Westfalia 7163-9001-044 Guide

Westfalia Landtechnik GmbH Postanschrift:
Werner-Habig-Straße 1 -D-59302 Oelde Westfalia Landtechnik GmbH
Telefon [phone] -Telefax (02522) 77-2488 D-59299 Oelde
Printed in F.R.Germany
7163--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

3
Table of contents
1 Introduction 6...........................................................
1.1 Safety Instructions 6...............................................................
1.2 Danger Signs on the Automatic Calf Feeder 7.........................................
1.3 Information Signs on the Automatic Calf Feeder 7......................................
1.4 Construction Parts System--Machine Combi 8.........................................
1.4.1 Motherboard and Distribution Board SM 2 Plus 10.................................
1.4.2 Heat Exchanger / Circulation Pump 11...........................................
1.4.3 Hand--Actuated Feeding Pump 12...............................................
2 Specifications Automatic Calf Feeder 13...................................
3 Locating the Automatic Calf Feeder 15.....................................
3.1 Local Electrical Connection 15........................................................
3.2 Installing the Automatic Calf Feeder 15................................................
3.3 Mounting the Sucking Station 16......................................................
3.4 Mounting the Race--Way 17..........................................................
3.5 Connecting the Micro--Identification “Calfscan” 17.......................................
3.6 Water and Milk Connection 18........................................................
3.6.1 Water Connection 18..........................................................
3.6.2 Milk Connection 19............................................................
4 Operating Elements 20....................................................
4.1 Keyboard 20.......................................................................
4.1.1 Operational Control Keys 21....................................................
4.1.2 Entering the Values 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 Heating 27...............................................................
5.7.1 Adjusting the Thermostats 27...................................................
5.7.2 Recommendations for Temperature Settings 28...................................
5.7.3 Measuring the Temperature 28..................................................
5.8 Heating for Milk Powder Outlet and Protection against Frost 29...........................
6 Functioning of the Automatic Calf Feeder 30...............................
6.1 Preparing the Milk Portions 30........................................................
6.2 Distributing the Milk 30..............................................................
6.2.1 In the Restricted Mode 30......................................................
6.2.2 In the Ad Libitum Mode 31......................................................
7 Settings in Setup 32......................................................
7.1 Different selections in Setup 32.......................................................
7.2 Function Table „Setup“ 34............................................................
7.3 How to make entries in Setup 35......................................................
8 Connecting the System--Machine to the Feeding Computer 36...............
8.1 Connecting the System--Machine to the VC3--Bus 36....................................

4Table of contents
9 Entries on the Feed Computer 38..........................................
9.1 Setup in DP5 38....................................................................
9.2 Setup in DP4.4 44..................................................................
9.3 Setup in C16 47....................................................................
9.4 Setup Related to the Automatic Feeder 47.............................................
9.5 Settings for Animal--Specific Increase of the Concentration on C16 48.....................
9.6 Settings for Animal--Specific Fresh Milk Ratio of the Feed Portion 48......................
10 Functions of the Menu Key 49............................................
10.1 Hand Functions 49.................................................................
10.2 Portion Values 50..................................................................
10.2.1 Selecting the Concentration 50.................................................
10.2.2 Entering the Milk Ratio 51.....................................................
10.2.3 Entering the Additive 51.......................................................
10.2.4 Restricted/Adlib--Mode 51.....................................................
10.3 Milk Values 52....................................................................
10.3.1 Selecting the Operating Mode 52...............................................
10.3.2 Entering the Milk Value 52.....................................................
10.3.3 Commuting to MP--mode 53...................................................
10.3.4 Commuting to 1--Circle--Mode 53...............................................
10.4 Calibration 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 Checking 61.................................................................
10.7 Version 62........................................................................
10.8 Function Table of the Menu Key for Connection to Bus--System 63.......................
11 Functions of the Automatic Key 65.......................................
11.1 Display in the Automatic--Mode 65...................................................
11.2 Releasing an Extra--Portion 67......................................................
12 Functions of the Cleaning Key 68.........................................
12.1 Entering the Figures 69.........................................................
12.2 Selecting the Options 70............................................................
12.3 Cleaning 71.......................................................................
12.3.1 Mixer Cleaning 71............................................................
12.3.2 Cleaning the Heat Exchanger 72...............................................
12.3.3 Heat Exchanger with Suction Hoses 74.........................................
12.3.4 Air Cleaning 76..............................................................
12.3.5 Heat Exchanger with Sponge 77...............................................
12.4 Settings 79.......................................................................

5
Table of contents
12.4.1 Mixer Cleaning 79............................................................
12.4.2 HE Cleaning 79..............................................................
12.4.3 Air Cleaning 79..............................................................
12.4.4 HE/Hose Cleaning 80.........................................................
12.4.5 Hose Cleaning 80............................................................
12.4.6 Detergent 80................................................................
13 Service and Maintenance of the Automatic Calf Feeder 81..................
13.1 The Day after the First Commissioning 81............................................
13.2 Carrying Out a Regular Check Routine 82............................................
13.3 Shutdown 82......................................................................
14 Fault 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 89.........................
15.5 Detergent Dosing Pump 89.........................................................
15.6 Protection against Flies 90..........................................................
16 Replacement of the Program Chip 91.....................................
EC DECLARATION OF CONFORMITY A.......................................

6Introduction
1 Introduction
1.1 Safety Instructions
Be sure to read and follow all instructions contained in this manual before connecting and
using the automatic calf feeder.
:Use the appliance only to feed calves.
:Servicing and installation of the automatic calf feeder has to be restricted to qualified
and authorised service personnel.
:Read the user’s manual carefully before installing or operating the machine.
To facilitate customer service on the calf feeders, store the documentation accompanying
the appliance near to the automatic feeder.
:The faultless functioning of the automatic calf feeder requires expert installation, 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 responsible for choosing
other feeding methods for those animals.
:The manufacturer accepts no responsibility for damages and their consequences caused
by incorrect installation and operation, improper use, inadequate service and mainte-
nance or false entries.
:Remove any projecting object from the stable (e.g. pipe ends), because Responder
collars could get caught in it.
:You will find further safety instructions in the following chapters.

7
Introduction
1.2 Danger Signs on the Automatic Calf Feeder
CAUTION!
This sign warns you of rotating parts starting to work automatically.
This sign is located on potential danger areas such as the milk powder
hopper, the milk powder outlet, the mixer as well as the outlet for pow-
der additives on the additive dispenser.
In order to avoid injuries, before carrying out any kind of operation on
above listed parts, it is imperative to make the automatic feeder current-
less by turning the main switch to position „0/OFF“ or by pulling the
mains plug.
CAUTION!
This sign warns you of electric shocks.
In order to avoid injuries, before 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 instructions.
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

8Construction Parts System--Machine Combi
1.4 Construction Parts System--Machine 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

9
Construction Parts System--Machine Combi
Circulation valve*
Thermostat for minimum
operating temperature
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

10 Motherboard and Distribution 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.