 Hand terminal 9 3 2 1 CAN bus off If a short circuit or electromagnetic discharges negatively affect the CAN cable the message terminal Vxx xx CAN bus off will appear in the display You can correct the fault as follows Check the CAN bus for short circuits and other faults and correct them 9 3 2 2 CAN bus heavy The following faults trig...

Page 106: ...ows Check that the feeder is working If the message is not automatically hidden in about 10 seconds you must check the feeder control 9 3 3 Boot loader 9 3 3 1 Waiting for update The following faults trigger the message boot loader Vxx xx waiting for update The automatic feeder s control program is not able to run Update the program using an SD card or the FTP Manager The boot loader was accidenta...

Page 107: ...e work For each regular service there are various service packages sets of spare parts with the spare parts required which will differ depending on the type of feeder and type of service After re placing the parts subject to wear you must also check that the feeder is working properly for example the calibration The service work is described in the installation information for the sets of spare pa...

Page 108: ...to open the water valve The valve remains open as long as you hold the key down 3 In the Gully valve 2 menu press A new menu in which you can check the gully valve will open 3 1 Confirm Water to the gully by choosing to rotate the valve towards the gully or confirm Water to the mixer by choosing to rotate the valve towards the gully The check behind the selected line show the last position to whic...

Page 109: ...pump Check that cleaning agent flows from the outlet WARNING Hazardous or irritant materials Collect the cleaning agent residues and additive residues and dispose of them safely When doing this be sure to comply with the manufacturer s instructions and national regulations for the use and disposal of the cleaning agent and additive being used In addition a mixer cleaning must then be performed 6 C...

Page 110: ...e mixer beaker 3 3 Confirm Mixer draining by choosing to pump out the liquid again 9 5 3 2 Button for the manual feeding pump Check the button as follows 1 Navigate via Diagnostics Sensors to the MP button sub menu 2 In the right hand column check the status active or inactive 9 5 3 3 Temperature in the mixer and boiler Check the temperature of the liquid in the mixer or boiler as follows 1 Naviga...

Page 111: ...mitter near the antenna 3 In No you check the transmitter number If the transmitter number is not recognized proceed as follows 1 Check in the setup whether the correct identification system is configured 2 Check that the data lines between antenna and automatic feeder are undamaged 3 Check the setup for the allocation of the station that is causing identification problems You check the feeding bo...

Page 112: ...ncorrect CAN address incorrect ID How often the automatic feeder could not switch to automatic mode because for example the liquid and powder feed components were not calibrated calibration How often the same address has been assigned in the CAN bus to devices duplicate ad dress How often a fault has occurred in connection with the ID chip How often Unknown transmitter was detected by the identifi...

Page 113: ...etup sub menu 2 Go to the desired sub menu and check the settings 9 5 9 Software This menu is only intended for the manufacturer s development department 9 5 10 Remote maintenance During remote maintenance the automatic feeder is operated via the CalfCloud 1 Navigate via Diagnostics to switch to the Remote maintenance sub menu 2 In start you permit remote maintenance of the automatic feeder 3 In e...

Page 114: ...user that the water should be of drinking water quality Excessive calcium and or iron and or manganese concentrations may cause premature wear Tell end users that the hose which goes from the mixer drain valve to the drain shaft may not be lengthened Tell end users that the feeder and cables must be protected against exposure to sun light Set up the automatic feeder on an even surface Remove the w...

Page 115: ... electronic none Equipment Mixer drain fitted yes no Additive dispenser 1 2 powder or liquid fitted yes no Flushing agent pump fitted yes no Flushing agent sensor no rod Circulation valve fitted no Air valve pulsating compressed air cleaning fitted yes no Gully valve 2 fitted yes no Mixer temperature sensor fitted yes no Water meter fitted yes no Point electrode fitted yes no Identification Set ty...

Page 116: ...ation 1 Select concentrate feeder type Issue CAN bus addresses To do this put IFS C station into search mode and then via search assign the address Configure scales controller s 1 x To do this set the CAN address on the scales con troller circuit board via HEX switch and enter the set address in setup Activate any weighing units 1 2 Terminal Assign address Communication Institute yes no Printer no...

Page 117: ...matic Reading transmitter numbers Set registration mode no automatic available transmitter numbers Register the animals Plans OK Feed Feeding plans Concentrate plans Quantity limitation check minimum saved amount maximum saved amount Check the maximum speed of the hose pumps and adjust them if necessary Weaning Concentrate Concentrate plan Portion size Quantity limitation check minimum saved amoun...

Page 118: ...ter connection of automatic feeder to milk tank using new hose Commission the cleaning agent supply Fitting a new teat Connect teat to feeding box valve rationed mode or to mixer beaker ad lib mode us ing new hose Install hose with downwards gradient to automatic feeder Connect mixer drain valve and the drain channel using a hose The hose may not be extended Replace the dummy plug with the cable g...

Page 119: ...Silicon carbide Carbon V2A V4A Plastics PET TPE silicone PVC NBR ABS PUR Viton Vulcanized fiber graphite loaded Rubber Bronze and confirm Boiler fill by choosing Input the time and date using Device data Date and Time Run cleaning programs Fill milk powder MP Perform calibration Check setup settings ...

Page 120: ...er solenoid valve and boiler 5 Open vent screw on boiler cover and drain boiler 6 Reattach water hose and tighten vent screw Disconnect and dispose of water hose Tip out liquid in mixer Disconnect hose between teat and feed station valve or mixer Replace hoses and teats Disconnect hose between mixer drain valve and drain channel Close cable glands of Ethernet Connection with dummy plugs Close ante...

Page 121: ...Appendix 121 10 4 Standard feeding plans ...

Page 122: ...122 Appendix ...

Page 123: ... If possible do not change the standard addresses Automatic feeder 1 Adress 11 Scale 1 Adress 21 Scale 2 Adress 22 IFS F station 1 Adress 41 IFS F station 2 Adress 42 IFS C station 1 Adress 51 IFS C station 2 Adress 52 IFS F quadruple 1 Adress 61 IFS F quadruple 2 Adress 62 CalfRail Adress 72 Default addresses 01 10 Hand terminal 11 20 Automatic feeder s 21 30 Scale s 41 50 IFS F station s 51 60 I...

Page 124: ...Adress Adress Adress Adress Adress Adress Adress Adress Adress Adress Adress Adress Default addresses 01 10 Hand terminal 11 20 Automatic feeder s 21 30 Scale s 41 50 IFS F station s 51 60 IFS C station s 61 70 IFS F station s quadr 71 79 CalfRail Automatik feeder Adress Automatik feeder Adress ...

Page 125: ...al components must be checked regularly for electrical safety in accordance with the intervals and test methods defined in the national regulations If any faults or damage are detected during the inspection the faulty components have to be replaced before the automatic feeder can be used again ...

Page 126: ...ls 81 Change registration 82 82 Changing the registration of animals 82 Checking components 35 Checking components by means of measure ments 125 cleaning agent lance 31 cleaning agent supply pipe 31 Cloud 42 Communication Cloud 69 Gateway 70 MultiReader 70 Network 69 Printer 69 Restart 70 D Data backup 52 with cloud 54 with SD card 53 Data restoration 53 Date 62 Deleting the transmitter number 78 ...

Page 127: ...ty 16 Poisoning 16 Heating system 64 66 Heating system diagram 11 I ID chip 67 Identification 27 66 Identification range 27 Initial start up Calibration 71 Connecting antenna cables 27 Connecting the Ethernet cable 28 External cleaning agent supply 31 Filling the boiler 33 Filling the powder container 30 Installing feeding station 24 Installing stand partitions 25 Installing the antennas 26 Instal...

Page 128: ... 44 Setting the time 46 Setting up the automatic feeder 22 Setup 59 67 Shutdown 83 Permanent shutdown 86 Temporary shutdown 83 Sleep mode 42 Software update 56 Square brackets 41 Squelch 66 Squelch values 27 Stations 68 Switching on the automatic feeder 33 Symbols 41 T Terminal Address 68 Contrast 68 Sleep mode 68 Time 62 Transmitter numbers 75 Transmitters Assigning animal numbers 76 Calling up t...

Page 129: ...Index 129 Unknown transmitter 101 Water connection 12 Water pressure 24 Weight 12 ...

Page 130: ...d amending Directive 95 16 EG recast 2014 30 EU Directive 2014 30 EU of the European Parliament and of the Council of 26 February 2014 on the harmonisation of the laws of the Member States relating to electromagnetic compatibility recast Reference to the harmonised standards used as referred to in Article 7 2 EN ISO 12100 2010 11 Safety of machinery Electrical equipment of machines Part 1 General ...

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Förster-Technik TAP5-VS2-50, Original Service Manual

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