Westfalia 7163-9001-044, Operating Instructions And Spare Parts List

Page 1: ...163 9001 044 Combi 7163 9001 046 Fresh Milk 07 2002 as of Program Version 01 01 Automatic Calf Feeder PREMIUM BOY PREMIUM BIG BOY SM TAK5 SM2 27 F1 VDW5 SM2 27 F1 TAK5 SM2 28 P1 VDW5 SM2 28 P1 TAK5 SM2 30 P1 VDW5 SM2 30 P1 TAK5 SM2 32 P1 VDW5 SM2 32 P1 TAK5 SM2 38 P1 VDW5 SM2 38 P1 DAIRY PROGRAM controlled by CALFSCAN Operating Instructions and Spare Parts List Westfalia Landtechnik ...

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Page 3: ... 22 4 1 3 Selecting the Options 23 5 Installing the Automatic Calf Feeder 24 5 1 Connecting the Automatic Calf Feeder to the Mains Supply 24 5 2 Filling the Boiler of the Heat Exchanger with Water 24 5 3 Deaerating the Circulation Pump if available 25 5 4 Filling the Milk Powder into the Powder Hopper 25 5 5 Filling the Milk Storage Tank 25 5 6 Calibrating the Feed Components 26 5 7 Setting the He...

Page 4: ...ion 54 10 4 1 Calibrating Water Milk MP 54 10 4 2 Calibrating Additives and Detergent 56 10 5 Machine Values 57 10 5 1 Intermediate Mix 57 10 5 2 Mixer Afterrun 57 10 5 3 Emptying Mixer 57 10 5 4 Press out the Milk 58 10 5 5 Entering the Distribution Pause 58 10 5 6 Box 1 Box 2 59 10 6 Diagnosis 60 10 6 1 Valves Motors 60 10 6 2 Sensors 60 10 6 3 Calibration 61 10 6 4 Identification 61 10 6 5 Chec...

Page 5: ...ault Messages 84 14 1 Memory Error 84 14 2 Heat Exchanger 84 14 3 Temperature 85 14 4 Electrode Fault 85 14 5 Communication 85 14 6 Identification 85 14 7 Milk Empty 85 14 8 Lack of Water 86 14 9 Emptying Mixer 86 15 Accessories 87 15 1 Two Group Valve Unit 87 15 2 Additive Dispenser 88 15 3 Fully Automatic Heat Exchanger Cleaning 88 15 4 Electrical Vapour Screen for MP and Powder Additive Outlet ...

Page 6: ... correct handling as well as careful care and maintenance Incorrect data entries may have serious consequences Therefore check the correctness of all data entries The livestock owner is responsible for a regular and scrupulous control of his animals and the functioning of the appliance If for any reason the system should break down or some calves should not make use of it the livestock owner is re...

Page 7: ...ore opening the control unit it is impera tive to make the automatic feeder currentless by turning the main switch to position 0 OFF or by pulling the mains plug 1 3 Information Signs on the Automatic Calf Feeder Before connecting the automatic calf feeder to the mains supply and activating the heating see chapter 5 Installing the Automatic Calf Feeder page 24 carefully read the operating instruct...

Page 8: ...achine Combi Main switch ON OFF Milk resp water outlet Quick acting closure for sponge cleaning Mixer Milk powder hopper Dosing slide Control unit with operating elements Milk connection Water connection Pilot lamps for milk powder outlet heating and protection against frost ...

Page 9: ...e Milk pump Heating thermostat Water connection Milk valve Circulation valve Water valve heat exchanger Water valve boiler Milk connection Detergent pump accessory Box valve 2 accessory Receptacle for detergent accessory Box valve 1 Water connection for hose cleaning not available on model TAK5 SM2 27 F1 ...

Page 10: ... Board SM 2 Plus 1 4 1 Motherboard and Distribution Board SM 2 Plus On the motherboard are located the transformer for weak current supply of the processor control the relays the connectors for external components the fuses and LEDs ...

Page 11: ...ulation pump not available on model TAK5 SM2 27 F1 and stainless steel coil The circulation pump keeps the warm water in the boiler running at high speed effecting in this way a rapid heat transfer to the liquid inside the stainless steel coil Solenoid valve for milk supply Solenoid valve water supply heat exchanger Milk pump for flow and dosing of the liquid components Mixer outlet valve Feeding ...

Page 12: ...rol The milk is then delivered directly from the mixer via the valve unit to the teat and into the mouth of the calf You can also use the feeding pump e g to drain off manually the rinsing water in the mixer jar via the mixer outlet valve To this end press Menu key and select Emptying Mixer in submenu Hand Functions Mixer outlet valve Suction hose Feeding pump Hose connection mixer Box valve 1 Hos...

Page 13: ...230 V 230V L N PE 50 Hz 16 A TAK5 SM2 28 P1 only for U S A and Canada 240V L1 L2 Grd 60 Hz 15 A TAK5 SM2 30 P1 only for Japan 200V L1 L2 Grd 50 60 Hz 20 A TAK5 SM2 32 P1 230V L N PE 50 Hz 20 A VDW5 SM2 38 P1 VDW5 SM2 27 F1 400 V 230V 400V 3 N PE 50 Hz 16 A VDW5 SM2 27 F1 230 V 230 V L N PE 50 HZ 16 A VDW5 SM2 28 P1 only for U S A and Canada 240V L1 L2 Grd 60 Hz 15 A VDW5 SM2 30 P1 only for Japan 2...

Page 14: ...powder additives 66 cm with dispenser for powder additives Weight with basic equipment approx 62 kg Water connection 1 2 hose with 3 4 hose coupling The local water pressure has to be between 2 5 and 6 bar Heat exchanger Boiler capacity approx 7 l Capacity of the stainless steel coil 0 5 l Milk powder hopper storage capacity with top section Approx 35 kg Number of sucking stations Each calf feeder...

Page 15: ...rt coupling As it is technically impossible to protect the installation against lightning stroke separately it is to the owner to install an adequate lightning protection such as e g a lightning protec tion system for the entire building We recommend to conclude a lightning protection insurance 3 2 Installing the Automatic Calf Feeder It is advisable to place the calf feeder in a dry location if p...

Page 16: ...can easily be tipped in forward direction The suction hoses should not exceed a length of 2 m Mount the suction bracket with splash board towards the bottom Make sure that there is no sag in the connecting hose between mixer and feeding pump in order to prevent accumulation of water or milk Teat at max 65 cm height Suction hose Teat bracket The teat should be mounted in the feeding station approx ...

Page 17: ...case of Micro Identification Calfscan you can set the range by the antenna Squelch see chapter 8 1 page 36 Con necting the System Machine to the Feeding Computer The following table contains the Squelch values and identification ranges for the different Responders These Squelch values are empirical and have already been factory set Responder Squelch standard values identification range X Responder...

Page 18: ...elow 2 5 bar Take care that there is no pressure variation of the water pipe In case of water pipes with small cross section it may happen that in the feeding mode or when water is taken out of the same pipe simultaneously the water pressure will drop When the water pressure is below 2 5 bar you have to use a header tank Install additional water stop valve Since September 1 2000 the pressure reduc...

Page 19: ...ontaining pipes very long and thin as well as thin walled pipes being prone to con tract lead to untimely switching off or change over of the system Should the milk pipe be made of several sections make sure that the connections both at the milk tank and the automatic feeder are reliably leakproof For hygienic reasons avoid gross differences of diameter Only use couplings and joining pieces easy t...

Page 20: ...r settings and operations concerning e g operating mode portion values calibration cleaning diagnosis etc via the keyboard The display shows all current settings Arrow Up key Arrow Down key Enter key Cleaning key Menu key Automatic key with LED Display Key for feeding pump Automatic ...

Page 21: ...vate the feeding pump Press Cleaning key to access the cleaning menu You will find more detailed information on the individual functions in chapter 12 3 3 page 74 ff Press Menu key to select several functions resp main menus For more detailed informa tion see chapter 10 page 49 ff Press Arrow Up Arrow Down to move through the different menus and to change the settings Press Enter key to open the m...

Page 22: ... Arrow Down to decrease the set value The longer you keep the relevant Arrow key pressed the faster you can change the displayed value Once you set the correct value press Enter to store it the value stops flashing In case you do not wish to change the value press the Menu key to return to the main menu Example for the input of values within the functions of the Menu key hand functions portion val...

Page 23: ...shing Press Arrow Up Arrow Down to move to the available options Press Enter as soon as the display shows the desired option The option is then marked by an asterisk and subsequently stored In case you do not wish to change the option press the Menu key to return to the main menu Example for the input of values within the functions of the Menu key hand functions portion values concentration 120 g ...

Page 24: ...ting thermostat Thermostat for minimum operating temperature Connect the mains plug and switch the automatic feeder on by turning the main switch to position I ON As soon as the display shows the program version press the Menu key and observe the instructions contained in chapter 5 2 Filling the Boiler of the Heat Exchanger with Water 5 2 Filling the Boiler of the Heat Exchanger with Water Press t...

Page 25: ...perative to make the automatic feeder current less by turning the main switch to 0 OFF or by pulling the mains plug Only fill in milk powder that is suitable for calf feeding Do not put paper or other foreign matter into the powder hopper There is no warning in case the powder hopper should be empty The automatic feeder continues working in the feeding mode without milk powder 5 5 Filling the Milk...

Page 26: ...omatic feeder cannot prepare an exact feed mix in feeding mode Calibration is defined as the input into the computer of the amount of water milk and milk powder MP distributed during a fixed period of time In case the automatic feeder is additionnally equipped with a detergent dosing pump or and a dispenser for powder additives it is imperative to calibrate both of them For more detailed informati...

Page 27: ...the following message Factory settings The minimum operating temperature is factory set between 38GC and 39GC The minimum operating temperature should always be set 3GC below the heating temperature in order to avoid overlaps in the control range The heating temperature is factory set between 42GC and 43GC The calibration menu helps you checking the water temperature For calibration refer to chapt...

Page 28: ...ing of the heating is related to the portion size and the drinking speed of the calves To measure the temperature do not extract more than 0 5 l In case of further measurements wait until the boiler has restored the temperature Heat transmission time depends on the input and outlet temperature of the liquid and may vary between 10 and 25 seconds To measure the temperature procede as follows Press ...

Page 29: ...nd off the heating for the milk powder outlet The right switch is used for switching the heating cable on and off In summer it is imperative to set both switches to 0 OFF The heating for the milk powder outlet prevents formation of condensate on the milk powder outlet The heating cable with temperature control is available as an accessory and can be retrofit ted at any time It is active when tempe...

Page 30: ...tion hose to the teat in the sucking station You can interrupt the preparation of a feeding portion at any time by pressing the Automatic Cleaning Menu or Enter key 6 2 Distributing the Milk 6 2 1 In the Restricted Mode The rod level electrode is free When an animal with drinking right enters the feeding box and is identified the automatic calf feeder prepares a milk portion as soon as the mixer j...

Page 31: ...l identification As soon as the rod electrode is free the machine starts preparing the next portion In case of two sucking stations both suction lines are open In case of prolonged ad libitum mode the 2 group valve unit heats considerably There fore connect the suction hoses directly to the mixer and plug out the plug of the 2 group valve unit ...

Page 32: ...owing options Option No Interface the automatic feeder runs in the adlib mode without connection to the feeding computer Option Relay signal the automatic feeder is controlled by a feeding computer with Station Controller The automatic feeder gets the relay and ready signals from the feeding computer Option Priority this option indicates which feeding station or calf group should be fed as a matte...

Page 33: ...matic feeder has a thermostat for minimum operating temperature Here you can enter whether the automatic feeder is equipped with a circulation pump Select yes in menu air valve when the automatic feeder is equipped with compressed air cleaning Enter yes in case the automatic feeder is equipped with a circulation valve that is needed for heat exchanger cleaning In case the automatic feeder is equip...

Page 34: ...k KR no Interface relay signal Interface priority Alcom Bus VC3 Bus Address Squelch 0 x 255 Box 1 Box 2 yes no servo gradient Additive Dispenser yes no Calibration scales yes no Heating system thermostat electronic Thermostat for Minimum Operating Temperature yes no Circulation pump yes no Air valve yes no Circulation valve yes no Detergent pump yes no ...

Page 35: ... means of Arrow Up Arrow Down and confirm with Enter Now call up the other available menus by pressing Arrow Up Arrow Down For modifica tions press Enter to open the memory Select the desired option by pressing Arrow Up Arrow Down Confirm with Enter All selected options are marked by an asterisk In order to leave Setup switch the automatic feeder off and then on In this way all modifications will ...

Page 36: ... higher address as an additional bus address Input of the Bus address see chapter 7 1 page 32 Setup Different selections in Setup Press Arrow Up Arrow Down to move to menu Squelch Press Enter Enter the relevant squelch value In order to activate the selected functions switch the machine off and subsequently on The antenna type is decisive for the identification range In case of micro identificatio...

Page 37: ...37 Connecting the System Machine to the Feeding Computer ...

Page 38: ... if the computer crashes it will restart automatically and operation of the feeders can always be guaranteed If the program is running in the background this will be indicated by the DP symbol on the left hand side of the Taskbar next to the clock In order to be able to operate the automatic feeder using DAIRYPLAN a number of set tings must be entered in DAIRYPLAN and coordinated with each other f...

Page 39: ...m Setup Feed Types menu Feed types 4 6 are the standard settings entered in the program for calf feeders although other feed types can also be selected and entered accordingly We recommend that this setup is used as the corresponding feed lists are also set up for these feed types and otherwise they will have to be changed accordingly The standard settings are Feed type 4 Milk Powder Feed type 5 F...

Page 40: ... The setting 24 20 can also be used for calf fee ders The number of total or entitlement intervals should be the same for feed types Feed and Milk Powder However the intervals for Feed 6 Supplementary Feed can be different and can be set to 3 for example in order to add medicine to the feed three times a day 2 Setup for the feeding box The setup for the feeding box is entered in the menu DPSetup E...

Page 41: ... for all calves at this feeding station With constant concentration the feed program only transfers the amounts of feed to be dis pensed to individual animals The milk powder concentration remains the same for all the calves and is specified at the automatic calf feeder itself and only after that will feeding commence Nevertheless the Basic Powder Concentration for calculating the powder con sumpt...

Page 42: ...sic Powder Concentration in the Setup menu for the feeding box The settings for the Amount of Feed and the Supplementary Feed correspond to the set tings from the details described under constant concentration see above With variable concentration you also have the option to replace a freely definable percen tage of the feed with milk This percentage can also be specified for each animal indivi du...

Page 43: ...ified are then allocated in a 24 hour cycle commencing at the start of feeding The start time for feeding can be specified under DPSetup System General Feed Control Feeding Times For a quick reference to the current feed entitlements of individual animals please select DPSingle from the main menu click on the cow s head icon in the bottom right hand cor ner and select the corresponding animal In o...

Page 44: ...p for Feed Type The Setup menu for the feed types is located in the main menu under Setup Setup Feeding Setup Feed Types You can toggle between the individual feed types using the arrow keys on the keyboard As far as the setup is concerned the main difference from DP5 is that you specify the Feed Code instead of selecting Feed Type in the DP5 Setup menu In DP4 you must enter 1 for Milk Powder 2 fo...

Page 45: ...lity is to be provided for controlling the variable percentage of milk for individual animals using DP 4 4 at least DP Version 4 418 will be required The percentage of milk has been added to the screen shown below Feed options can then be entered in a second screen The fourth feed type will appear automatically if the automatic calf feeder is equip ped with the corresponding program chip the chara...

Page 46: ... resave changes Feeding details for individual animals The amounts of feed for the individual animal can be both entered manually in the main menu under Feed and also calculated automatically using the feed graph The same prerequisites as described under Setup in DP5 apply to the entry of feed quan tities Press F3 or F4 to find out whether an animal has a current feed entitlement Once all the requ...

Page 47: ...ystem Machine in the menu Portion values additive xx g l In order to guarantee a correct dosage and calculation of the extra feed additive you have to multiply the portion size required for the extra feed additive dispenser by a factor 100 before entering the data into the CODATRON computer not necessary on C16 C calf pro grams see corresponding operating instructions Example Portion size required...

Page 48: ...1 3 1 Maximum per Interval Feed 1 3 1 9 6 Settings for Animal Specific Fresh Milk Ratio of the Feed Portion In case the animal specific fresh milk share should be controlled via the computer you have to do without the dispense of extra feed additive Feed station In order to carry out an animal specific setting of the fresh milk share deviating setting parameters are necessary Interval 3 1 Portion ...

Page 49: ...ic settings carried out in Setup particular menus are not displayed on the screen 10 1 Hand Functions In the main menu level you can access the first main menu Hand functions by pressing the Menu key once again In this menu you can activate the functions of the automatic feeder individually and manually You may choose between the following functions Emptying Mixer Water HE HE Heat Exchanger Start ...

Page 50: ...um water share corresponds to 10 approx or milk powder is added to the milk In the mixed milk water operating mode milk powder is automatically added to the water share until the entered concentration is reached Generally the dry matter content of whole milk is 120 130 g l Enter the amount of dry matter in main menu Milk Values see chapter 10 3 2 page 52 Milk Values hand functions portion values c...

Page 51: ...mal specific variable additive share In this case the System Machine does not display submenu Additive anymore You have to enter the additive value into the feeding computer 10 2 4 Restricted Adlib Mode The automatic calf feeder runs as a standard in the restricted mode but you can also commute to the ad libitum mode In the restricted mode the automatic calf feeder operates with animal identificat...

Page 52: ...submenus Milk Value and Switch to MP mode 10 3 2 Entering the Milk Value In submenu Milk Value you can enter the solid matter content SM content of the milk Depending on the entered concentration and the selected milk value the automatic feeder calculates whether and how much milk powder should be added to the milk or whether the milk should be diluted with water In case the concentration is above...

Page 53: ...k share you can enter up to which milk share the heat exchanger has to operate in the 1 circle mode Press Arrow Up Arrow Down to move to submenu 1 circle mode 30 milk Confirm with Enter Press Arrow Up Arrow Down to select the desired value Confirm with Enter Standard value 30 milk When the milk ratio is 10 30 the water is taken out of the stainless steel coil in the heat exchanger 1 circle mode Wh...

Page 54: ...any responsibility for errors due to inadequate calibration The calibration process of the feed components is always the same First press the Menu key and move to menu Calibration by means of Arrow Down Then press Enter to access the submenus Hold an empty measuring vessel under the discharge Press Enter The automatic feeder distributes the quantity of e g water that has been calibrated The set qu...

Page 55: ...r boiler start milk start MP start calibration water HE targ 500 ml water HE act 500 ml water HE act 490 ml additive start e g 10x dosing process is running weigh the quantity dispensed hold measuring ves sel under discharge detergent start Calibrate all components that can be selected in the submenus ...

Page 56: ...the dispensed quantity and enter the measured resp weighed value In case there are no available precision scales repeat calibration a number of times in order to get a larger quantity of additive Then divide the measured quantity by the number of calibration processes and enter the value Measure liquid additives and detergent by means of a cylinder Repeat the calibration procedure in order to be s...

Page 57: ...10 5 2 Mixer Afterrun In this menu you can enter how many seconds the mixer has to run after the last feed por tion has been dispensed Press Menu key Press Arrow Up Arrow Down to move to main menu Machine values Press ENTER and then Arrow Down The display shows the following message Press ENTER again Press Arrow Up Arrow Down to enter the desired time and confirm with ENTER You can enter 3 to 12 s...

Page 58: ...s water portion is distributed and drained off via the mixer outlet valve as soon as a calf with drinking right is identified 10 5 5 Entering the Distribution Pause The distribution pause regulates milk distribution As soon as the automatic feeder starts to prepare the milk portion the stop valve or the two group valve unit close for the duration of the entered distribution pause It is advisable t...

Page 59: ...seconds Press Menu key Press Arrow Down to move to main menu Machine values and confirm with ENTER Press Arrow Down to move to submenu Box 1 Box 2 Press ENTER Select Draining time Press ENTER Press Arrow Up Arrow Down to select draining time Possible entry 10 to 60 seconds standard value 16 s Confirm with ENTER When the feeding station is additionnally equipped with servo or gradient control here ...

Page 60: ...Press Enter to open the water valve The water valve is open so long as you press the Enter key The same applies to the other valves Water valve Bo Bo Boiler Milk valve Mixer outlet valve Circulation valve Air valve Box valve 1 2 and the motors Milk pump Mixer Powder motor Additive dispenser Detergent pump Feeding pump Circulation pump 10 6 2 Sensors The sensors such as e g the supply and the rod l...

Page 61: ...ackups on the memory chip cleaning faults as well as water and milk checks In submenu Power failures you can view the number of re boots of the automatic feeder after power failure In case of memory data error the computer can fall back upon an internal backup in submenu Backup Each backup is counted In submenu Cleaning fault you can view faults that occur red during automatic cleaning In submenu ...

Page 62: ...62 Functions of the Menu Key 10 7 Version Here you can read the version number of Eprom identifica tions for box 1 and 2 and interface System Machine xxxx xx x xx ...

Page 63: ...ortion Values Concentration xxx g l Milk ratio xxx Additive x g l Operating mode Restricted Operating mode Ad libitum Operating mode MP milk mode Operating mode MP mode Milk Values Milk value xxx g l Milk Values When milk empty Switch to MP When milk empty Machine stop 1 circle mode xx milk Calibration Water HE start Targ 500 ml Water boiler start Targ 500 ml Milk start Targ 500 ml MP start Targ x...

Page 64: ...ensors Rod electrode covered free Point electrode Supply electrode covered free Temperature ok too low Detergent C lib i W HE b il ilk Calibration Water HE water boiler milk Calibration Water HE water boiler milk Calibration Water HE water boiler milk MP additive detergent MP additive detergent MP additive detergent Identification Identification box 1 2 Checking Power failures Backup Cleaning faul...

Page 65: ...e is covered or empty the rod elec trode is free Please note Press Arrow Down to scroll the text on the display The information displayed last in the second line of the screen will appear in the first line of the following screen Combi mode i e with milk powder and fresh milk When the level electrode in the mixer is free the display shows Empty When the electrode in the mixer is covered the displa...

Page 66: ...the level electrode is not earthed cove red anymore After draining time has lapsed the automatic feeder starts mixer cleaning As feed distribution has priority over cleaning a pause has been incorporated into the SM2Plus system This means if within five minutes after dispense of the last portion no furt her calf requests its milk portion the automatic feeder starts mixer cleaning After mixer or an...

Page 67: ...r wards confirm with ENTER Same procedure for the milk ratio A milk portion is mixed up Meanwhile the display shows the values of the portion that is being prepared After the milk portion has been mixed up press Arrow Up Arrow Down to enter the number of the feeding station where the milk portion should be distributed Confirm with Enter After draining time has lapsed the automatic feeder returns a...

Page 68: ...milk You can interrupt the cleaning processes at any time by pressing any main menu key or the Enter key In case you have utilized some detergent during the main cleaning process you can switch back to the automatic operating mode only after the automatic feeder has carried out afterrinsing The Cleaning Menu contains the following functions Cleaning mixer Cleaning HE Cleaning HE hose Air cleaning ...

Page 69: ...is submenu press the Cleaning key located on the panel and subse quently Arrow Down Press ENTER to modify a figure The displayed figure starts flashing e g 20 Arrow Up is used to increase and Arrow Down to decrease the figure The longer you keep the relevant Arrow key pressed the faster the displayed figure is going to be modified Once you set the correct figure press ENTER again to store it the f...

Page 70: ...n starts flashing Press Arrow Up Arrow Down to scroll the available options Press ENTER to confirm the desired option This option is marked by an asterisk and stored In case you do not wish to modify the op tion press the Cleaning key once to return to the corresponding submenu Example for the selection of options within the functions of submenu Settings cleaning mixer cleaning HE settings air cle...

Page 71: ...ter values between 0 and 25 ml Confirm with ENTER Automatic cleaning starts running When the rod electrode is covered the remaining portion in the mixer jar is drained off via the mixer outlet valve before each cleaning Prerinsing starts running with 0 5 liters of wa ter The main cleaning process is carried out with 1 3 liters of water and the entered detergent amount After the mixer has run for 3...

Page 72: ...e mixer outlet valve and prerinsing starts running As soon as the mixer jar is empty again the main clea ning cycle with detergent starts running Mixer cleaning may become unnecessary as during automatic heat exchanger cleaning the mixer jar is cleaned too Automatic mixer cleaning with detergent takes place up to nine times day provided that the automatic feeder is equipped with a detergent pump t...

Page 73: ...ckwards from 10 to 0 minutes Press Start Stop to cut off the cleaning process at any time After 10 minutes have lapsed the liquid in the mixer jar is pumped out via the mixer outlet valve Afterrinsing In order to be sure that there is no detergent in the coil of the heat exchanger anymore after rinsing starts running 800 ml of water are automatically delivered from the coil into the mixer jar and ...

Page 74: ...right is identified within 1 hour the milk is pressed out of the stainless steel coil by some water and subsequently drained off via the mixer outlet valve In case in menu Milk Values you selected when milk empty machine stop the milk in the stainless steel coil is fed to the following calf In case the calf does not drink up the milk in the mixer jar within 1 hour the rod electrode is covered the ...

Page 75: ...as the suction hoses are ready for cleaning confirm with ENTER in order to activate prerinsing Prerinsing During prerinsing the milk is pressed through the coil by the incoming water and is subse quently drained off via the mixer jar the box valves box 1 and box 2 in turn and the connected hoses Before starting prerinsing enter the amount of water max 10 liters used for prerinsing in menu Settings...

Page 76: ... the mixer jar where they are stirred for about 20 seconds and drained off via the mixer outlet val ve In case no disturbance should occur the display shows Cleaning HE hose finished Now you can disconnect the hoses from the quick acting closures of the cleaning adaptor and connect them to the mixer jar the milk tank if available and the milk connection of the automatic calf feeder 12 3 4 Air Clea...

Page 77: ...anical cleaning aid Insert the cleaning sponge via the easily accessible quick coupling into the milk supplying pipe The cleaning sponge is then pressed through the heat exchanger by the wa ter After the cleaning process has been completed take the cleaning sponge out of the mixer jar refer to above mentioned safety instructions In case the cleaning sponge pushes forward dirt or deposits repeat th...

Page 78: ...rease the cleaning effect dip the cleaning sponge into some cleansing agent In this case you have to rinse with some clear water Procede as follows Press Menu key and confirm with Enter Press Arrow Down the display shows menu Water HE start Keep the Enter key pressed until some clear water co mes out of the water outlet of the mixer jar Empty the mixer jar refer to above mentioned safety instructi...

Page 79: ... the stainless steel coil in the heat exchanger has been fed to the calves When cleaning time has come and there is still milk in the coil the automatic feeder tries to feed the milk 0 5 liters for one hour A calf being entitled e g to 1 5 liters of milk gets the first portion with milk and the following with milk powder water In case the calf does not drink the milk the automatic feeder carries o...

Page 80: ...nd afterrinsing of the suction hoses 12 4 5 Hose Cleaning Here you can activate suction hose cleaning Press Cleaning key and then Arrow Down until Settings is displayed on the screen Confirm with ENTER Press Arrow Down until the display shows Cleaning hose Press ENTER to open the menu Select yes in case suction hose cleaning should be activated 12 4 6 Detergent In menu Settings detergent you can e...

Page 81: ...it Thoroughly clean the milk supply hose regularly CAUTION In order to avoid injuries before carrying out any kind of operation on the milk powder outlet it is imperative to make the automatic feeder currentless by turning the main switch to position 0 OFF or by pulling the mains plug Carry out daily check of the milk powder outlet and if necessary remove incrustations Incrustations impair dosing ...

Page 82: ...leansing agent but do not overdose it Carry out cleaning by using the cleaning sponge or a hose cleaning pistol When the cleaning sponge gets stuck connect a high pressure cleaner Use the high pressure cleaner only with cold water and slowly raise pressure In case these measures do not show any improvement check whether the milk pump is running Insufficient pump pressure can reduce the liquid amou...

Page 83: ...ey pressed until just air comes out of the water resp milk outlet Commissioning the automatic calf feeder once again When commissioning the feeder again check whether there is enough water in the heat exchanger Proceed as for first commissioning Fill the boiler of the heat exchanger with water You do not need to top up the boiler regularly in case some calves are fed with milk that has been dilute...

Page 84: ...ion the automatic feeder checks whether the heat exchanger with separate heating circuits is filled with water Immediately after you switched the System Machine on the automatic feeder carries out a water check in order to find out whether the supply electrode is hit in water mode The automatic feeder tries to find out up to 5 times by means of a repeat handle whether the water really does not com...

Page 85: ...en there is no communication between the automatic feeder and the feeding computer Check the connecting line to the feeding computer The fault message disappears automatically as soon as the fault has been removed When switching the System Machine on it may last some seconds before the automatic feeder builts up the connection to the feeding computer 14 6 Identification Connection to a Bus system ...

Page 86: ...ts the supply electrode Check the water supply to the automatic feeder Press the Automatic key in order to delete the alarm message 14 9 Emptying Mixer In case the liquid inside the mixer jar does not drain off because the mixer outlet is e g clogged the display shows the following error message Check whether the mixer outlet is clogged Check the mixer outlet hose and clean it if necessary Check e...

Page 87: ...xer outlet to the hose connection of the feeding pump that is located below the solenoid valves The feeding pump is connected to the box valves by means of a PVC joining piece The box valves are connected to the feeding stations via suction hoses Suction hose connection 1 Suction hose connection 2 Hose connection mixer Hose of mixer outlet valve Take care that suction hose connection 1 runs to fee...

Page 88: ...automatic feeder is equipped as a standard with a cable with cubi cle plug for the additive dispenser For mounting or installation of the additive dispenser refer to instructions manual Precision Doser for Powder Additives or Dosing Pump for Liquid Additives 15 3 Fully Automatic Heat Exchanger Cleaning The fully automatic heat exchanger cleaning facilitates fully automatic time controlled cleaning...

Page 89: ...pour screen for milk powder outlet 15 5 Detergent Dosing Pump Thanks to the detergent dosing pump liquid additives are added automatically to the water during the various cleaning cycles There is no need anymore to add the detergent manually The detergent dosing pump is located in the left interior of the automatic calf feeder below the two group valve unit The detergent is taken from a container ...

Page 90: ... occurring particularly in summer we recommend to protect the mixer jar by means of a large fly screen Water vapour can escape through the openings of the fly screen You can attach the fly screen together with the dispenser for powder additives to the automatic calf feeder ...

Page 91: ...and remove the old program chip chip with adhesive label SM2 Plus XX XX Use appropriate tools in order not to damage the strip conductors on the main circuit card If necessary remove the main circuit card 4 Put in the new program chip with the notch upwards XX XX SM2 Plus 5 Close the control unit box 6 Connect the System Machine When starting the machine the display shows the new program version I...

Page 92: ...rolled 72 entering the figures 69 heat exchanger 72 heat exchanger with sponge 77 heat exchanger with suction hoses 74 mixer 71 selecting the options 70 settings 79 HE cleaning 79 HE hose cleaning 80 cleaning key 68 compressor 76 connecting the mains plug 24 connection additive dispenser 88 for milk pipe 19 milk pipe 19 suction hose 16 water 18 construction parts 8 D deaerate the circulation pump ...

Page 93: ...der to the mains supply 24 deaerating the circulation pump 25 filling the boiler of the HE with water 24 filling the milk powder into the powder hopper 25 filling the milk storage tank 25 installing the automatic calf feeder 15 intermediate mix 57 K keys Automatic 65 Cleaning 68 Menu 49 L lightning protection 15 locating the automatic calf feeder local electrical con nection 15 M machine type mach...

Page 94: ...ice maintenance 81 service and maintenance 81 carry out regular check routine 82 shutdown 82 settings air cleaning 79 cleaning 79 detergent 80 hose cleaning 80 mixer cleaning 79 Setup 32 different selections in Setup 32 function table 34 how to make entries 35 shutdown 82 signs danger signs 7 information signs 7 specifications automatic calf feeder 13 electrical connection 13 heat exchanger boiler...

Page 95: ...1 EN 292 2 06 95 Basic concepts of general design of machines part 2 EN 294 8 92 Safety clearance for upper limbs EN 349 6 93 Minimum clearance for avoiding crushing upper limbs EN 50081 1 3 93 Norm concerning electromagnetical emissions on residential areas business districts and industrial areas EN 50082 1 11 97 Norm of the resistance to jamming against line directed disturbances induced by high...

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Page 97: ...1 7163 9001 044 AU supplement 01 2006 Automatic Calf Feeders Supplement keypad guide improved electrical grounding wiring diagrams parts list DairyPlan Calf Feeder Combi model ...

Page 98: ...ox valve 2 open HE fill Portion Values Concentration xxx g l Milk ratio xxx Additive x g l Operating mode Restricted Operating mode Ad libitum Operating mode MP milk mode Operating mode MP mode Milk Values Milk value xxx g l Milk Values When milk empty Switch to MP When milk empty Machine stop 1 circle mode xx milk Calibration Water HE start Targ 500 ml Water boiler start Targ 500 ml Milk start Ta...

Page 99: ...vered free Temperature ok too low Detergent Calibration Water HE water boiler milk Calibration Water HE water boiler milk MP additive detergent Identification Identification box 1 2 Checking Power failures Backup Cleaning fault Check water Check milk Version System Machine Identification box 1 2 Interface Press Enter to move from the main menus to the correspon ding submenus Press Arrow Up or Arro...

Page 100: ... 75 mm LT1 A2 LT1 power unit SA2 Plus X1 LT1 A1 distribution board power card 6 install an additional bonding point the liquid in the mixer jar overflows resp there is lack of water in case of problems with the electrode in the mixer jar ...

Page 101: ...0Hz mains connection 230V 2700W TAK5 SM2 27 F1 230V 230V 3200W TAK5 SM2 32 P1 HE1 heat exchanger LV1 power distributor line filter heating heating minimum operating heating pilot lamp temp thermostat thermostat overheating thermostat ...

Page 102: ... exchanger 400V 2700W TAK5 SM2 27 F1 400V L1 L3 N PE L2 line plug 400V 3 N PE 50Hz mains connection LV1 power distributor line filter minimum operating temp thermostat thermostat overheating thermostat heating heating pilot lamp heating ...

Page 103: ...N PE distribution board motherboard motherboard ...

Page 104: ...mixer motor powder motor MAP pneumatic valve detergent pump box valve 2 outlet valve mixer box valve 1 powder additive motherboard motherboard ...

Page 105: ...detergent valve HE milk pump milk solenoid valve circulation pump option 230V heating heating cable mixer jar frost protection thermostat for transformer motherboard for frost protection ...

Page 106: ... MAP feeding box 1 2 supply sensor signal empty point sensor option 12V hand activated feeding pump temp 12W operating minimum 1 4 l rod sensor leakage detector detergent sensor sensor motherboard motherboard ...

Page 107: ... see sep diagram update cable display keyboard motherboard Interface RS232 for update motherboard for update RS232 Interface card ...

Page 108: ...motherboard VC3 Bus IN VC3 Bus interface board for connection to Bus identification OUT VC3 Bus Micro identification 1 Micro identification 2 ...

Page 109: ...ication VC3 Bus interface VC3 Bus X2 X3 ST1 A5 X4 X1 ST1 A1 A1 VC3 Bus interface 12V X6 H1 X1 for connection to Bus identification plug for board K17 X11 H20 H2 H17 K13 H18 K14 F2 F20 F3 F4 F1 X10 X1 K8 H12 H13 H15 H14 K9 K11 K10 H16 K12 K6 H8 K4 H9 K5 H10 K7 H11 X6 H6 H3 K1 K2 K15 H19 K3 H7 T1 transformer ST1 A1 motherboard 12V REL X23 Flash X15 H5 5V eprom F30 H4 12V MAP H1 K18 jar R87 R86 H21 s...

Page 110: ... pump Relais for 12V external components LED for voltage display 12V MAP Fuse for 12V external components Connector for electrodes Potentiometer for rod electrode Potentiometer for supply electrode Connector for optional relais 12V Potentiometer to adjust contrast of the display Electronic card Flash eprom Interface Plug for keyboard Plug for display Connector for leakage sensor and detergent sens...

Page 111: ...Ersatzteillisten spare part lists für Kälbertränkeautomat for Calf Feeder ...

Page 112: ......

Page 113: ...ainless steel pump Milch Wasserversorgung TAK5 6 2 fach VA Pumpe ab 01 06 01 milk water inlet as of 01 06 01 012 Grundgestell 5 SM2 TAK Grundgestell 5 SM2 TAK 018 Wärmetauscher 5 heat exchanger 021 Steuerung control unit 024 Anschlussleitung connecting line 027 Absperrventil Spülventil manuelle Antränkp TA3 TA5 TA6 stop valve rinsing valve hand actuated feeding pump TA3 TA5 030 7163 9983 010 Spülm...

Page 114: ......

Page 115: ...5 Rührflügel mit Feder 235mm und kleiner Feder ab 19 10 00 stirring blade with scraper 235mm and with short scraper as of 19 10 00 018 7721 0030 012 Federstern 10mm star wheel 10mm 027 7721 0020 008 Rührflügel mit Feder 110mm center stirring rod 110mm 030 7721 0091 582 Pulvertrichter kompl powder hopper compl 033 7721 0060 117 Sternmutter M5 headed star nut M5 036 7721 0060 043 Dosierzunge Pulverf...

Page 116: ......

Page 117: ... 1 4 AG ID 7 5 10 L 30mm as of 01 09 00 054 7721 0099 259 Umspüladapter 2 fach kompl für 1 2 SchlauchkupplungTA3 TA5 adapter for rinsing double compl for 1 2 hose coupling TA3 057 7721 0098 056 Schlauchkupplung 1 2 Einhandkupplung 1 2 hose pipe coupling 1 2 072 7721 0040 374 Pumpe VA 230V 50Hz 250W mit BR Pumpenrad o Pumpenbl kompl pump StSt 230V 50Hz 250W w BR pump wheel w o pump pl compl 075 772...

Page 118: ......

Page 119: ...re parts list shows the different variants of the above mentioned structural group Pos Teile Nr B e z e i c h n u n g Item Part No D e s c r i p t i o n 132 7721 0090 687 Ventilteil O Ring 18x1 5 valve component o ring 138 7721 0090 311 Ventilteil Plunger mit Teller für Magnetventil 8 5 230V tappet for solenoid valve 280 8 5 M G 12F NCS42 230V 147 7721 0040 780 Ventilteil Teileset Ventil 8 5 ohne ...

Page 120: ...98 60 57 54 69 66 72 78 132 141 144 138 126 129 41325 09 02 63 15 105 108 108 111 114 108 117 120 57 60 102 99 15 165 162 159 156 153 51 123 124 148 147 136 87 135 150 151 75 81 84 ...

Page 121: ...5mm 048 7721 0097 477 Kugelhahn 1 4 IG IG ball cock 1 4 internal thread internal thread 051 7721 0040 549 Steckverschraubung 1 4 AG ID 7 5 10 L 30mm plug type bolting 1 4 AG ID 7 5 10 L 30mm 054 7721 0099 259 Umspüladapter 2 fach kompl für 1 2 SchlauchkupplungTA3 TA5 adapter for rinsing double compl for 1 2 hose coupling TA3 057 7721 0098 056 Schlauchkupplung 1 2 Einhandkupplung 1 2 hose pipe coup...

Page 122: ...98 60 57 54 69 66 72 78 132 141 144 138 126 129 41325 09 02 63 15 105 108 108 111 114 108 117 120 57 60 102 99 15 165 162 159 156 153 51 123 124 148 147 136 87 135 150 151 75 81 84 ...

Page 123: ...5 230V tappet for solenoid valve 280 8 5 M G 12F NCS42 230V 147 7721 0040 780 Ventilteil Teileset Ventil 8 5 ohne Magnetteil valve component set valve 8 5 without solenoid component 153 7721 0099 434 Schlauch 8 0x3 0mm TPE trüb bis 05 11 02 hose 8 0x3 0mm TPE up till 05 11 02 159 7721 0041 060 Rückschlagventil Rückflussverhinderer D 15mm m Feder 0 4bar nonreturn valve D 15mm 162 7721 0060 160 Dich...

Page 124: ...40813 01 02 3 6 9 9 12 15 18 21 24 24 24 27 30 33 ...

Page 125: ... der o g Baugruppe dar The spare parts list shows the different variants of the above mentioned structural group Pos Teile Nr B e z e i c h n u n g Item Part No D e s c r i p t i o n 009 7721 0090 411 Hauptschalter M221 20A main switch M221 20A Anschlussleitung 400V TA5 TA6 Hauptschalter u EMV Schiene connecting line 400V TA5 with main switch and EMC rail ...

Page 126: ...18 9 78 79 80 81 102 103 6 3 3 12 15 24 24 21 77 27 45 33 48 51 54 36 39 60 75 63 30 30 30 36 30 42 39 30 36 39 24 66 69 72 24 36 87 99 96 90 93 84 114 111 108 105 40955 02 02 ...

Page 127: ...trode and union nut 030 7721 0060 160 Dichtung 18 5x12 0x2mm hart Vulkanfiber rot washer 18 12 2mm graphitized 057 7721 0098 464 Rückschlagventil Auslauf WT Wasser flap valve flowing out hole WT water 060 7721 0098 524 WT1 Kunststoffbehälter mit Dichtung heat exchanger tank 069 7721 0070 567 Schlauchschelle 1 2 12 20 Zebra hose band clip 1 2 12 20 Zebra 075 7721 0099 146 Dichtung Stärke D 5mm für ...

Page 128: ...18 9 78 79 80 81 102 103 6 3 3 12 15 24 24 21 77 27 45 33 48 51 54 36 39 60 75 63 30 30 30 36 30 42 39 30 36 39 24 66 69 72 24 36 87 99 96 90 93 84 114 111 108 105 40955 02 02 ...

Page 129: ... B e z e i c h n u n g Item Part No D e s c r i p t i o n 7721 0040 947 Wärmetauscher 5 P1 2 8KW 240V SM CSA UL heat exchanger 5 P1 2 8KW 240V SM CSA UL 7721 0040 948 Wärmetauscher 5 P1 3 0KW 200V SM heat exchanger 5 P1 3 0KW 200V SM 7721 0040 951 Wärmetauscher 5 P1 3 2KW 230V SM heat exchanger 5 P1 3 2KW 230V SM 7721 0040 952 Wärmetauscher 5 P1 3 8KW 400V SM SA3 heat exchanger 5 P1 3 8KW 400V SM ...

Page 130: ...24 28 15 21 33 30 12 99262 11 02 27 17 18 19 2 1 3 4 5 36 37 ...

Page 131: ...xer 024 7721 0080 019 O Ring 58 0x3 0mm NBR 50 Shore Mixermotor 0 ring 58x3mm for mixer motor 027 7721 0080 020 Gleitringdichtung kompl sliding ring seal assembly 028 7721 0090 549 Gleitringdichtung kompl aus Siliciumkarbid floating ring seal compl silicon carbide 030 7721 0060 014 Quirl für Intensivmixer D 58mm twirling disc for intensive mixer 036 7721 0080 017 Schlauchtülle 1 4 GES 8 R hose pip...

Page 132: ...45 30 30 33 36 4 6 51 54 57 60 63 66 9 75 189 183 27 186 69 12 111 87 90 21 51 102 93 177 84 96 174 195 30 168 171 126 124 123 162 108 111 166 165 3 121 40520 01 02 144 159 156 153 150 147 141 138 136 135 132 129 207 208 204 205 206 24 203 202 201 117 115 ...

Page 133: ...50A normal lag 5x20mm 045 7721 0070 165 Steck Schraubkl 15pol RM 5 08 VL connector 15 pin RM 5 08 VL 057 7721 0096 321 Steck Schraubkl 6pol RM 3 81VL connector 6 pin RM 3 81 075 7721 0041 064 Kabelbaum SM2 VC3 BUS cable form SM2 VC3 Bus 078 7721 0070 480 Buchse 4mm BU 4400S schwarz Isolierring u 2 Muttern socket 4mm BU 4400S black insulating ring and 2 nuts 079 7721 0098 546 Entstörsatz für Elektr...

Page 134: ...45 30 30 33 36 4 6 51 54 57 60 63 66 9 75 189 183 27 186 69 12 111 87 90 21 51 102 93 177 84 96 174 195 30 168 171 126 124 123 162 108 111 166 165 3 121 40520 01 02 144 159 156 153 150 147 141 138 136 135 132 129 207 208 204 205 206 24 203 202 201 117 115 ...

Page 135: ... air valve 141 7721 0040 874 Kabel Mixer SM2 cable for mixer SM2 144 7721 0040 873 Kabel Pulverförderung SM2 cable for powder supply SM2 147 7721 0040 872 Kabel Zuastzdosierer SM2 cable for doser SM2 150 7721 0040 885 Kabel Milchventil SM2 cable for milk valve SM2 153 7721 0040 884 Kabel Spülventil WT SM2 cable for circulation valve SM2 156 7721 0040 883 Kabel Wasserventil WT SM2 cable for water v...

Page 136: ...45 30 30 33 36 4 6 51 54 57 60 63 66 9 75 189 183 27 186 69 12 111 87 90 21 51 102 93 177 84 96 174 195 30 168 171 126 124 123 162 108 111 166 165 3 121 40520 01 02 144 159 156 153 150 147 141 138 136 135 132 129 207 208 204 205 206 24 203 202 201 117 115 ...

Page 137: ...oard program chip SM2 DA 204 7721 0041 860 Platine Programmchip SM2 FI board program chip SM2 FI 205 7721 0041 853 Platine Programmchip SM2 FR board program chip SM2 FR 206 7721 0041 857 Platine Programmchip SM2 SC board program chip SM2 SC 207 7721 0041 858 Platine Programmchip SM2 NO board program chip SM2 NO 208 7721 0041 859 Platine Programmchip SM2 JA board program chip SM2 JA 7721 0040 533 S...

Page 138: ......

Page 139: ...entilkörper valve part valve body 027 7721 0097 145 Magnetventilgehäuse 91711 2 2 Wege Ventil geschlossen solenoid valve body 2 2 way valve default closed 030 7721 0098 223 O Ring 26x1 2 NBR 70 Shore Gruppenventil 0 ring 26 0x1 3mm 033 7721 0097 146 Magnetventilgrundplatte 91711 mit Schlauchtülle und O Ring solenoid valve plate with nozzle and o ring 036 7721 0091 711 2 2 Wege Ventil geschlossen 2...

Page 140: ...40605 10 01 3 6 9 12 15 18 21 24 33 36 30 39 42 45 27 54 48 51 ...

Page 141: ...03 7721 0040 463 Dosierpumpe DSP 230V mit Halteblech dosing pump DSP 230V with holding plate 006 7721 0041 350 Schlauch 4 8x1 6mm PS 140Ph Länge 14cm Flüssigdosierer DSP hose 4 8x1 6mm PS 140Ph length 14cm additive dispenser DSP 009 7721 0041 411 Schlauchhalter mit Überlauf für Flüssigdosierer hose coupling support with overflow f liquid additive doser 024 7721 0099 044 Flasche 1 5l Weithals mit S...

Page 142: ... ...

Page 143: ...2 12 20 Zebra hose band clip 1 2 12 20 Zebra 7721 0010 212 Dichtungssatz für Tränkeautomaten set of seals for automatic feeder 7721 0099 592 Schwammgummikugel 5 er Pack 11mm Durchm sponge pellet 11mm packet of 5 7721 0070 522 Schwammgummikugel 5 er Pack 12mm Durchm sponge pellet 12mm packet of 5 7721 0080 001 Schlauchtülle für Sauger Tüllendurchmesser 5mm hose pipe nozzle 5mm for teat 7721 0040 04...