Related Manuals for Forster CalfRail
Summary of Contents for Forster CalfRail
- Page 1 June 29, 2017 Original Service Manual CalfRail Versions: IFS 6.10 / Feeder S 2.00 CRS2-IF1-WH...
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Page 2: Table Of Contents
CalfRail viewed from the right........ - Page 3 CalfRail travel to parking........
- Page 4 CalfRail travel to box........
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Page 5: Introduction
1. Introduction This manual enables you to commission the CalfRail safely as intended. • The end user must provide you with the operating manual of the CalfRail and the safety data sheets for the cleaning agents. • Carefully read all operating instructions and safety data sheets before initial commissioning or recommissioning of the CalfRail. -
Page 6: Overview Of The Calfrail
Introduction Overview of the CalfRail 1.1.1 CalfRail viewed from the right Direction of travel 1 Service door 2 Screws to adjust teat height 3 CalfRail unit 4 Service opening for suction sensor 5 Teat 6 AFeed button with entitlement LED... -
Page 7: Interior View
Introduction 1.1.2 Interior view 1 Servopump 2 Pump for teat cleaning (optional) 3 Connectors for hose group... -
Page 8: Front View
6 Feed button with entitlement LED 7 Teat cleaner (optional) 8 Return valve (internal) Continue button If during feeding the CalfRail is in front of a box and this button is pressed, the CalfRail moves on to the next box. -
Page 9: Name Plate
Name plate There is a name plate on the left-hand exterior side of the CalfRail and on the rear of the control box and there is a component name plate on the rear of the heating system. They provide in- formation about the manufacturer, type and number of the CalfRail, information for connecting the feeder to the mains as well as the certifications of the CalfRail. -
Page 10: Supply Line
Introduction 1.1.5 Supply line 1 CAN bus cable (violet) 2 CalfRail power supply (gray) 3 Suction hose return line ø7 mm (without marking) 4 Heating system return line (2 x, blue) 5 Teat cleaner ø5 mm (optional) 6 Heating system feed line (blue) 7 Suction hose (red) 1.1.6... -
Page 11: Heating System
4 Port for feed line 5 Temperature sensor 6 Control box cover (not shown) 7 Port for CAN bus cable (CalfRail 1) 8 Port for CAN power supply (CalfRail 1) 9 Port for other CAN participants (e.g. IFS) 10Port for CAN bus cable to automatic feeder... - Page 12 Introduction Single unit rear view 1 Expansion vessel 2 Component name plate 3 Main switch 4 Mains connection 5 Filter...
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Page 13: Technical Data
6 Filter Technical data 1.2.1 Electrical connection Note: The electrical connection specifications of the CalfRail can be found on the name plate on the left-hand side of the CalfRail unit and on the component name plate of the heating sys- tem. -
Page 14: Dimensions
Introduction 1.2.2 Dimensions 1.2.3 Weight CalfRail unit: approx. 40 kg. Water heating system: approx. 35 kg. 1.2.4 Number of feeding stations and animals CalfRail/automatic feeder Calves/CalfRail Calves/side Max. 2 Max. 32 Max. 16 1.2.5 Installation requirements 1.2.5.1 Structural integrity of the carrier system... - Page 15 • A roof over the running rail is recommended. • The maximum length of the hose group from the automatic feeder to the CalfRail is 30 me- ters for each CalfRail. • The running rails may not be welded to the carrier system.
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Page 16: Disposal
Also specify the device type and the program version of your automatic feeder and your CalfRail so that you can obtain service tailored to your automatic feeder. The device number and model are located on the name plate on the left of the housing of the automatic feeder and the CalfRail unit. -
Page 17: Important Safety Instructions
The CalfRail has been designed in accordance with accepted rules of engineering and ap- proved safety standards. Hazards and adverse effects may nevertheless arise during operation. These hazards are indicated by the warning signs directly on the CalfRail as well as the warning messages in this service manual. -
Page 18: How Am I Warned Of Hazards
Make sure that all the specified safety signs are fitted to your CalfRail and that they are in a legible condition. If the safety signs are difficult to read, replace them immediately. New safety... -
Page 19: What Are The Components Of A Hazard Description
The word ATTENTION warns you about the risk of material damage. The CalfRail or an object in its vicinity, such as a calf, can be damaged. Prohibitory signs on the CalfRail: A pictogram with a red line through it in a white circle with a red border indicates what you may not do. -
Page 20: Safety Signs
Important safety instructions Safety signs Different safety labels are attached at the hazardous points on the CalfRail. Warning signs, pro- hibition and instruction notices. What are warning signs? Warning signs consist of: • A pictogram in a yellow triangle illustrating the potential hazard. - Page 21 Important safety instructions Danger due to hot surfaces! Burning/scalding Automatic startup...
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Page 22: Safety Devices
No spraying Grounding symbol 2.5.2 Safety devices The CalfRail may be operated only if the safety devices are complete and intact. The CalfRail has the following safety equipment: • The safety signs (warning signs, mandatory signs and prohibitory signs). •... - Page 23 Important safety instructions The safety temperature limiter is triggered if the water is too hot or if the heating system has run dry. The safety temperature limiter can be found behind the cover shown below. 1 Cover of the safety temperature limiter...
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Page 24: Commissioning
Commissioning 3. Commissioning In this chapter, you will learn how to connect the CalfRail unit to an already installed carrier sys- tem. The end user must provide you with the operating manual of the CalfRail, the separate operat- ing manuals of the automatic feeder and the safety data sheets for the cleaning agents. - Page 25 Commissioning 3. Attach the supplied running rail holders to the previously installed hanger. 1 Hanger (example) 2 Running rail 3 Running rail holder 4. Push the individual rail pieces into the running rail holder. 5. Align the rail and ensure that the distance to the floor does not change and that the rail is installed horizontally.
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Page 26: Mounting The Calfrail
The CalfRail unit weights 40kg. ► Never carry the CalfRail by yourself. 2. Loosen the quick release on the carriage of the CalfRail unit so that you can mount the unit. 1 Quick release 3. Threading the CalfRail unit into the running rail. - Page 27 ► Therefore do not tighten the screws of the rail carriage tightly, in order to avoid damaging the hose package. 9. Push the CalfRail unit onto the other end of the rail. Ensure that the supply line sags slightly between the rail carriages.
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Page 28: Connecting The Can Bus And Power
The supply line can be damaged if it is taut. ► Adjust the position of the rail carriages as necessary. 10. Tighten the quick release using the clamping lever. The CalfRail unit should be difficult to move by hand. Note: If there is too much contact pressure, the motor will be overloaded and the CalfRail will move in a jerky fashion. - Page 29 6. Connect the power supply for the CalfRail to the control unit of the heating system as shown in the circuit diagram, and attach the ferrite choke included in the scope of supply to the ca- ble.
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Page 30: Run And Connect Supply Line
Commissioning 1 Mains adapter in 2 Housing out 8. Install the temperature sensor for the outside temperature at the parking position of the Cal- fRail and secure it in an appropriate position. Run and connect supply line 1. Install the last clamp or fastener for the supply line so that the insulation extends behind the automatic feeder. -
Page 31: Activating The Heating System
Note: Connect the hoses to the connectors on the right. The connectors on the left are for when a second CalfRail is connected. 5. If the teat cleaning feature is used (optional), place the fluid container next to the automatic feeder and insert the hose for cleaning. -
Page 32: Inserting The Servopump Hose
9. Set the heating system level again on the installation area. Inserting the servopump hose 1. Open the service door on the right side of the CalfRail unit. 2. Undo the screws on the pump housing and remove the transparent cover. -
Page 33: Attaching The Magnets For The Stopping Positions
(direction of travel, see 1.1.1 "CalfRail viewed from the right" - 6). Note: To ensure that the sensor on the drive carriage of the CalfRail detects the magnets, they must be positioned at the level of the sensor. -
Page 34: Activating The Calfrail
5. Choose the box to which you want to assign the CalfRail in Allocation. 6. In Address, choose an address that can be used to identify the CalfRail in the CAN bus sys- tem. The address range is between 71 and 79. -
Page 35: Testing The Calfrail
► Once the heating system is switched on, please fill the hoses as quickly as possible with water. 3.10 Testing the CalfRail To check whether the correct settings were made at the setup, the CalfRail should be tested during commissioning. - Page 36 , until the first magnet is detected and the CalfRail stops. Press , again until the CalfRail has reached the next magnet. Note: If the CalfRail stops in a position offset from the output of the box, the magnets must be moved in order to optimize the stopping position. 4.3.
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Page 37: Calibration
Boiler water, start? to fill the mixer with water. 2. Navigate to > Diagnosis > Stations > Feeds 3. Use , to select the desired CalfRail and in pump forward press , until the hose is filled with water and contains no air. 4. Navigate to >... -
Page 38: Cleaning The Calfrail
For hygienic reasons, any coolant and lubricant residues must be completely removed from the system prior to first putting into operation. To do so, perform the cleaning cycle (see the Clean- ing chapter in the operator's manual for the CalfRail). WARNING! Chemical burns from cleaning agents. -
Page 39: Transmitter And Animal Management
Transmitter and animal management 4. Transmitter and animal management Calves are registered for the CalfRail in basically the same way as they are registered in a group with a collar. However instead of a transponder number, a box number from 999101 to 999432 is assigned. - Page 40 Example: If 6 boxes are on one side, 6 stopping positions are entered. If the boxes are ar- ranged on the right side of the CalfRail (drive direction), register the animals under numbers 1- 6. If the boxes are arranged on the left side, register the animals under numbers 7-12.
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Page 41: Canceling Animals Or Animal Groups
Transmitter and animal management Follow these steps to manually register animals for CalfRail: 1. Navigate to > Animal management > Registration to the Animal sub-menu. 2. Select one of the available animal numbers that you wish to register. 3. Select the group to which the animal is to be allocated. -
Page 42: Canceling A Group
Transmitter and animal management 4.2.2 Canceling a group Follow these steps to cancel a group: 1. Navigate via > Animal management > Cancelation to the Group sub-menu. 2. Select the desired group. 3. In Registered, you can see how many animals are being fed in accordance with the respec- tive plan. -
Page 43: Changing The Box For The Calfrail
6. Confirm the prompt Register animal no. xx in group X? with 4.4.2 Resetting a transmitter Proceed as follows to change the box of a calf for the CalfRail and create a new transmit- ter number: 1. Navigate via > Animal management > CalfRail box change to the Reset transmitter sub-menu. - Page 44 Transmitter and animal management Example: 5-2 means that – counting from the right – the second to the fifth numeral of the transmitter number is accepted as the animal number. 6-1 means that – counting from the right – the first to the sixth numeral of the transmitter number is accepted as the animal num- ber.
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Page 45: Feeding
The CalfRail travels automatically to the registered calves with feed entitlement at specific set feeding times: In a two-sided arrangement (16 stopping positions), the CalfRail, starts on the right, traveling to a maximum of 16 boxes on the right side (Nos. 1 to 16), then travels back to the parking position. -
Page 46: Feeding Times
► When defining feeding times, note the defined feeding plan. Blocked periods (feed restric- tion) should be in the time between feedings because the CalfRail does not move to the calves if they are not entitled to feed. -
Page 47: Plan For Maximum Speed
Feeding NOTICE! If only the calves at the CalfRail receive medicine, the calves in the group box cannot consume feed during CalfRail feeding. NOTICE! Medicine must always be dispensed to all CalfRail calves, otherwise the feed distribution will be disrupted. -
Page 48: Waiting Times
3. In the Min. waiting time line, specify the desired time. The minimum waiting time specifies how long the CalfRail waits at a box if the calf has not consumed any feed. If the calf does not drink within the defined time, the CalfRail moves on. -
Page 49: Starting The Calfrail Manually
Note: If a calf does not drink when the CalfRail is in front of its box, the CalfRail can be ad- vanced to the next calf with entitlement by pressing the Advance button. This speeds up feed- ing. -
Page 50: Move Feeding Forward
Feeding has already taken place. 5.7.3 Stop feeding With this menu option, you can stop the feeding run at any time. The CalfRail unit moves to the parking position and cleaning is performed. You can stop feeding as follows: 1. -
Page 51: Maintenance Work
Injuries due to being pulled in or trapped. The CalfRail unit is attached to the carriage by means of a slewing ring. ► In order to prevent injuries to fingers, do not touch the CalfRail while it is slewing. WARNING! Risk of burns due to hot surfaces. -
Page 52: Annual Care And Maintenance Intervals
You replace the servopump hose as follows: 1. Switch off the heating system and disconnect the mains plug. 2. Open the service door on the right side of the CalfRail unit. 3. Undo the screws on the pump housing and remove the transparent cover. -
Page 53: Replacing The Hose For The Teat Cleaner
The pump may start up automatically at any time, crushing your hand or fingers. ► Do not reach into the hazard area of the pump. Disconnect the CalfRail from the power source before you replace the pump hose. Do not connect the pump to the power mains un- less the transparent cover is in place. -
Page 54: Replacing The Suction Hose In The Supply Line
2. Use , to select the desired CalfRail. 3. Choose Move carriage forward? to move the CalfRail to the last magnet on the rail. 4. Empty the suction hose. 5. Switch off the automatic feeder and the heating system via the main switch and disconnect the mains plug of the heating system. -
Page 55: Cleaning The Return Valve
11. Attach the pilot wire to the new suction hose and pull the it through the supply towards the CalfRail unit. Make sure the suction hose is not twisted. 12. Remove the pilot wire and close the hook and loop fastener of the supply line. -
Page 56: Cleaning The Suction Sensor
6. Reassemble the valve and tighten the screws. NOTICE! ► Make sure that the hoses are seated correctly on the valve and teat holder. 7. Close the CalfRail arm. 8. Reconnect the mains plug of the heating system and switch the heating system on. 6.2.5... -
Page 57: Cleaning The Water Filter
Maintenance work NOTICE! Using pressure washers can damage the housing. ► Only clean the housing by hand using a damp cloth. 3. Clean the louvers with a dry brush. NOTICE! ► Do not use any sharp or sharp-edged objects, since these could damage the components in the housing. - Page 58 Maintenance work NOTICE! ► Do not use any sharp or sharp-edged objects, since these could damage the filter. 5. Reinstall the filter. 6. Reconnect the mains plug of the heating system and switch the heating system on. 7. Refill the heating system with water and antifreeze if applicable (see 3.6 "Activating the heat- ing system"...
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Page 59: Shutdown And Recommissioning
To make the procedure easier and ensure that you do not miss any points, see the checklist (9.4 "Shutdown checklist" - 76) in the appendix. To ensure that the CalfRail does not become a breeding ground for germs, which could endan- ger the health and life of the calves when you recommission the feeder, you must thoroughly clean the CalfRail before shutting it down. - Page 60 ► Always disconnect the power plug before continuing. 5. Switch off the heating system and the automatic feeder, and disconnect the mains plug. 6. Disconnect the suction hose that runs from the CalfRail to the connections on the automatic feeders.
- Page 61 NOTICE! Risk of infection ► To prevent infections, use a new pump hose when recommissioning. 11. Clean the outside of the CalfRail with a damp cloth. Clean all areas that are not reached by the cleaning program. NOTICE! Damage caused by high-pressure cleaner.
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Page 62: Permanent Shutdown
Consult your yellow pages or your waste disposal company to learn about the regula- tions that apply to you. In the appendix of the operating manual, you will find a list of the materials used in the CalfRail (see 9.2 "Materials list" - 73). - Page 63 , to select the desired heating system. 11.10. In Unit 1, select the desired CalfRail to be allocated to the heating system. 11.11. If two CalfRails are to be allocated to one heating system, select the desired CalfRail in Unit 2.
- Page 64 22. Check the settings of the CalfRail (see 3.10 "Testing the CalfRail" - 35) and adjust them if necessary. 23. Check the settings of the feeding (see 5. "Feeding" - 45).
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Page 65: Faults And Warnings
To rectify the fault, proceed as follows: 1. Open the control unit of the CalfRail unit. 2. Press the round button (S2) on the main board of the CalfRail unit in order to activate search mode. 3. Wait until the green LED (H4) is flashing 10 times per second. -
Page 66: Calfrail Pivot Arm
2. In pivot arm right/left?, press and check whether the CalfRail detects the positions. Note: The CalfRail may not be rotated more than 180°. Instead, it must be rotated back to the starting position by confirming movement in the opposite direction. -
Page 67: Cr Feeding/Flushing
8.1.5 CR feeding/flushing During a flushing run or when heating the CalfRail, if water is not pumped through the hose with- in a certain amount of time (usually max. 2 minutes), the CR feeding/flushing warning ap- pears on the display. -
Page 68: Heating System Temperature
Faults and warnings 1. Check whether the water level in the expansion vessel of the heating system is between the Min. and Max. markings and add water as necessary. 2. Confirm CR heat. water shortage with and once the fault has been rectified, delete the warning. -
Page 69: Heating Sensor
Faults and warnings 5. Close the metal cover again. 6. Reattach the cover to the heating system. 7. Reconnect the mains plug. 8.1.10 Heating sensor If a temperature sensor or float switch short circuits, or the sensors are not connected correctly, the CR heat. -
Page 70: Diagnosis
Checking stations In this menu you can perform the following settings: • In No. ‡ , you can check the box number at which the CalfRail has currently stopped. The parking position is number 0. • In Travel to parking?, you can move the CalfRail unit to the parking position. - Page 71 Faults and warnings • In Search?, you can search for the registered CalfRail. • In CR water heating system, you can control the settings of the heating system. • In Allocation, you can see which heating system is allocated. •...
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Page 72: Appendix
Appendix 9. Appendix Note: You must carefully read and comply with the operating manual and the safety instruc- tions, in particular, before every initial commissioning and recommissioning of the CalfRail. Initial commissioning checklist Initial commissioning Check whether the carrier system is correctly installed and is situated at a height of at least 2.20 meters above floor level. -
Page 73: Materials List
Enter the correction days. Define plans. Monitor first feeding. Train young calves Materials list The following materials are used in the CalfRail, among others: • V2A, V4A • Plastics: TPE, silicone, PVC, NBR, ABS, PUR, PA, PC, POM, PP, CR, EPDM, PE •... -
Page 74: Care And Maintenance Schedule / Routine Work
Note: Repair work and the replacement of wearing parts on or in the CalfRail, with the exception of the teats, may be carried out only by a service technician. -
Page 75: Maintenance Intervals And Activities
Appendix 9.3.2 Maintenance intervals and activities Care/maintenance interval Daily Week- months months Suction hose • Replace all milk hoses from the automatic feeder to the teat. Servopump • Replace the pump hose. Suction sensor • Disassemble and clean the suction sensor, replace the diaphragms. Return valve ... -
Page 76: Shutdown Checklist
Drain residual water from the pump of the teat cleaner, if present, and remove the hose from the water tank. The registration of the CalfRail must be canceled in setup for the automatic feeder. Disconnect the mains plug. Disconnect the suction hose from the automatic feeder and dispose of it. -
Page 77: Index
Activating the heating system 32 Installation prerequisites Attaching magnets 33 Automatic feeder 15 Calibration 37 Installation requirements 14 Cleaning the CalfRail 38 Igloo/Calf box 15 Connecting the CAN bus 28 Running rail 15 Connecting the electricity 28 Structural integrity of carrier system 15... - Page 78 Monitoring the first feeding 48 CalfRail 65 Move feeding forward 50 CalfRail pivot arm 66 Move to park 36 CalfRail travel to box 66 CalfRail travel to parking 66 name plate 13 CR feeding/flushing 67 Number assignment 39 CR heating system heating system sensor...
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