ROBBE TAK5-SA2-KFA-27-F1 User manual

Instruction Manual
Automatic Calf Feeder Stand Alone 2 Plus Combi
with Concentrate Feeder and Animal Scales
As of Program Version 00.16
T A K 5 -- S A 2 -- K F A -- 2 7 -- F 1
T A K 5 -- S A 2 -- K F A -- 2 8 -- P 1
T A K 5 -- S A 2 -- K F A -- 3 0 -- P 1
T A K 5 -- S A 2 -- K F A -- 3 2 -- P 1
T A K 5 -- S A 2 -- K F A -- 3 8 -- P 1
September 2003

3
Table of contents
1 Introduction 8...........................................................
1.1 Icons Used in This Manual 8........................................................
1.2 Safety Instructions 9...............................................................
1.3 Safety Signs on the Automatic Feeder and the Concentrate Feeder 10.....................
1.4 Information Signs on the Automatic Feeder 10..........................................
1.5 Construction Parts Stand Alone Combi 11..............................................
1.6 Construction Parts Concentrate Feeder 12.............................................
1.7 Control of the Automatic Feeder 14...................................................
1.7.1 Operating and Control Unit (with Motherboard) 14.................................
1.7.2 Power Unit Combi 15..........................................................
1.7.2.1 Relay Board 15..........................................................
1.7.2.2 Distribution Board 16.....................................................
1.8 Heat Exchanger with Separate Heating Circuits for Milk and Water 17.....................
1.9 Accessories (not illustrated) 17.......................................................
1.10 Manual Feeding Pump 18...........................................................
2 Technical Data of the Automatic Feeder 19.................................
3 Specifications Concentrate Feeder 21......................................
4 Locating the Automatic Feeder 22.........................................
4.1 Local Electrical Connection 22........................................................
4.2 Locating the Automatic Feeder 22....................................................
4.3 Mounting the Feeding Station 23......................................................
4.4 Mounting the Race--Way 24..........................................................
4.5 Connecting the Micro--Identification 25.................................................
4.5.1 Identification „Mikro--Nedap“ 25.................................................
4.5.2 Identification „Mikro--Tiris“ 25....................................................
4.6 Water and Milk Connection 26........................................................
4.6.1 Water Connection 26..........................................................
4.6.2 Milk Connection 27............................................................
5 Locating the Concentrate Feeder 28.......................................
5.1 Mounting the Concentrate Feeder 28..................................................
5.2 Filling the Concentrate Feeder 29.....................................................
5.3 Connecting the Mains Plug 29........................................................
5.4 Checking and Adjusting the Dosing Flap 29............................................
6 Operation and Operating Elements 31......................................
6.1 Operating Elements 31..............................................................
6.1.1 Program Switch and Switch Menu 31............................................
6.1.2 Keyboard and Keyboard Menu 31...............................................
6.1.3 Manual Keys 34...............................................................
6.2 Input Routine 35....................................................................
6.2.1 Exercises Concerning the Switch Menus 36.......................................
6.2.2 Exercises Concerning the Keyboard Menus 36....................................
7Start--Up 37...............................................................
7.1 Connecting the Mains Plug 37........................................................
7.2 Filling the Boiler of the Heat Exchanger with Water 37...................................
7.3 Dry--Running Protection for Circulation Pump (if available) 38.............................
7.4 Deaerating the Circulation Pump (if available) 38........................................
7.5 Filling the Milk Powder into the Powder Hopper 38......................................

4Table of contents
7.6 Filling the Milk Storage Tank 39.......................................................
8 Basic Inputs during Installation 40.........................................
8.1 Checking Date and Time 40..........................................................
8.2 New Installation 40..................................................................
8.3 Setup 42..........................................................................
8.3.1 Activating the Concentrate 42...................................................
8.3.2 Setting the Baud Rate for PC and Concentrate Feeder 43..........................
8.3.3 Selecting the Printing Function 44...............................................
8.3.4 Selecting the Animal Scales 45..................................................
8.3.5 Carrying Out an Interface Test 46................................................
8.3.6 Registering and Cancelling the Feeding Stations 46................................
8.3.7 Portion 47....................................................................
8.3.8 Heat Exchanger 48............................................................
8.3.9 Deactivating the Detergent Pump 48.............................................
8.3.10 Activating Compressed Air--Cleaning 49.........................................
8.3.11 Institute 49..................................................................
8.4 Connection Test towards the Concentrate Feeder 50....................................
8.5 Calibration 51......................................................................
8.5.1 Calibrating Water, Milk, MP and Detergent 51.....................................
8.5.2 Calibrating Additives 52........................................................
8.5.3 Calibrating the Concentrate 53..................................................
8.6 Setting the Heating 54...............................................................
8.6.1 Adjusting the Thermostats 54...................................................
8.6.2 Recommendations for Temperature Settings 55...................................
8.6.3 Measuring the Temperature 55..................................................
8.7 Heating for Milk Powder Outlet and Protection against Frost 56...........................
8.8 Animal Identification and Responder Number Input 57...................................
8.8.1 Animal Identification 57........................................................
8.8.2 Check Connection between Micro--Identification and Stand Alone 58.................
8.8.3 Automatic Reading of the Responder Numbers and Antenna Test 58.................
8.8.4 Manual Input of Responder Numbers 59..........................................
8.9 Registering the Animals 60...........................................................
8.9.1 Registering Individual Animals 60................................................
8.9.2 Registering Groups 62.........................................................
8.9.3 Registering Automatically 63....................................................
8.10 Entering the Correction Days 64.....................................................
8.11 Entering Deviations (Addition/Reduction) 65...........................................
8.11.1 Deviations of Milk Portions 65..................................................
8.11.2 Deviations of Concentration 66.................................................
8.11.3 Deviations of Concentrate 66..................................................
8.11.4 Deviations of Additives 67.....................................................
8.12 Accustoming Aid 68................................................................
9 Functioning of Automatic Feeder and Concentrate Feeder 69................
9.1 Preparing the Milk Portions 70........................................................
9.2 Distributing the Milk 71..............................................................
9.2.1 In the Restricted Mode 71......................................................
9.2.2 In the Ad Libitum Mode 71......................................................
9.3 Distributing the Concentrate 72.......................................................
9.3.1 In the Restricted Mode 72......................................................
9.3.2 In the Ad Libitum Mode 72......................................................
9.4 Releasing an Extra--Portion 73.......................................................

5
Table of contents
9.4.1 The Long Electrode is free 73...................................................
9.4.2 The Long Electrode is Covered 74...............................................
9.5 Feed Delay/Delete Consumption 75...................................................
9.5.1 Delete Feed Delay 75..........................................................
9.5.2 Delete Consumption for the Entire Group 76......................................
9.5.3 Delete Consumption for Individual Animals 76.....................................
9.6 Daily Calculation 77.................................................................
10 Altering the Operational Data 78..........................................
10.1 Feeding Plans 78..................................................................
10.1.1 Age--Dependent Drinking 78...................................................
10.1.2 Weaning 80.................................................................
10.2 Concentration Plans 82.............................................................
10.3 Concentrate Plans 83..............................................................
10.4 Entitlement Intervals 85............................................................
10.4.1 Feeding Intervals 85..........................................................
10.4.2 Concentrate Intervals 86......................................................
10.5 Limited Quantities 87...............................................................
10.5.1 Minimum Save--Up Quantity and Maximum Quantity for Milk 88....................
10.5.2 Carryover of the Milk 89.......................................................
10.5.3 Limited Quantities for Concentrate 90...........................................
10.5.4 Carryover of the Concentrate 91...............................................
10.6 Warning Levels 92.................................................................
10.6.1 Warning Levels for Milk 92.....................................................
10.6.2 Warning Levels for Concentrate 93.............................................
10.7 Machine Data: Station Number 94...................................................
10.8 Restricted/Ad Libitum Mode 95......................................................
10.8.1 Restricted/Ad Libitum Mode (Automatic Feeder) 95...............................
10.8.2 Restricted/Ad Libitum Mode (Concentrate Feeders) 96............................
11 Milk Functions 97........................................................
11.1 Selecting the Milk Mode 97..........................................................
11.2 Commuting to Milk Powder Mode 97.................................................
11.3 Entering the Milk Value 97..........................................................
11.4 Activating Milk Expelling 98.........................................................
11.5 Selecting the Milk Ratio for Change--Over to Single Heating Circuit 99....................
11.6 Entering the Milk Ratio Plan 100......................................................
12 Additives 101.............................................................
12.1 Making Out Medicine Prescriptions 101................................................
12.2 Making Out the Electrolyte Prescription 104............................................
12.3 Distributing the Medicine 105.........................................................
12.4 Distributing the Electrolyte 107.......................................................
12.5 Blocking the Remaining Portion with Additive 108.......................................
12.6 Additives Info 109...................................................................
13 Check Functions 111.....................................................
13.1 Switch Position „Feeding Mode“ 111..................................................
13.2 Animal Verification 113..............................................................
13.2.1 Feeding Behaviour 113.........................................................
13.2.2 C1 and C2 114................................................................
13.2.3 Animal Verification C1 114......................................................
13.2.4 Animal Verification C2 115......................................................

6Table of contents
13.2.5 Visits 115....................................................................
13.2.6 Animal Scales 115.............................................................
13.2.7 Number of Animals 116........................................................
14 Alarms 117...............................................................
14.1 Machine Alarms 117................................................................
14.1.1 Connection Error concerning Animal Scales or Concentrate Feeder 117..............
14.1.2 Checking the Calibration Values for Concentrate 118...............................
14.1.3 The Shaft is Blocked 118.......................................................
14.1.4 Idling of the Shaft on the Concentrate Feeder 118.................................
14.1.5 Mixer Outlet 119..............................................................
14.1.6 Remaining Detergent 119......................................................
14.2 Animal Alarms 120..................................................................
14.2.1 Drinking Alarms 120...........................................................
14.2.2 Break 121....................................................................
14.2.3 Drinking Speed 121............................................................
14.2.4 Additive Alarm 121............................................................
14.2.5 Unknown Transmitters 122.....................................................
14.3 Concentrate Alarms 123.............................................................
14.4 Expire Date 124....................................................................
14.5 Animal Data and Info 126............................................................
14.5.1 Weight, Days Fed 126.........................................................
14.5.2 Ration/Day/Animal 128.........................................................
14.5.3 Cancel Registration 129........................................................
14.5.4 Change Registration 130.......................................................
14.6 Consumption 131...................................................................
14.7 Total Consumption 132..............................................................
15 Cleaning 133.............................................................
15.1 HE with Sponge 133................................................................
15.2 Heat Exchanger 134................................................................
15.3 Heat Exchanger with Suction Hoses 136...............................................
15.4 Mixer 138..........................................................................
15.4.1 Automatic Mixer Cleaning (Time--Controlled) 138..................................
15.4.2 Calling Up Automatic Mixer Cleaning Manually 139................................
15.4.3 Compressed Air--Cleaning 140..................................................
15.5 Cleaning Settings 140...............................................................
15.5.1 Cleaning Settings Heat Exchanger 140...........................................
15.5.2 Cleaning Settings Mixer 141....................................................
15.5.3 Cleaning Settings Suction Hose 142.............................................
15.5.4 Cleaning Settings Remaining Portion 143.........................................
15.5.5 Cleaning Settings Detergent 144................................................
15.5.6 Cleaning Settings Compressed Air--Cleaning 144..................................
16 Service and Maintenance 146..............................................
16.1 Service and Maintenance of the Automatic Feeder 146..................................
16.1.1 The Day after the First Commissioning 147.......................................
16.1.2 Carrying Out a Regular Check Routine 148.......................................
16.1.3 Shutdown 148................................................................
16.2 Service and Maintenance of the Concentrate Feeder 149................................
17 List Printing 150..........................................................
18 Error Messages 151.......................................................
18.1 Checking the Calibration Values of the Milk 151.........................................

7
Table of contents
18.2 The Heat Exchanger Is Not Active 151................................................
18.3 The Feeding Mode Cuts Off 151......................................................
18.4 The Data Are Deleted 151...........................................................
18.5 The Supply Electrode is Earthed 152..................................................
18.6 Milk Shortage 152..................................................................
18.7 Water Shortage 153.................................................................
18.8 Power Failures / Backups / Water and Milk Checks 153..................................
19 Animal Scales 155........................................................
19.1 Testing Connection, Taring Animal Scales,Carrying Out Weighing 155.....................
20 Accessories 157..........................................................
20.1 Two--Group--Valve--Unit 157..........................................................
20.2 Additive Dispenser Powder and Additive Dispenser Liquid 158............................
20.3 Electrical Vapour Screen for MP-- and Powder Additive Outlet 159.........................
20.4 Fully Automatic Heat Exchanger Cleaning 160..........................................
20.5 Detergent Dosing Pump 161.........................................................
20.6 Fly Protection Door 162.............................................................
EC DECLARATION OF CONFORMITY A.......................................
Connection between Printer and Stand Alone B...............................
Functional Steps „Cleaning, Heat Exchanger“ (see chapter 15.2) C.............
Functional Steps „Cleaning, HE with Suction Hoses“ (see chapter 15.3) E......
Standard -- Feeding Plan Group A H..........................................
Standard -- Feeding Plan Group B I..........................................
Standard -- Feeding Plan Group C J..........................................
Standard -- Feeding Plan Group D K..........................................
Example: Milk ratio plan group A L...........................................
Example: Milk ratio plan group B M...........................................
Form: Feeding plan N.......................................................
Form: Concentration plan O.................................................

8Introduction
1 Introduction
1.1 Icons Used in This Manual
The little graphic pictures that frequently appear in the margin of this book should give you
a better overall view on the user’s manual.
Attention: The exclamation point within an equilateral triangle is intended to alert you to
follow the instructions contained in this manual in order to avoid injury and damage to
persons, animals and appliance.
This icon is intended to signal you that here you can find important information and addi-
tional explanations on the operation of the automatic feeder.
You will find this icon next to examples in the user’s manual.
This icon invites you to enter the figures into the corresponding menu.
This icon invites you to turn the program switch to the displayed position, in order e.g. to
select the corresponding switch menu.
Icon for measuring cylinder for collecting and weighing the feed components.
Icon for scales used to weigh the feed components during calibration.
Icon for thermometer to measure the body temperature.
Icon for collar with identification system.

9
Introduction
1.2 Safety Instructions
Read and understand the instruction manual and all safety instructions before using the
equipment.
:Use the equipment only to feed calves.
:The equipment is to be serviced by trained and authorized personnel only.
:To facilitate servicing, store the instruction manual next to the equipment.
:Expert installation, correct handling, as well as careful care and maintenance are the pre-
requisits to ensure faultless functioning of the equipment.
:Incorrect data input may have serious consequences. Therefore, check the correctness of
data input.
:The livestock owner is liable for a regular and scrupulous control of his animals and the
functioning of the equipment. If, for any reasons, the system should break down or some
calves should not make use of it, the livestock owner is liable for choosing other feeding
methods for those animals.
:The manufacturer will not assume liability for injury, loss or damage, direct or conse-
quential, of any kind from the use or inability to use the equipment.
:Remove any projecting objects from the calf house (e.g. pipe ends), because collars
might get caught in them.
:You will find further safety instructions in the following chapters.

10 Introduction
1.3 Safety Signs on the Automatic Feeder and the Concentrate Feeder
WARNING! Crush and cut hazard.
Moving parts starting automatically can crush and cut.
Keep hands and fingers clear before operating!
This sign is located on potential danger areas on the automatic feeder,
such as the milk powder hopper, the milk powder outlet, the mixer as
well as the outlet for powder additives on the additive dispenser. Moreo-
ver, this sign is also located on potential danger areas on the concentrate
feeder.
Turn off and lock out power before carrying out any kind of operations
on the above--mentioned parts.
DANGER! Electric shock hazard.
Hazardous voltage!
Contact may cause electric shock, burn or death.
This sign is located on potential danger areas on the automatic feeder,
such as e.g. the power unit. Moreover, this sign is also located on poten-
tial danger areas on the concentrate feeder.
Turn off and lock out power before opening the power unit.
The power unit is to be opened and serviced by qualified electricians
only.
1.4 Information Signs on the Automatic Feeder
Before connecting the automatic feeder to the mains supply and acti-
vating the heating (see chapter 7 „Installing the Automatic Feeder“,
page 37), read and understand the instruction manual.
Any questions about this product? Then feel free to get
in touch with us. Before calling us, please write down
the information (machine type, machine number) on
the nameplate located at the left of the feeder chassis,
as well as the program version (refer to chapter „Menu
1--99, Machine data“).
Our address:
Förster--Technik GmbH,
Gerwigstr. 25,
D--78234 Engen,
Tel. [phone],
Fax [phone]
Internet: www.foerster--technik.de

11
Construction Parts Stand Alone Combi
1.5 Construction Parts Stand Alone Combi
Control: Operating
unit with processor
Thermostats and overheating
protection (integrated laterally)
Milk-- resp. water outlet
Milk powder hopper
with top section
Push--button for
feeding pump
Dosing slide
Mixer
Storage container for liquid
additives and detergent, deter-
gent dosing pump, manual
feeding pump, box valves,
draining valve (integrated la-
terally)
Milk supply
Quick coupling for sponge
cleaning of heat exchanger
Solenoid valves for water-- and
milk supply, heat exchanger,
milk pump (integrated laterally)
Water supply
Control: power unit
Double electrode
Nameplate
Main switch „ON/OFF“
Quick coupling for suction
hose cleaning (not illustra-
ted)
Dimensions of the automatic feeder: height = approx. 1260 mm, width = approx. 720 mm,
depth without additive dispenser = approx. 570 mm, depth with additive dispenser =
approx. 660 mm.

12 Construction Parts Concentrate Feeder
1.6 Construction Parts Concentrate Feeder
Feeding bowl
Storage tank for
concentrate
(with top section)
Dimensions of the concentrate feeder: Height = approx. 955 mm, width = approx. 496 mm,
depth without feeding bowl = approx. 383 mm, depth with feeding bowl = approx. 650 mm.
Light Emitting Diode
(LED) for reed switch
Dosing flap
Adjustable plate with reed switch
(to adjust the dosing flap)

13
Construction Parts Concentrate Feeder
Maste
r
-- c o n t
r
ol
(Control unit at the
rear of the Master--
Concentrate feeder)
Codingswitchtosetthebaudrate Slide s
w
itch
f
or adlib or
restricted mode
RESET keyProgram chip
Interface card RS 422
(for connection to Stand
Alone)
Calibration button (to
carry out calibration)
LED (green) for
data exchange
between concen-
trate station and
Stand Alone
LEDs (yellow) for
dosing flap
(1=Master, 2=Slave)
LED on = signal
empty
LEDs (green) for
identification
(1=Master,
2=Slave)
LEDs (red) for
alarms on concen-
trate station
(1=Master,
2=Slave)
LED (green) for
power supply
Identification Slave (green)
Reed switch Slave (yellow)
Calibration button
Slave--cont
r
ol
(at the rear of the
Slave--Concentrate
feeder which is con-
trolled by the Master)

14 Control of the Automatic Feeder
1.7 Control of the Automatic Feeder
1.7.1 Operating and Control Unit (with Motherboard)
On the operating and control unit are located the following operating elements:
program switch, keyboard, manual keys and display.
The boards for display, keyboard, distribution as well as the motherboard are located inside
the operating and control unit of the automatic feeder. The motherboard represents the pro-
cessor.
In case you do not use the connections located at the bottom of the operating unit, take care
to close them by means of sealing covers.
The motherboard is hard--faced, among other things, with:
-- interfaces for external components (PC/printer, animal scales in feeding box 1 + 2,
concentrate 1 + 2, option)
-- memory card to store all animal data
-- 2 program chips
Plug for display
Memory card
Interfaces for:
channel 5
channel 4
channel 3
channel 2
channel 1
Potentiometer to adjust
contrast of the display
Program chips
(EPROMS)
Plug to connect interface 1
(together with D--Sub--
plug located in the opera-
ting unit)
Connector to connect interfaces for channel 2--5

15
Control of the Automatic Feeder
1.7.2 Power Unit Combi
Relay board as well as distribution board are located next to each other inside the power
unit.
1.7.2.1 Relay Board
On the relay board are located the transformer for weak current supply of the processor
control, the relays, the connectors for external components, the fuses and LEDs.
Transformer for weak
current supply
LED to control the fuses
Fuse for
transformer
Fuse for 230 V
external components
Connector power
supply 230 V
Connector for output to
230 V external components
LED to control the fuses
Fuses for 230V
external components
Fuse for weak current
external components
Relays for external components
LED to control
weak current
Plug for relay control via operating unit
Connector for weak
current external components
L
ED to control the fuses
Connector for
weak current sup-
ply of the opera-
ting unit

16 Control of the Automatic Feeder
1.7.2.2 Distribution Board
On the distribution board are located, among other things, two integrated switches. By
means of the left switch you can switch on and off the heating of the milk powder outlet
(vapour screen). By means of the right switch you can switch on and off the heating cable.
See chapter 8.7, page 56, „Heating for Milk Powder Outlet and Protection against Frost“.
Connector 230V for heating
ON/OFF switch for milk powder
outlet heating (optional)
ON/OFF
switch for
heating cable
(optional)
Distribution connector for protection conductor (PE)
Distribution connector for neutral conductor (N)

17
Heat Exchanger with Separate Heating Circuits
1.8 Heat Exchanger with Separate Heating Circuits for Milk and Water
Heat exchanger with
stainless steel coil.
Milk pump to deliver
and dose the milk Hose connection to water line
Hose connection to milk tank
Mixer jar to mix up
the feed components
Sucking station for
milk distribution
Mixer outlet valve
Stop valve
1.9 Accessories (not illustrated)
You will find a more detailed description of the accessories in chapter 20, page 157, „Ac-
cessories“.
:2--Group--Valve--Unit
:Additive dispenser for powder or liquid additives
:Electrical vapour screen for milk powder or additive powder outlet
:Fully automatic heat exchanger cleaning for Combi or Fresh milk feeder consisting of:
-- circulation valve for cleaning cycle
-- detergent dosing pump
:Detergent dosing pump
:Fly protection door

18 Manual Feeding Pump
1.10 Manual Feeding Pump
Thanks to the manual feeding pump calves may get easily accustomed to the teat. The fee-
ding pump is located between mixer exit and feeding station. You can activate it by pushing
a button at the lower side of the chassis or at the feeding station. The milk is then delivered
directly from the mixer 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 draining valve or the suction hoses.
Mixer draining valve
Suction hose connection 1
Suction hose connection 2 Feeding pump
Suction hose connection to mixer
Box valve 1
Hose connection for mi-
xer draining valve
Box valve 2
Never clean the feeding pump by means of the cleaning sponge!

19
Technical Data of the Automatic Feeder
2 Technical Data of the Automatic Feeder
Please observe the information on the nameplate located at the left of the chassis!
Electrical Connection
TAK5--SA2--38--P1, TAK5--SA2--27--F1 (400 V)
230V / 400V / 3 / N / PE, 50 Hz, 16 A
TAK5--SA2--27--F1 (230 V)
230V / L / N / PE, 50 Hz, 16 A
TAK5--SA2--32--P1
230V / L / N / PE, 50 Hz, 20 A
TAK5--SA2--30--P1
200V / L1, L2 / Grd / 50/60 Hz, 20 A
TAK5--SA2--28--P1 (only for U.S.A. and Canada)
240V / L1, L2 / Grd / 60 Hz, 15 A
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

20 Technical Data of the Automatic Feeder
Number of feeding stations
An automatic feeder can feed 20 -- 30 rearing calves or 15 -- 20 fattening calves per feeding
station. In case of two feeding stations an automatic feeder can provide approx. 50 -- 60 rea-
ring calves or 20 -- 30 fattening calves or 20 rearing calves and 15 fattening calves with
feed.
Technical data are subject to change without prior notice.