Förster-Technik TAK5-CH2-25 User manual

22FWREHU 2013
Original Operating Instructions
Automatic calf feeder
Compact type Combi
Program version 8.00 and higher
TAK5-CH2-25 / VDW5-VH2-25

Table of contents 3
Table of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1 Automatic feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Overview of the automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.1 Front and right side view of automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.2 Left-hand view of automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.3 Heat exchanger with separate heating circuits for milk and water . . . . . . . . . . . . . . . . . . . 12
1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.1 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.2 Dimensions of the automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.3 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.4 Water connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.5 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.6 Milk powder container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.7 Number of feeding stations and animals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Symbols and abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4.1 Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 14
1.4.2 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Contact details of the manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Your requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Hazards arising from the automatic feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.1 Material damage caused by the automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Your obligations when handling the automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 What hazard warnings are provided? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.1 Components of a hazard description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.2 Hazards causing death or injury . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.3 Material damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.6 Safety labels on the automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.6.1 Warning signs on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.7 Safety equipment on the automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3 Hygiene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4 Operating the automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.1 Offline mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Hand terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.1 The 15-key hand terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.2 The 12-key hand terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2.3 Auto LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2.4 Data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3.1 Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 36
4.3.2 Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3.3 Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5 Shutting down and restarting the automatic feeder. . . . . . . . . . . . . . . . . . . . . . . . . .41
5.1 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1.1 Temporary shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1.2 Permanent shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Table of contents
5.2 Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2.1 Restart after temporary shutdown without change of location . . . . . . . . . . . . . . . . . . . . . . 44
5.2.2 Restart after long-term shutdown or change of location . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6 Running the automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.1 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1.1 Rationed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1.2 Ad lib mode (emergency mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2 Routine tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.3 Transmitter and animal management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3.1 Managing transmitters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.3.2 Registering animals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.3.3 Canceling animals or animal groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.3.4 Changing the registration of animals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.4 Cleaning the automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.4.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.4.2 Preparing for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.4.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 61
6.5 Feeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.5.1 Replenishing feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.5.2 Feed preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.5.3 Feed distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.5.4 Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 76
6.5.5 Checking and changing feeding data for individual animals . . . . . . . . . . . . . . . . . . . . . . . 79
6.5.6 Feeding plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.5.7 Winter feeding plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.5.8 Alarm levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.6 Animal control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.6.1 Animal list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.6.2 Entitled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.6.3 Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.6.4 Plan over date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.6.5 40FIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.6.6 Marked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 96
6.6.7 New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.6.8 Double . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.6.9 Unknown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.6.10 All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.6.11 Total consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.6.12 Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.6.13 Searching for animals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.7 Care and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.7.1 Daily care and maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.7.2 Weekly care and maintenance tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.7.3 Care and maintenance tasks every 4 month . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.7.4 Annual care and maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7 Failures and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
7.1 Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.1.1 CRC error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.1.2 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7.1.3 Temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7.1.4 Water shortage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7.1.5 Mixer emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7.1.6 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Table of contents 5
7.1.7 Boiler temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.1.8 Milk/circulation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.1.9 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 116
7.1.10 Box/drain valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.1.11 Uncontrolled output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.2 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.2.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 117
7.2.2 Mixer emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.2.3 Temperature sensor, mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.2.4 Milk empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.2.5 Unknown transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.2.6 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 120
7.2.7 Calibration scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.2.8 Circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.2.9 CalfRail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.2.10 Double animal number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.2.11 Machine capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.2.12 Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.2.13 Checking the SD card (15-key hand terminal only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.3 Other failures and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.3.1 Automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.3.2 Hand terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.3.3 Bootloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.4 Service messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
8.1 Disposing of residual cleaning agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 127
8.2 Disposing of hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8.3 Disposing of cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8.4 Disposing of the hand terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8.5 Processor board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
8.6 Disposing of the automatic feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
9 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
9.1 Feeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9.1.1 Standard feeding plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9.1.2 Basic principle of interval feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
9.1.3 Milk powder conversion table (MP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
9.2 Automatic feeder material list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.3 User maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
9.3.1 Care and Maintenance schedule / routine work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
9.4 Automatic feeder shutdown checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
9.5 Recommissioning checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

6 Table of contents

Introduction 7
1 Introduction
This chapter explains how your automatic feeder is designed and how to operate it safely as
intended.
Read the operating manual carefully before operating the automatic feeder and ask your ser-
vice technician to explain anything that is unclear to you before you use it for the first time.
Do not operate the automatic feeder until you have read and understood the safety chapter
(see Chapter 2Important safety instructions, page 17). Resolve any questions with your ser-
vice technician before operating the feeder.
The operating manual for the automatic feeder, the operating manuals of all additional equip-
ment to be connected and the safety data sheets for cleaning agents must be kept readily
available at all times and passed on to the next user.
Observe all of the warnings and safety instructions in this operating manual.
If your automatic feeder has additional equipment, you must also observe the separate oper-
ating manuals and the safety warnings and safety instructions for the additional equipment.
1.1 Automatic feeder
Modern calf rearing businesses primarily use feeding systems with individual animal identifi-
cation functions. Calves are identified via their collar transponders or electronic earmarks and
fed based on their individual requirements.
Feed is always prepared fresh and dispensed to calves in small portions at the temperature
and concentration that you have specified.
The hand terminal provides quick and easy access to the controls of the automatic feeder
when you are right near your animals. You can connect the automatic feeder to your PC via
the CAN Ethernet Gateway and then control the feeder from your computer.

8 Introduction
Your advantages:
•Added functions eliminate cumbersome routine tasks and save you time.
•Automatic cleaning programs improve feed hygiene.
•The hand terminal gives you quick access to important animal data.
•The animal control list provides a clear and easy way of monitoring animals.
•The automatic feeder offers you a wide range of options for feeding plans and recipes.
•You can expand the functionality of the automatic feeder by integrating concentrate feeders,
animal scales and PC programs with graphical analyses.
•The automatic feeder's rugged and reliable design makes it easier to use in pens.
•The automatic feeder can be integrated into the feeding systems of well-known dairy tech-
nology manufacturers.

Introduction 9
1.2 Overview of the automatic feeder
1.2.1 Front and right side view of automatic feeder
1 Milk powder container 9 Water connector
2 Milk powder discharge 10 Temperature sensor
3 Water supply 11 Right door
4 Mixing jar 12 Nozzle for sponge cleaning
5 Bar electrode 13 Connection screw for potential equalization
6 Hose connection from mixer to box valve 14 Control switch
7 Mixer motor 15 Hand terminal
8 Milk connector

10 Introduction
1.2.2 Left-hand view of automatic feeder
The name plate is located above the left side door on the outside of the automatic feeder. It
contains information about the manufacturer, type and number of the automatic feeder, infor-
mation for connecting the feeder to the the mains as well as the certifications of the automatic
feeder. An example of a name plate is shown below.
Name plate
1 Name and address of the manufacturer
2 Type and number of the automatic feeder
3 Information for connection to the mains
4 Certifications of the automatic feeder

Introduction 11
Behind the left side door
1 Storage container for detergent
2 Feeding pump
3 Detergent dosing pump
4 Mixer drain valve
5 Feeding station valve(s)

12 Introduction
1.2.3 Heat exchanger with separate heating circuits for milk and water
1 Milk valve 8 Feeding station valve
2 Hose connection for milk tank 9 Hose connection between feeding station
valve and teat
3 Water valve for heat exchanger 10 Mixer drain valve (optional)
4 Hose connection for water pipe 11 Feeding pump
5 Boiler water valve 12 Stainless steel milk pump
6 Heat exchanger with stainless steel coil 13 Circulation valve
7Mixer

Introduction 13
1.3 Technical data
1.3.1 Electrical connection
Note: The electrical connection specifications for your automatic feeder is located on the name
plate above the left side door on the outside of the automatic feeder (see 1.2.2 Left-hand view
of automatic feeder on page 10).
1.3.2 Dimensions of the automatic feeder
Depth when the fly protection door is opened ~ 690 mm
1.3.3 Weight
Approximately 80 kg.
1.3.4 Water connector
The water connection is made using a 1/2 inch hose with a 3/4 inch screwed connection.
The water pressure to be provided by the customer must be between 2.5 and 6 bar.

14 Introduction
1.3.5 Heat exchanger
The stainless steel coil holds 0.5 l of water or milk.
1.3.6 Milk powder container
The milk power container with attachment holds approximately 35 kg of milk substitute.
1.3.7 Number of feeding stations and animals
Your automatic feeder has 2 feeding stations. You can feed up to 50 calves, with 30 calves per
feeding station.
1.4 Symbols and abbreviations
1.4.1 Symbols
You can find a list of the symbols and abbreviations as used in this operating manual in the
following.
The places in the text marked with this symbol only apply to the automatic feeder
Compact.
The places in the text marked with this symbol only apply for the automatic feeder
Compact+.
Option: A white plus sign on a black background indicates that optional functions
or equipment are being described.
1.4.2 Abbreviations
Abbreviation Meaning
abs. Absolute
Ad lib Ad lib
save amt. Amount saved up
feed.pump Feeding pump
out. pause Output pause
sw.off del. Switch-off delay
dr. time Drink-out time
bo Boiler
dos. Dosage
El Electrode
electrol. Electrolyte
sw. on del. Switch-on delay
gradient Gradient control
gr. A (B) Group A (B)

Introduction 15
1.5 Contact details of the manufacturer
Please contact us if you have any questions on our products or require technical support.
When you contact us, always specify the model, serial number and program version of your
automatic feeder in order to receive custom service for your unit.
The device number and model are located on the name plate on the left of the automatic feeder
housing. When operating your automatic feeder for the first time, ask your service technician
for the device number and model.
IFS TR Intelligent feeding station feed
IFS KF Intelligent feeding station concentrate
IV Interval feeding program
KF Concentrate
conc./concentr. Concentration
dra.v. teat Drain via teat
w. entitle. With entitlement
w/add. or w/addiv. With additive
MAP Manual feeding pump
MP Milk substitute
max Maximum
milk rat. Milk ratio
Min. temp. Minimum temperature
mix. full Mixer full
mixer cl. Mixer cleaning
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
rel. Relative
Drinking speed Drinking speed
ho. Hose
clo.? Close?
servo Servo control
det. pump Detergent pump
Tem p . Temperature
TR Feeding station
fd.sensor Feeding sensor
water bo. Boiler water
HE Heat exchanger
inc./dec. Increase/reduction
add. disp. Additional dispenser

16 Introduction
You can call up the program version via your hand terminal. The menu item for the program
version can be found under > Diagnosis > Version > Feeder. When operating your auto-
matic feeder for the first time, ask your service technician for your program version.
You can note the device type, serial number and program version in the fields provided.
Device type:
Serial number:
Program version:
Our contact details:
Förster-Technik GmbH
Gerwigstrasse 25
D-78234 Engen, Germany
Phone: +49/ (0)7733/ 9406- 0
Fax: +49/ (0)7733/ 9406- 99
[email protected]
www.foerster-technik.de

Important safety instructions 17
2 Important safety instructions
SAVE THESE INSTRUCTIONS!
This chapter outlines:
•The hazards caused by your automatic feeder and how to avoid them.
•The safety labels attached to the automatic feeder and what they mean.
•How to operate the automatic feeder safely.
The automatic feeder is state of the art and is produced in compliance with recognized safety
regulations. However, hazards and adverse effects may arise when using it. Both warning
signs directly on the automatic feeder and warning notices in this manual provide warning of
these hazards.
2.1 Intended use
The automatic feeder may only be used for preparation, heating, and dosing of liquid feeds,
for example milk, for calves.
2.2 Your requirements
You must have experience in calf rearing, many years of professional experience in agriculture
and an excellent command of technical agricultural practice.
You must be familiar with accident prevention regulations and the generally recognized safety
regulations.
2.3 Hazards arising from the automatic feeder
Hazards to health caused by the automatic feeder:
When using electric appliances, basic precautions should always be followed,
including the following:
•Read all the instructions contained in the operating manual before using the automatic feed-
er.
•To prevent the risk of injury, close supervision is necessary when an appliance is used near
children.

18 Important safety instructions
•Do not touch any moving components of the automatic feeder, for example the mixer
blades.
•Only use genuine spare parts from the manufacturer.
•Turn off the automatic feeder and disconnect the mains plug before carrying out any main-
tenance or cleaning work on the automatic feeder.
•Do not use the automatic feeder outdoors.
•If connection is made to a potable water system, the system shall be protected against
backflow.
•The following specific hazards are associated with the automatic feeder's electrical system:
•Electrical breakdown. If there is an electrical or voltage breakdown, electric current
flows through parts of the automatic feeder that are normally insulated. Contact can
cause a fatal electric shock. Make sure that an earth leakage circuit breaker is in-
stalled.
•Short circuit, Indirect contact. If there is a short circuit, current at many times the
level of the operating current can flow. Contact can cause a fatal electric shock. Make
sure that an earth leakage circuit breaker is installed.
•The solenoid valves and the pipes to the valves can reach temperatures of up to 70°C. Con-
tact can cause burns. Do not touch the solenoid valves and pipes during operation.
•Liquid at temperatures of up to 70°C can spray out of the pipes to the valves. This can cause
scalding. Do not touch the pipes during operation. Carry out the recommended mainte-
nance on the hoses.
•The mixer and powder supply start up unexpectedly if a calf with feed entitlement approach-
es. 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. Only use the scraper supplied for
cleaning the powder discharge opening.
•Poisoning. Additives that are fed to the calves may contain substances that are hazardous
to human health. Avoid direct contact and always wear protective gloves and goggles when
handling these substances.
•Chemical burns. The cleaning agent used for cleaning the automatic feeder contains caus-
tic substances. These can cause severe injuries to the hands or the eyes. Avoid direct con-

Important safety instructions 19
tact and always wear chemical-proof protective gloves and goggles when handling the
cleaning agent.
•Excessive strain. The automatic feeder weighs 80kg. Never attempt to carry it alone as
this can cause excessive physical strain.
2.3.1 Material damage caused by the automatic feeder
The automatic feeder can cause the following types of material damage:
•Infection. Improper cleaning or incorrect operation can result in calves becoming infected
by pathogens from the automatic feeder. This can lead to medical costs or to the death of
the calves.
•Corrosion. Improper cleaning or maintenance can result in the automatic feeder ceasing
to function correctly.
•Loss of stability. The automatic feeder must be set up on a level surface. Otherwise, the
automatic feeder can tip up and suffer damage.
2.4 Your obligations when handling the automatic feeder
•Prevent misuse by children.
•Read the operating manual carefully before commissioning the automatic feeder and ask
your service engineer to explain anything that you do not understand before you use it for
the first time.
•Follow the health and safety and accident prevention regulations.
•Only clean the automatic feeder with the cleaning agents recommended in this manual (see
6.4.1 Cleaning agents on page 60).
•When cleaning the automatic feeder, observe the safety instructions stipulated in the safety
data sheet for the cleaning agent.
•Where the safety equipment specified in the safety data sheet for the cleaning agent, such
as goggles and chemical-proof protective gloves, when cleaning the automatic feeder.
•Only operate the automatic feeder if it is in proper condition and is fully functional.
•Only operate the automatic feeder if the safety equipment is fitted and intact.

20 Important safety instructions
•Check the fitted safety equipment regularly to ensure that it functions properly. You will find
a care and maintenance schedule in the Appendix (see 9.3.1.2 Maintenance intervals and
activities on page 137), which provides recommendations of how often to check the differ-
ent safety equipment.
•Inspect the automatic feeder visually for possible damage. You will find a care and mainte-
nance schedule in the Appendix (see chapter 9.3.1.2 Maintenance intervals and activities,
page 137), which provides recommendations of how often you should check different parts
of the automatic feeder.
•Repair any damage to the automatic feeder, or if you are not authorized to or capable of
doing this yourself, have it repaired by a service engineer.
•Never carry out any unauthorized modifications to the automatic feeder.
•Keep all safety labels on the automatic feeder in a legible condition. Replace damaged or
illegible safety labels immediately. You can order new safety labels from Förster-Technik
GmbH.
•Only use genuine accessories, spare parts, and wearing parts. These are available from
your dealer.
2.5 What hazard warnings are provided?
Hazards are indicated directly on the automatic feeder by safety labels (warning signs, instruc-
tion and prohibition notices), and in the operating manual by specially marked hazard descrip-
tions.
The warnings for hazards that can cause death or injury to people are emphasized more than
those for material damage, for example through the colors, hazard words or symbols used.
Safety labels are an important element of the overall automatic feeder safety concept. They
provide warnings about hazards and explain how to avoid them.
Make sure that all the specified safety labels are fitted to your automatic feeder and that they
are in a legible condition. If the safety labels are difficult to read, replace them immediately.
New safety labels are available from Förster-Technik GmbH.
2.5.1 Components of a hazard description
A hazard description is always made up of the following elements: