Foerster HygieneBox Basic Installation instructions

Original Operating Manual
HygieneBox Basic /
HygieneBox Teat lock
TA version S 3.07 and higher
3. February 2021

2 Table of contents
Table of contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Manufacturer's contact details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Important safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.1 Necessary qualifications of the owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.2 Necessary qualifications of the service technician . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Your duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 How am I warned of hazards? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5.1 What are the components of a hazard description? . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5.2 Potentially fatal hazards or health hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5.3 Material damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5.4 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Structural alterations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Scope of delivery of the HygieneBox Basic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Scope of delivery of the HygieneBox Teat lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Scope of delivery of the HygieneBox Basic add-on parts . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1.1 HygieneBox Basic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1.2 HygieneBox Teat Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Connecting hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.3 Connecting the antennas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4 Install the ball valve externally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5 Software updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.6 Activation in the setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.7 Activating the auto teaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.8 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5. Hygiene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...29
6.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2 Automatic cleaning of the tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3 Teat cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.4 Teat cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.5 Manually starting tube cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.6 Cleaning the HygieneBox manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Table of contents 3
6.7 Cleaning the discharge tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7. Maintenance/servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...33
7.2 Maintenance intervals and activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.2.1 Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
7.2.2 Every 3 months. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.2.3 Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8. Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.1 Shut down teat cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2 Temporary shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.3 Permanent shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9. Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...37
9.1 Disposing of cleaning agent residues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2 Disposing of hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.3 Disposing of cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.4 Disposal of the HygieneBox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10. Faults and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.1 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.1.1 HygieneBox valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.1.2 Hoses circuit clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.1.3 Flushing circuit leaking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.2 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.2.1 HygieneBox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.3 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.3.1 Checking stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.3.2 Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...42
11.1 Checklist for commissioning and recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.2 Materials list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11.3 Care and maintenance schedule/routine tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11.4 Shutdown checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
11.5 Checking components for compliance with national regulations . . . . . . . . . . . . . . . . . . . 44
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4 Introduction
1. Introduction
This operating manual allows you to operate the HygieneBox/Teat lock Basic/Teat lock safely
in the intended manner.
The term HygieneBox/Teat lock is used for subsequent description in the operating manual.
• Please read this operating manual carefully before putting the HygieneBox/Teat lock into
service.
• Keep the operating manual readily available at all times and pass it on to the next user.
• Observe all of the warnings and safety instructions in this operating manual at all times.
1.1 Functional description
The HygieneBox Basic/Teat lock is an advanced version of a feeding station linked to the auto-
matic feeder.
Your advantages:
• Easy to clean due to its small surfaces.
• Sealed enclosure for optimum protection against dirt, dust and water.
• Teat locking for training young calves.
• Installation support for cables and hoses can be adapted to suit the position of the antenna
and the local conditions.
• No tools are required in order to exchange the teat.
• Automatic hose cleaning ensures a high degree of hygiene.
• Exterior cleaning of the teat after each calf.
1.2 Manufacturer's contact details
Our contact details:
Förster-Technik GmbH
Gerwigstrasse 25
78234 Engen, Germany
Phone: +49/ (0)7733/ 9406- 0
Fax: +49/ (0)7733/ 9406- 99
[email protected]
www.foerster-technik.de

Important safety instructions 5
2. Important safety instructions
2.1 Intended use
The purpose of the HygieneBox is to provide feed delivery to calves, provide support of the fully
automatic cleaning function, record the movements of the teat during consumption of the feed
and control the automatic feed delivery start function.
2.2 Target group
2.2.1 Necessary qualifications of the owner
The owner must be a trained farmer or have good practical experience in farming. He must
know the relevant accident prevention regulations and generally accepted safety regulations.
2.2.2 Necessary qualifications of the service technician
Only trained service technicians are authorized to install, commission, maintain and repair the
HygieneBox/HygieneBox Teat Lock.
Service technicians are specialists with the appropriate qualifications. Service technicians are
able to assess the work assigned to them and detect potential risks on the basis of their tech-
nical training as well as their knowledge of the relevant standards. They are familiar with the
relevant accident prevention regulations, generally accepted safety regulations and country-
specific standards and provisions.
2.3 Residual risks
Hazards to health and life caused by the HygieneBox:
WARNING!
Danger from electric current
The automatic feeder to which the HygieneBox is connected is electrically operated.
►You must observe the general precautions for handling electrical equipment.
• Read the operating manual before operating the HygieneBox.
• Keep children away from the HygieneBox.
• Only use genuine spare parts from the manufacturer.
• Turn off the automatic feeders and disconnect the power plug before carrying out any main-
tenance or cleaning work on the HygieneBox.
• The electrical system of the HygieneBox can present the following special hazards:
•Electrical discharge. If there is an electrical discharge or voltage breakdown, electric
current flows through parts of the HygieneBox that are normally insulated. Touching the
unit can cause a fatal electric shock. The HygieneBox must be checked regularly for
electrical safety in compliance with national regulations (repeated inspection). Make
sure that a 30 mA residual current device (RCD) is installed.

6 Important safety instructions
•
•Short circuit, indirect contact. If there is a short circuit, current at many times the level
of the operating current can flow. Touching the unit can cause a fatal electric shock.
Make sure to install fuse protection (provided by the customer) and an earth leakage cir-
cuit breaker (ELCB) of 30 mA in compliance with local regulations.
•Burns. The solenoid valves can reach temperatures of up to 100°C. Touching them can
cause burns. Do not touch the solenoid valves during operation.
•Poisoning, difficulty in breathing, suffocation. Liquids used to clean the teats may con-
tain substances that are hazardous to human health. Avoid direct contact and always wear
protective gloves and goggles when handling these liquids.
•Rough ambient conditions. The HygieneBox operates in a rough working environment.
Damage of any kind can result in hazards. Regularly check the HygieneBox for damage and
have any damage rectified as necessary by a service technician.
Material damage caused by the HygieneBox
The following material damage can be caused by the HygieneBox:
•Infection. Improper cleaning can result in calves becoming infected by pathogens at the
teat. This can lead to medical costs or cause the death of the calves. Observe the specifi-
cations issued by the manufacturer of the cleaning agent that is used.
2.4 Your duties
The owner has a duty to:
• Prevent misuse by children.
• Keep children, youths, and people with restricted physical, sensory and mental abilities
away from the HygieneBox.
• Carefully read and understand this operating manual before putting the HygieneBox into op-
eration.
• Only allow operating personnel to work with/on the HygieneBox who:
• Are familiar with the basic operational safety and accident prevention regulations.
• Have been given instructions on working with/on the HygieneBox.
• Have read and understood this operating manual.
• Comply with the operational safety and accident prevention regulations.
• When cleaning the HygieneBox, observe the safety instructions stipulated in the safety data
sheet for the cleaning agent.
• Wear the safety equipment specified in the safety data sheet for the cleaning agent, such as
goggles and chemical-proof protective gloves, when cleaning the HygieneBox.
• Provide the required personal protective devices for the operator.
• Operate the HygieneBox only as intended.
• Keep all safety signs on the HygieneBox in legible condition and renew any that become
damaged.
• Desist from changing the design or functions of the HygieneBox.
• Operate the HygieneBox only when it is in perfect functional condition.

Important safety instructions 7
• Subject the HygieneBox to regular visual inspection for possible damage and have it recti-
fied by a service technician if necessary.
• Check the safety devices applied to the HygieneBox regularly for perfect working order.
• Make sure the HygieneBox is operated only with safety devices installed.
• Make sure that the HygieneBox and all parts which can be manually cleaned or which are
needed for cleaning procedures are easy to access at all times.
• Protect the HygieneBox and all corresponding cables from exposure to sunlight.
• Use only original accessories, original spare parts and original wearing parts. These are
available from your dealer.
• Keep the working environment of the HygieneBox clean and tidy.
• Deactivate teat cleaning during frost.
2.5 How am I warned of hazards?
Hazards are indicated directly on the HygieneBox by safety labels (warning signs, instruction
and prohibition notices), and in the operating manual by specially marked hazard descriptions.
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 HygieneBox 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 HygieneBox 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 What are the components 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?).
2.5.2 Potentially fatal hazards or health hazards
Depending on their severity and the probability of them occurring, hazards that can cause death
or injury to people are indicated by a hazard symbol (warning triangle with exclamation
mark) and the following hazard words:
DANGER!
The word DANGER indicates an imminent hazard that will lead to death or serious injury.
Warning signs in the operating manual: DANGER (white text on red background).

8 Important safety instructions
WARNING!
The word WARNING indicates a potentially hazardous situation that could lead to death
or serious injury.
Warning signs in the operating manual: WARNING (black text on orange background).
CAUTION!
The word CAUTION indicates a potentially hazardous situation that could lead to minor
injury.
Warning signs in the operating manual: CAUTION (black text on yellow background).
2.5.3 Material damage
NOTICE!
The word ATTENTION indicates possible material damage. The HygieneBox or anything
in its vicinity, such as a calf, may be damaged or injured.
Prohibition notice on the HygieneBox: a pictogram crossed out in red in a white circle with a red
border indicates something you are not allowed to do.
Operating manual: white text on blue background
2.5.4 Safety signs
Different safety labels are attached at the hazardous points on the HygieneBox. Warning signs,
prohibition and instruction notices.
What are warning signs?
Warning signs consist 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?
Instruction notices show a pictogram of what you are being instructed to do in a
blue circle. They illustrate what you have to do. In the example, the pictogram
means that you must always disconnect the plug first.

Important safety instructions 9
2.5.4.1 Warning signs on the machine
Danger of death by electric shock
Burning/scalding
Warning about injuries to the hand
No spraying
2.6 Safety devices
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!

10 Important safety instructions
2.7 Structural alterations
The HygieneBox must not be subjected to any unauthorized alterations at any time.
Only genuine spare parts, wearing parts and accessories may be used, since any warranty
claims will otherwise be void.