GEA Farm Technologies

Milking parlour feeding system

DairyFeed C
PF 21 Basic
- Herring bone milking parlours
Instruction Manual / Installation Instructions / Parts List
(Translation of the original instructions)
7300-9001-007
11-2009

GEA Farm Technologies - The right choice.

 Contents
1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Information on the instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Manufacturer’s address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Manufacturer’s declaration / Installation declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Owner’s obligation of care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Explanation of the safety symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Correct applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Changes to the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Design of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6 Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.1 DPSetup default settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Safety instructions for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Checking what has been delivered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Information on disposing of packing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1 Special personnel qualification required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Safety instructions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Assembly preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4 Environmental prerequisites for setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.5 Installation of the feeding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.5.1 Installation of feeding system with accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.5.2 Installation of feed bowl complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.5.3 Installation of electrical controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.5.4 Installation of power supply for feed dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.5.5 Installation of DPNet power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.6 Installing the gate controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.7 Installation of StandBy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.8 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.9 Information on disposing of installation material after installation is finished. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6 Initial Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1 Special personnel qualification required for initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 Safety instructions for initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3 DairyPlan settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.1 Feeder set-up ”General” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.3.2 Feeder Setup ”Motor 1-3 / Motor 4-6” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3.3 Feed setting ”DPNet feeding at the milking place” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.4 Specific settings for individual milking places (eg time interval, portion weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.3.5 Transfer settings to DPNet equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.4 Determining portion weight using DairyPlan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.5 Checks before initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.6 Checks after initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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 7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.1 Special personnel qualification required for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2 Safety instructions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.3 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.4 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

8 Operating faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.1 Special personnel qualification required for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.2 Safety instructions for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.3 Fault messages and troubleshooting help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.1 Special personnel qualification required for maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.2 Safety instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.3 Scheduled maintenance responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.3.1 Feed dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.3.2 Feed dropper tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.4 Scheduled maintenance responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

10 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.1 Special personnel qualification required for decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.2 Safety instructions for decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.3 Temporary decomissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

11 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.1 Feed dispenser with accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.2 Feed dispenser with accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.3 Feed bowl complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.4 Electrical control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.5 Gate control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11.6 Animal Identification System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12.1 Specialist terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12.2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7300-9001-007
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Preface
Information on the instructions

1 Preface
1.1 Information on the instructions

These instructions are supplied with the product.

D They are designed modular and are only in relation to the mentioned
product.
For details of the components which are relevant to the product, please refer
to the appropriate manuals.
This applies especially for safety information!
D They should be kept close at hand and remain with the equipment even if
the equipment is sold.
D This manual is not subject to an amendment service. The most recent
version at any time can be obtained through the technical dealer or directly
from the manufacturer.
The manufacturer reserves the right to make changes due to technical
developments in the data and images given in this manual.
Reproductions, translations and copies of any kind, even of extracts, require
written authorization from the manufacturer.
Abbreviations, units, specialist terms, special names or specialist terminology
are explained in more detail in the ”Appendix”.

Pictograms used

Note!
This pictogram indicates information that will help towards a better
understanding of the working processes.

A correction bar in the margin indicates changes to the previous

edition.

This pictogram refers to another document or chapter.

If a manual number is given, the middle 4 figures indicate the language, as

follows:
Language Language Language
-9000- German -9013- Dutch -9032- Serbian
-9001- English (Great -9015- English (America) -9034- Slovakian
Britain)
-9002- French (France) -9016- Polish -9036- Lithuanian
-9003- Italian -9021- Danish -9038- Portuguese (Brazil)
-9004- Romanian -9022- Hungarian -9039- French (Canada)
-9005- Spanish -9023- Czech -9040- Latvian
-9007- Swedish -9024- Finnish -9041- Estonian
-9008- Norwegian -9025- Croatian -9043- Spanish (North
America)
-9009- Russian -9027- Bulgarian
-9010- Greek -9029- Slovene
Possibly not all above-mentioned languages are available.

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 Preface
Customer service

1.2 Manufacturer’s address

GEA WestfaliaSurge Deutschland GmbH

Siemensstraße 25-27
D-59199 Bönen (Germany)
+49 (0) 2383 / 93-70
+49 (0) 2383 / 93-80
contact@gea-farmtechnologies.com
www.gea-farmtechnologies.com

1.3 Customer service

If necessary, please contact your nearest authorised technical dealer.

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Preface
Manufacturer’s declaration / Installation declaration

1.4 Manufacturer’s declaration / Installation declaration

Valid until 28.12.2009: Valid from 29.12.2009:
Manufacturer’s declaration in accordance with the Installation declaration in accordance with the
machinery directive: machinery directive:
D 98/37/EC- Annex:II B D 2006/42/EC- Annex:II B

Manufacturer: GEA WestfaliaSurge Deutschland GmbH

Siemensstraße 25-27
D-59199 Bönen (Germany)
Product category: Feeding in the milking parlour
Name / Model: DairyFeed C - PF 21 Basic
The named product is in conformity with the requirements of the following European directives:
98/37/EC Machinery Directive (valid until 28.12.2009)
2006/42/EC Machinery Directive (valid from 29.12.2009)
2006/95/EC Low voltage guideline
2004/108/EC Electromagnetic compatibility directive
Conformity with the requirements of these directives is testified by complete adherence to the following
standards:

D Harmonized European standards

EN 349 Minimum distances to prevent pinching parts of the body
EN 1088 Interlock equipment on conjunction with isolating protective equipment
EN 12100-1 Machine safety, basic terms, general design guidelines.
Part 1: Basic terminology, methods
EN 12100-2 Machine safety, basic terms, general design guidelines.
Part 2: Technical guidelines and specifications
EN ISO 13857 Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs
EN ISO 14121-1 Safety of machinery - Risk assessment - Part 1: Principles
EN 60204 Electrical equipment of machines
EN 60034-5 Rotating electrical machines
Part 5: Classification of types of protection provided by housings for rotating machines
EN 60335-1 Safety of electrical appliances for household use and similar purposes.
Part 1: General requirements
EN 61000-6-1 Electromagnetic compatibility (EMC)
Basic technical standard on testing the immunity of devices in the domestic, business and commercial field
EN 61000-6-2 Electromagnetic compatibility (EMC)
Basic technical standard on testing the immunity of devices in industry
EN 61000-6-3 Electromagnetic compatibility (EMC)
Basic technical standard on measuring the interference emitted by devices in the domestic, business and
commercial field
EN 61000-6-4 Electromagnetic compatibility (EMC)
Basic technical standard on measuring the interference emitted by devices in industry

Attention!
We would point out that commissioning is not permitted until it has been established that the
machine/system in which this product is installed meets the conditions of the directives on which they
are based.
Person responsible for compiling the Josef Schröer
relevant technical documents: GEA WestfaliaSurge GmbH
Siemensstraße 25-27
D-59199 Bönen (Germany)
 +49 (0) 2383 / 93-70
Reinhard Frenser
(Head of Research and
Bönen, 11-2009 Development)
The undersigned is acting by virtue of power of attorney from the management of:
GEA WestfaliaSurge Deutschland GmbH, Siemensstraße 25-27, D-59199 Bönen (Germany)

This declaration certifies compliance with the guidelines indicated, but does not establish any guarantee in the sense of paragraphs
443, 444 BGB.

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 Safety
Owner’s obligation of care

2 Safety
2.1 Owner’s obligation of care
The product has been designed and constructed while taking account of a
potential risk analysis and after careful selection of the harmonized standards
and other technical specifications to be complied with. It therefore guarantees
a maximum level of safety.
This safety can only be achieved in practice on the farm however when all of the
necessary measures have been taken. It is part of the owner’s obligation of care
to plan these measures and check that they are carried out.

In particular, the owner must ensure that

D Anyone who is involved in the operation, maintenance, inspection or
handling of this product in any other way reads and understands this manual
(especially the safety information and warnings).
D A full set of legible instructions is always kept by the product.
D Anyone who has to carry out work on the product can look at the instructions
at any time.
D The instructions in the section entitled ”Basic safety instructions” are
observed.
D The legal requirements are observed.
D Operating instructions are produced for the farm. These must be especially
adapted to the conditions of the business, once again, expressly taking
account of safety aspects.
D The product
- Is only used for its intended purpose.
- Is only used if it is in perfect operating condition and, in particular, the
safety equipment is regularly checked to make sure it is in perfect
operating condition.
D Safety signs, plates and decals, which are attached to the product, must be
replaced immediately if they become illegible or lost.
D All safety or warning instructions applied are not removed and remain
legible.
D Escape routes are marked by means of signs in accordance with national
regulations!
D The personal protective equipment required for personnel carrying out
operation, maintenance and repairs is made available and used.
D Unauthorised persons (e.g. children) are not allowed in hazardous areas
and do not have access to cleaning agents or disinfectants.
D Anyone who has been fitted with an implanted device (eg: pacemaker) is not
allowed to enter indicated no-go areas.
D All personnel who operate, maintain, inspect or otherwise handle this
product read and understand the safety instructions and warnings in this
manual.
D The work to be carried out is performed by a sufficiently qualified person!
Attention!
Particular qualifications are described in the corresponding
chapters!

7300-9001-007
11-2009 7
Safety
Owner’s obligation of care

Work which may only be performed by trained personnel:

- Instruction
- Operation
- Maintenance
- Cleaning

Work which may only be performed by authorized personnel:

- Installation
- Commissioning
- Maintenance
- Troubleshooting
- Repairs
- Shut-down
D These personnel are regularly instructed in all relevant matters of safety at
work and protection of the environment and be familiar with the manual,
particularly the safety instructions it contains.
D Operating personnel who require training only work on the product under the
supervision of an experienced person. The successful completion of training
is to be confirmed in writing.

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 Safety
Basic safety instructions

2.2 Explanation of the safety symbols used

Safety symbols draw attention to the importance of the adjacent text.
The design of the warnings is based on ISO 3864-2 and ANSI535.6.

Safety symbols and signaling word

Attention!
The indication ”N.B.” signals important information on risks for the
product or the environment.

2.3 Basic safety instructions

Note!
There are warnings about specific residual dangers in the
corresponding chapters.

Note!
If the work requires special qualifications, these are described in the
corresponding chapters!
D There are dangers involved in the operation and maintenance of dairy farm
equipment. For your own safety, please carefully read and observe the
instructions (especially the section on ”Safety instructions”)!
D The chapter on ”Technical data” gives the permissible working conditions
(pressure ranges, temperature ranges, airflow quantities etc.) and these
must be observed!
D Do not open or dismantle devices (risk of injury)!
D Do not remove any protective devices (risk of injury)!
D When working with products from other manufacturers always observe the
warnings from the safety data sheets and operating instructions from the
product manufacturer!
D Always keep the control cabinet, all electricity supply units, and electrical
control units closed. Access is only permitted to authorized personnel with
a key or special tool.
D Protect live and high-voltage components against moisture. Under no
circumstances may water jets or high-pressure cleaners be directed at
these!
D In the event of a fire, switch off the power supply at the mains immediately.

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11-2009 9
Safety
Protective devices

2.4 Personnel qualification

Anyone who performs work or activities relating to the Magnum 90 Autorotor
must carefully read the manual and sign to confirm that they have understood
it and will be act accordingly!
In this respect
D Participation in corresponding product training is necessary.
D In principle, all work on electrical equipment and electrical connection work
should only be performed by trained electricians.
D In principle, all welding work should only be performed by trained welders.
In addition, special qualifications are required for the following activities:
D Commissioning
D Operation

Note!
Particular qualifications are described in the corresponding chapters!

2.5 Protective devices

It is not permitted to operate the feeding system, especially the feed motor,
without the components listed below!
D Safety signs, plates and decals, which 220
are attached to the product, must be 230
replaced immediately if they become
30
illegible or lost.
20
170

0020 7071-5746-030 Lid

Protection from nipping,
0030 7160-2459-000 Housing
jamming, ...
0170 7160-2347-000 Cap
Warning sign
0220 0024-6060-000
Automatic start
Warning sign
0230 0024-6063-000
Injury to hands

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 Description
Changes to the product

3 Description
The milking parlour feeding system is used in DPNet milking parlours with
automatic animal identification and DairyPlan.
Minimum requirements for DairyPlan:
- Module P-M

3.1 Correct applications

GEA WestfaliaSurge Deutschland GmbH components have been designed for
use in agricultural (mainly milk producing) operations.
Milking parlour feeding system ”DairyFeed C - PF 21 Basic” is intended only for
automating the feeding process with different feed types in GEA WestfaliaSurge
Deutschland GmbH herringbone milking parlours EuroClass 800/850 and
EuroClass 1200.
Any applications that are not listed here are not part of the intended purpose and
are therefore considered as improper use!
The manufacturer/supplier is not liable for any resulting damage. The user
alone bears the risk.
The following in particular are prohibited:
D use of the milking parlour feeding system in other milking parlours.
Correct use also includes reading the instructions and observing the inspection
and maintenance conditions.
D GEA WestfaliaSurge Deutschland GmbH original parts and accessories
have been designed especially for GEA WestfaliaSurge Deutschland GmbH
components.
D We expressly point out that parts and accessories that we have not supplied
and setting instructions that have not been issued by GEA WestfaliaSurge
Deutschland GmbH will not have been tested or approved by us either.
D the installation or use of such products may have a negative effect on the
specified properties of the GEA WestfaliaSurge Deutschland GmbH
products and may endanger people and animals.
D The manufacturer does not accept any liability for injury to people or
animals, or damage to the GEA WestfaliaSurge Deutschland GmbH
product, caused by the use of non-original parts and accessories or by
incorrect settings.

3.2 Changes to the product

For safety reasons, do not carry out any unauthorized changes!

Any planned changes must be approved in writing by GEA WestfaliaSurge
Deutschland GmbH.
For use in GEA WestfaliaSurge Deutschland GmbH components and
installations, parts and special equipment that have been procured from other
manufacturers must be expressly approved by GEA WestfaliaSurge
Deutschland GmbH, in writing.

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Description
Design of the equipment

3.3 Design of the equipment

1 13 14 16 18

19

17

12

Pos. Components
01 Feed dispenser with accessories
Power Supply Feed dispenser
02 Feed bowl complete
12 Inlet pipe
13 Pipe
14 Cable complete with connector
16 Cable duct
17 Sleeve
18 Electric control unit DPNet
19 Pipe insulating tape
Gate control
Animal identification X
DairyPlan C21 (Module P-M) X
X System components, to be ordered separately.
See the section entitled ”Environmental requirements for set-up”

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 Description
Functional description

3.4 Functional description

D The feeding system enables feeding with 1, 2, 3 or 6 types of feed for each
place in the milking parlour.
D The feed entitlements entered/calculated in DairyPlan will be sent to the
electronic cards for the corresponding milking places after the animals have
been automatically identified by DairyPlan.
D The feed entitlements for the milking time will be dispensed in portions
according to the settings (after an adjustable delay if necessary).
D A basic ration (adjustable) will be dispensed for all the animals.
D The feed quantity dispensed will be sent back to DairyPlan for settlement.
D The feed dispenser is triggered via DPNet.
D It cannot be operated in the milking parlour.

Automatic mode
Below is a description of how the feeding module operates automatically
according to the specifications from DairyPlan.
D At the start of milking, each animal identified will be sent to DairyPlan by the
gate control unit with details of the place number.
A basic ration can be dispensed for places without identification (or unknown
animal) when the entry gate is closed (global setting).
D DairyPlan calculates the feed entitlement for the animal based on the
settings and sends the data to the relevant electronic card for the milking
place.
D The electronic card starts the dispensing of feed in portions (with a delay if
necessary).
D The feed quantity dispensed will be sent back to DairyPlan for entry.
D If a fault should occur during the dispensing of feed, a fault message will be
sent to DairyPlan.
The fault message will be displayed on the PC (DPAlarm) with the place and
motor number.
D Feed operations still running will stop when the exit gate is opened at the
latest.

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Description
Default Settings

3.5 Technical Data

Electrical data

Current
- Maximum capacity, control card outputs 3A
Current consumption
- for each feed dispenser (when the motor starts up) 1 A (2 A)
- Board (DPNet) 0,5 A
Voltage
- Board 24 V
- Feed motor 24 V

3.6 Default Settings

Other settings can be used!

Changes may only be made by authorized personnel!
Check all factory settings before commissioning and adjust in line with the
individual requirements of the installation or animal if necessary.

Attention!
Incorrect settings can have a negative effect on the health of the
animals, the quality of the milk and milking results!

3.6.1 DPSetup default settings

Setting Value
Type of feeding 5
Number of feed motors at the feeding place 1
Portion weight [kg] 0,1
Time to first feed dispensing [sec] 10
Pause time [sec] 2
Feed grade number 1-16
Feed from another silo no
Feeding on ja
Basic ration [kg] (at 1st feeding output in feeding place) 0
Pulse length for other feed motors [s] 0

For a more detailed description, please refer to the section on

”Settings”.

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 Transport
Safety instructions for transport

4 Transport
4.1 Safety instructions for transport

To avoid damage to property and/or life-threatening injury to people during

transport, the following points must always be observed:

Also read the chapter on ”Safety”.

Special transport hazards:

D Projecting sharp edges may cause cuts.
D Suspended loads can fall and then there will be a risk of death - do not stand
underneath suspended loads!
D Parts which are stacked too high can collapse.
D If load suspension devices other than those indicated here are used, this
may lead to serious damage to property and/or life-threatening injury to
people.
D There is a fire hazard due to the highly flammable packing material - open
flames and smoking prohibited!

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11-2009 15
Transport
Checking what has been delivered

4.2 Checking what has been delivered

Check the goods supplied against the packing list enclosed for completeness
and damage.
Part No. Size of parlour
2x 2x 2x 2x 2x 2x 2x 2x
EuroClass 1200 3 4 5 6 7 8 10 12
2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x 2x
EuroClass 800 / 850 5 6 7 8 9 10 11 12 13 14 15 16

Feeding system
7071-5609-010 Feed dispenser with accessories 6 8 10 12 14 16 18 20 22 24 26 28 30 32
7300-5992-000 Power Supply 1 1 1 1 2 2 2 2 2 2 3 3 3 3
Accessories for feeding system
7071-5580-060 Feed bowl complete 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Pipe (up to ceiling height 2500)
7071-5627-440 6 8 10 12 14 16 18 20 22 24 26 28 30 32
200x4,3x500
Pipe (up to ceiling height 3000)
7071-5627-450 6 8 10 12 14 16 18 20 22 24 26 28 30 32
200x4,3x1000
7019-5665-030 Inlet pipe 6 8 10 12 14 16 18 20 22 24 26 28 30 32
7071-5378-010 Sleeve, rubber 6 8 10 12 14 16 18 20 22 24 26 28 30 32
7071-5378-030 Sleeve, plastic 6 8 10 12 14 16 18 20 22 24 26 28 30 32
0004-2829-818 Pipe insulating tape 4 6 7 8 10 11 12 14 15 16 17 19 20 22
DPNet parts
Electric control unit
7071-5900-040 2 2 2 2 4 4 4 4 4 4 6 6 6 6
DPNet
Cable complete with connector
7118-6933-450 (only EuroClass 1200) 2 4 4 4 6 8
6m
Power supply compl.
7300-5991-020 1 1 1 1 1 1 1 1 1 1 1 1 1 1
DPNet 27V, 10A
Fuse strip
7300-9047-000 1 1 1 1
DPNet
Electrical controller, compl.
7300-2680-060 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Standby
7300-9047-060 FT terminator 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Cable/cable duct
Cable (piece goods) 10 10 10 10 12 12 13 13
0005-0421-018 45 50 45 45 90 95
H 05 VV 2x2.5 0 5 5 5 5 5 0 0
Cable (piece goods) 10 10 10
0005-3999-048 45 50 40 40 85 90 95
DPNet 2x0,5+2x1.0 0 0 0
Cable
0005-3999-040 1 1 1 1
DPNet 2x0,5+2x1.0, 150m
Cable duct
7071-5845-010 6 7 6 6 7 8 8 8 8 8 8 10 10 10
2.6m
Gate control
Electrical gate control unit
7070-5900-070 1 1 1 1 1 1 1 1 1 1 1 1 1 1
(for 4 gates)
Pushbutton complete
7065-5910-000 (only for feeding system PF 4 4 4 4 4 4 4 4 4 4 4 4 4 4
21Basic)
Oelflex cable (piece goods)
0005-0420-048 26 32 36 40 46 50 56 60 64 68 76 80 84 88
2 x 0.75
Cable (piece goods)
0005-3999-048 34 35 36 37 38 40 41 42 43 44 45 47 49 51
DPNet 2x1 + 2x0.5

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 Installation
Safety instructions for installation

4.3 Storage conditions

D Storage temperature: - 10 to + 55 degrees Celsius

When storing the goods supplied, the location must provide protection
against:
D Moisture
D External damage (jolts, knocks, rodents, insects, . . . )

4.4 Information on disposing of packing material

After unpacking, the packing material is to be handled properly and disposed
of carefully in accordance with the valid local regulations on waste disposal and
utilisation.

5 Installation
If necessary, please contact your nearest authorised technical dealer.

5.1 Special personnel qualification required for installation

Installation may only be carried out by specially qualified personnel in

accordance with the safety instructions.

Also see the section on ”Personnel qualification”

5.2 Safety instructions for installation

To prevent damage to property and/or life-threatening injury to people during
installation, the following points must always be observed:
D Before installation, look for any damage caused during transport. Do not use
damaged components!
D In the area where the animals stand, all exposed conductive parts of
electrical equipment (components, housing, etc.) and any external
conductive parts which animals could come into contact with must be
connected to each other and to the PE conductor of the installation by
means of additional equipotential bonding.
D In the case of devices with 24 V direct voltage, the power supplies stipulated
by GEA WestfaliaSurge Deutschland GmbH and approved for the devices
must be used, because the safety of personnel and of the building cannot
be ensured otherwise.

Also read the chapter on ”Safety”.

7300-9001-007
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Installation
Safety instructions for installation

Special hazards during installation:

D Injury can be caused by the electrical current from live cable ends and
components.
D Lines which are not laid properly (eg bending radius too small) can cause
scorching and electrical fires.
If the bending radius is too small, it should be removed.
D Incorrect connection or electrostatic processes can cause damage to
electronic components.
Note!
Only touch the edge of the printed circuit board and avoid static
caused for example by clothing.

D Before working on electrical installations or equipment (components,

housings, etc.), they are to be disconnected from the mains.
Secure main switches or emergency stop switches with a padlock to ensure
they cannot be switched back on again and put up a warning sign.
D Components which have not been removed correctly may fall off or twist.
D Parts loosely placed on top of each other can slip and fall off.
D Components with sharp edges which are still open and accessible represent
a source of injury.
D Faulty pressure pipes and connections can lead to serious physical injury.

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 Installation
Environmental prerequisites for setting up

5.3 Assembly preparations

Necessary documents

Walk-through identification with VC4/3 Single

7160 - 90 . . - 408 2Plus in herringbone and Side-By-Side milking
parlours

7300 - 90 . . - 004 DPNet networks / DPNet power supply

7300 - 90 . . - 005 DPNet Power Supply - Milking Parlour Feeding

7300 - 90 . . - 001 Electronic control unit DPNet Standby II

Installation time / installation personnel

The following tasks should be performed by trained and experienced installation

personnel equipped with suitable tools.

Installation
Installation time
personnel
Installation stage per fitter
required
(hours)
(No. of people)
Feeding system for milking parlour
D Installation of feed bowl and frame (for each
0,5 1
place)
D Installation of electronic card with 6 feed
3 1
dispensers, incl. cable duct
D Electrical connection of electronic card with 6
2 1
feed dispensers

5.4 Environmental prerequisites for setting up

Install the product in a well-aerated and well-ventilated, frost-free room.
D Operating temperature, electronic card: - 10 to + 55 degrees Celsius

DairyPlan

Complete installation of the software, including module P-M.

For further information on the subject, see the manual

7160 - 90 . . - 520 Operation of DairyPlan C21
7160 - 90 . . - 521 Installation of DairyPlan C21

Animal identification

Complete installation of the animal identification system.

For further information on the subject, see the manual

7071 - 90 . . - 048 DPNet gate controller for group milking parlours

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Installation
Installation of the feeding system

5.5 Installation of the feeding system

D Install the feeding system as shown in the installation diagram.
D Lay the cable in the cable duct.

13 14 16 18 1000/2000 C-D
1 300 180

19

17

12

Assembly material
Pos. Part No. Description
Feeding system
01 7071-5609-010 Feed dispenser with accessories
7300-5992-000 Power Supply
Accessories for feeding system
02 7071-5580-060 Feed bowl complete
13 7071-5627-440 Pipe (up to ceiling height 2500) 200x4,3x500
13 7071-5627-450 Pipe (up to ceiling height 3000) 200x4,3x1000
12 7019-5665-030 Inlet pipe
17 7071-5378-010 Sleeve Rubber
17 7071-5378-030 Sleeve plastic
19 0004-2829-818 Pipe insulating tape
DPNet parts
18 7071-5900-040 Electric control unit DPNet
14 7160-6933-150 Cable complete with connector 2m
14 7118-6933-450 Cable complete with connector 6m
7300-5991-020 Power supply compl. DPNet 27V, 10A
7300-9047-000 Fuse strip DPNet
7300-2680-060 Electrical controller, compl. Standby
7300-9047-060 FT terminator
Cable/cable duct
0005-0421-018 Cable (piece goods) H 05 VV 2x2.5
15 0005-3999-048 Cable (piece goods) DPNet 2x0,5+2x1.0
15 0005-3999-040 Cable DPNet 2x0,5+2x1.0, 150m
16 7071-5845-010 Cable duct 2.6m

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 Installation
Installation of the feeding system

5.5.1 Installation of feeding system with accessories

Dichtring als
Montagehilfe

Assembly material

Pos. Part No. Description

7071-5609-010 Feed dispenser with accessories
001 7160-5610-100 Feed dispenser, compl. 160ml
002 0018-5825-810 Spiral hose 102x600
003 7071-5576-020 Pipe compl.
004 Pipe 200x3 according to job
005 7071-2165-010 Set of fasteners

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Installation
Installation of the feeding system

5.5.2 Installation of feed bowl complete

Pos. Part No. Description

7071-5580-060 Feed bowl complete
0010 7160-5518-010 Feed bowl
0020 7071-9901-080 Set of accessories

Pos. Part No. Description

7071-9901-080 Set of accessories
0010 7071-5453-650 Sheet
0020 7071-2777-000 Plug
0030 0019-6901-300 Hexagon head bolt ISO 4017 M8x16
0040 0013-0278-300 Hexagon head nut ISO 4032 M8
0070 0019-5578-300 Truss-head screw DIN 603 M8x40-MU

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 Installation
Installation of the feeding system

5.5.3 Installation of electrical controller

D Install the electrical controller (18) in the middle between the assigned feed
dispensers (maximum of 6).
Electric control unit

20

10

Pos. Part No. Description

7071-5900-040 Electric control unit
0010 7300-2680-010 Electronic control unit 150x200x75
0020 7300-2165-020 Set of fasteners Feeder, DPNet herringbone
0030 7118-6933-450 Cable complete Dispenser motor/connector; 6m

Set of fasteners

Pos. Part No. Description

7300-2165-020 Set of fasteners Feeder, DPNet herringbone
0010 7300-2853-010 Retaining plate DPNet controller
0020 0019-3362-300 Wood screw DIN 96 4x35
0030 0026-2302-890 Anchor Insert 6 x 30
0040 0019-2376-300 Cylindrical head screw ISO 1207 M 4 x 16
0050 0013-0274-300 Hexagon head nut ISO 4032 M4
0060 0026-1860-840 Washer 3,9x10x3
0070 0026-1362-300 Washer DIN 125 4,3

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Installation
Installation of StandBy

5.5.4 Installation of power supply for feed dispenser

For further information on the subject, see the manual

DPNet Power Supply - Milking Parlour Feeding
7300 - 90 . . - 005

Assembly material
7300-5992-000 Power Supply

5.5.5 Installation of DPNet power supply

For further information on the subject, see the manual

DPNet networks / DPNet power supply
7300 - 90 . . - 004

Assembly material
7300-5991-020 Power supply compl. DPNet 27V, 10A
7300-9047-000 Fuse strip DPNet
7300-9047-060 FT terminator

5.6 Installing the gate controller

For further information on the subject, see the manual

DPNet gate controller for group milking parlours
7071 - 90 . . - 048

Assembly material
Gate control
7070-5900-070 Electrical gate control unit (for 4 gates)
(only for feeding system
7065-5910-000 Pushbutton complete
PF 21Basic)
0005-0420-048 Oelflex cable (piece goods) 2 x 0.75
0005-3999-048 Cable (piece goods) DPNet 2x1 + 2x0.5

5.7 Installation of StandBy

For further information on the subject, see the manual

Electronic control unit DPNet Standby II
7300 - 90 . . - 001

Assembly material
7300-2680-060 Electrical controller, compl. Standby

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 Installation
Electrical connection

5.8 Electrical connection

Note!
Electrical installation work is to be carried out in accordance with:
D EN 60204, Point 14 (Electrical equipment on machines).
D VDE 0100 (Regulations on the erection of power installations)
D or corresponding country-specific regulations.

D Carry out the electrical connection as shown in the installation plan.

D The feed dispenser is supplied from a separate 24 V power supply.

For further information on the subject, see the manual

DPNet Power Supply - Milking Parlour Feeding
7300-90 . . -005

Legend to the installation plans

1 Transceiver left / right
2 Supply voltage 100-120 VAC/208-240 VAC
3 StandBy
4 Gate control
5 PC
6 Power Supply DPNet 10 A DC
7 Transceiver
Fuse bar
8 DPNet
9 Terminator
Motors 24 VDC, 18 A (for a maximum of 12
10 Power Supply
motors and 2 x feed controllers)
11 Automatic circuit-breaker 10 A
12 Fuse F1, 8 AT
13 Mains connection 230 V AC
Milking place, LH/RH side of the milking
14 M feeder controller
parlour
Connect a maximum of 4 DPNet feed controllers in series with an output from the
15
DPNet fuse block
br brown
bl blue
ge yellow
gn green
gr grey
rt red
sw black
ws white

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 Installation
Electrical connection

Installation plan ”Connection to DPNet”

7160-3350-650

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 Installation
Electrical connection

7160-3350-650

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 Installation
Information on disposing of installation material after installation is finished.

Installation plan ”Connection of feed motors”

14

18

10

6 Power Supply DPNet 10 A DC

Motors 24 VDC, 18 A (for a maximum of 12
10 Power Supply
motors and 2 x feed controllers)
Milking place, LH/RH side of the milking
14 Electronics card
parlour
18 Motor

5.9 Information on disposing of installation material after installation is finished.

Handle unused installation material properly and dispose in accordance with

current valid local regulations on waste disposal and utilization.

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 Initial Commissioning
Safety instructions for initial commissioning

6 Initial Commissioning
6.1 Special personnel qualification required for initial commissioning

Initial commissioning may only be performed by specially qualified personnel in

accordance with the safety instructions.
All settings that have to be made (e.g on control units) should always be
performed by people who have been suitably trained/instructed by GEA
WestfaliaSurge Deutschland GmbH.

Also see the section on ”Personnel qualification”

6.2 Safety instructions for initial commissioning

To prevent damage to property and/or life-threatening injury to people when
commissioning for the first time, the following points must always be observed:
D Before starting for the first time, check that all tools and other parts have
been removed from the danger area.
D Activate all safety equipment and emergency stop circuits before
commissioning.
D Check the direction of rotation of the motor before commissioning.
D Check that all of the operating media are suitable, present and connected.

Also read the chapter on ”Safety”.

Special risks involved in initial commissioning:

D Incorrectly wired connections may destroy electrical/electronic
components.
D Connections that have been mixed up will cause the motor to run in the
wrong direction - which may cause serious damage to property and/or
life-threatening injury to people.
D Electrostatic processes/interference may endanger electronic components
and also lead to software faults and data loss. Back up data regularly
therefore.
Note!
Only touch the edge of the printed circuit board and avoid static
caused for example by clothing.

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Initial Commissioning
DairyPlan settings

6.3 DairyPlan settings

Attention!
Make a backup before changing the settings!

Attention!
Make a backup before changing the settings!
During the set-up work:
D Produce a report on the settings
D Highlight settings that are individual to the farm
The settings for the feeding system are entered in DairyPlan using the DPSetup
Wizard.

For more information on feeding settings see the on-line help in the
”DairyPlan” program or the ”DairyPlan” manual
7160 - 90 . . - 520 Operation of DairyPlan C21
7160 - 90 . . - 521 Installation of DairyPlan C21

D The gate controller is to be set as displayed:

D Set the technical characteristics of the milking parlour:

- Activate feeding
- Determine the number of feed motors at the feeding place

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 Initial Commissioning
DairyPlan settings

D The only permitted type of identification is DPNet identification.

Attention!
Any change to the settings in the feeding system interactive window
must be sent to the DPNet devices via DPNetInstall!

See the section entitled:

Transferring settings to DPNet devices

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Initial Commissioning
DairyPlan settings

6.3.1 Feeder set-up ”General”

2
4

3
4

1 Name of feeder
2 Type of feeding
Set the type of feeding to ”5 DPNet feeding at the milking place (PF21)”
using the Setup Wizard.
3 Number of feed motors at the feeding place
Specify the number of motors to be controlled for each feeding place
(1,2,3,6).
4 Change the setting (without Wizard).

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 Initial Commissioning
DairyPlan settings

6.3.2 Feeder Setup ”Motor 1-3 / Motor 4-6”

C
B
D

A Feed grade number

- Setting ”Milking parlour”
- Feed from another silo

B Set milking places individually

Enter the settings for the selected milking places.
(see C + D)
C Portion weights and time intervals by means of group entry
Global standard setting for all electronic cards.
D Time to first dispensing of feed by means of group entry

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Initial Commissioning
DairyPlan settings

C Portion weights and time intervals by means of group entry

Attention!
The wrong setting for the amount of feed can have a negative effect
on animal health!
Risk of over-feeding!

Standard setting for portion weight and time interval for all motors and electronic
cards. (Normal case)

C1
C2

C1 Portion weight [kg]

The number of portions is calculated individually from the portion weight.
Enter the portion weight determined here.
See section on ”Determining portion weight”.

C2 Pause time [sec]

The time set here is the waiting time between the output of the individual
portions.
E Transfer settings.

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 Initial Commissioning
DairyPlan settings

D Time to first dispensing of feed by means of group entry

D1

D2
D3

D1 Time to first feed dispensing [sec]

The first dispensing of feed will be delayed by this length of time.
- The time will start when the animal is identified.
- The feed will be dispensed at the end of this period of time.
Minimum setting: ”0.1”. Corresponds to immediate dispensing of
feed.
- Maximum time (for place 1 in the row): 60 seconds

The possible settings for the time are:

D2 - The same at each place within the row

or
D3 - For each stall from the animal entrance to exit increased by (the
length of time set).
E Transfer settings.

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Initial Commissioning
DairyPlan settings

6.3.3 Feed setting ”DPNet feeding at the milking place”

2
Feeding with Metatron 21
When feed output starts
0: Feed output delayed after identification

Feed output over the time spent at the milking

place

Feed output stops when milking has ended for all animals in the row

0 Proportion of feed that is delivered on identification

(only with a certain setting for ”When feed output starts”)

1 Feeding on
Activates the feed controller

2 Basic ration [kg] (at 1st feeding output in feeding place)

- It will always be dispensed to each animal, regardless of the feed
entitlement or the extent of the current feed entitlement available.
(Minimum feed quantity)
- It refers to the feed types that are provided at the first feed motor in
the milking place.
- Setting range: 0.1-9.9 kg.
- The feed quantity dispensed will be settled in DairyPlan.

3 Impulse duration for special feed motors:

If there are no WestfaliaSurge feed motors installed in a milking parlour, the
feed portion can be defined using the operating time of the feed motors
which can be entered here.
For each feed portion an impulse signal is given for the set duration.
The ”break time” then starts to run.
”0.0” must be set if WestfaliaSurge feed motors are used so that standard
motor control (contact disc) and motor monitoring is used.
Important:
The motor speed is only monitored if the value is set to 0.0. Motor current
is monitored regardless of this setting.

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 Initial Commissioning
DairyPlan settings

6.3.4 Specific settings for individual milking places (eg time interval, portion weight)

DPSetup-> Equipment-> other DPNet components -> Equipment setting

D Select DPNet component ”Feeding”
D Select feed output
D Changing settings

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Initial Commissioning
DairyPlan settings

6.3.5 Transfer settings to DPNet equipment

Attention!
Settings must be updated each time a change is made!
(Applies to all settings which are entered in the interactive window for
the milking parlour feeding system)
The settings will be transferred to the DPNet equipment via DPNetInstall.
D Start DPNetInstall
After setting up the installation using the Wizard (including setting up the
feeding system), DPNetInstall will start automatically.

D Do you wish to scan the network?

Determine settings in DairyPlan and the DPNet equipment.

- Yes if you have already installed a network.

- No if you are installing it for the first time.
Then carry out the network installation first of all.

For further information on the subject, see the manual

DPNet networks / DPNet power supply
7300-90 . . -004

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 Initial Commissioning
DairyPlan settings

D Viewing the settings determined

If a difference is detected between DairyPlan and DPNet equipment
settings, then the following window will appear:
DairyPlan settings DPNet equipment settings

A A

B B

A Changing between views

- DairyPlan
- DPNet device

D Transferring the new settings to the device shown.

B - Click on ”DP”
D Message on completion of the scan and data transfer.

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Initial Commissioning
Determining portion weight using DairyPlan

6.4 Determining portion weight using DairyPlan

The weight of a feed type may vary from delivery to delivery.
In order to ensure that DairyPlan calculates the feed quantities correctly, the
portion weight must be determined after each new delivery of feed.
D Make sure that there is feed in the feed container.
D Start the Feed Calibration Wizard
”DPProcessControl -> Extras ->”
D Select the milking place for calibration.

D Dispense test portion to motor.

1 Motor ”X”
2 All motors together

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 Initial Commissioning
Determining portion weight using DairyPlan

D Specify the number of test portions to be dispensed.

D Start to dispense the test portion.

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Initial Commissioning
Determining portion weight using DairyPlan

D Weigh out the total weight of the test portions dispensed and enter the value
under ”Reference weight”.
The average portion weight will be calculated automatically.

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 Initial Commissioning
Checks after initial commissioning

6.5 Checks before initial commissioning

D Check wiring
D Switch on power supply
D Determining the Weight of the Portion

For more information on this subject see section on

Determining portion weight using DairyPlan

6.6 Checks after initial commissioning

D Compare feed quantities dispensed with settings.

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Operation
Safety instructions for operation

7 Operation
7.1 Special personnel qualification required for operation

Operation may only be performed by specially qualified personnel in

accordance with the safety instructions.
The operator may only carry out work on the AutoRotor Global 90/70
Automation package if he has been trained, instructed and authorized to do so
by the owner.
- Principles of the functions of feeding and DairyPlan

7.2 Safety instructions for operation

In order to prevent damage to property and/or life-threatening injury to people
when operating the equipment, the following points must always be observed:
D The product may only be used in accordance with the application for which
it was designed.
D Before switching on, find out what to do in an emergency.

Also read the chapter on ”Safety”.

Before operating, make sure you are adequately familiar with the following:
D the operating and control elements of the product
D The method of operation of the product
D what to do in an emergency

Mechanical hazards
D Never reach into the feed nozzle when the screw is in operation - risk of
crushing, shearing, cutting, being caught, dragged, pulled in, trapped, ...

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 Operation
Operating elements

7.3 Operating elements

Electronics card

Operating elements on the electronic card ”Milking parlour feeding system”

Servici
ng
Reset

Key Function
Reset Reboot the software
Servicing Mains installation (see installation manual 7160-90 . . -521
”DairyPlan C21”)

LED lights up if
Power Power supply connected
Service ”Service” button has been operated
TX data is being sent
RX data is being received
WINK Flashes when network installation has been completed

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Operation
Operating

7.4 Operating
If automatic mode has to be entered, this is possible as described below:

Checking and entering feed data

D Feed data are entered and reviewd via DairyPlan.

For further information on the subject, see the manual

7160 - 90 . . - 520 Operation of DairyPlan C21

Feeding an animal not to be milked (eg cow dry)

D It is not possible to enter or change the feed entitlement in the milking
parlour!
D If the basic ration is activated, the animal will receive at least this amount of
feed in any case.
D If the basic ration is deactivated, the animal will only be fed if a feed
entitlement is also entered.

No dispensing of the basic ration at unoccupied milking places

(incomplete row/last row)
D Do not close the entry gate manually.
D Milking
D Release animals at the end of milking.
D When the exit gate is opened, the basic ration not dispensed for unoccupied
milking places will be deleted.

For more information on this subject see section on

Feed settings ”DPNet feeding at the milking place”

Dispensing the basic ration for unidentified or unknown animals

D Close the entry gate manually.
D Basic ration will be dispensed (if activated).

For more information on this subject see section on

Feed settings ”DPNet feeding at the milking place”

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 Operating faults
Safety instructions for troubleshooting

8 Operating faults
If necessary, please contact your nearest authorised technical dealer.

8.1 Special personnel qualification required for troubleshooting

Troubleshooting may only be performed by specially qualified personnel in

accordance with the safety instructions.

Also see the section on ”Personnel qualification”

8.2 Safety instructions for troubleshooting

In order to prevent damage to property and/or life-threatening injury to people
during troubleshooting operations, the following points must always be
observed:
D Switch off power supply for DPNet and feed dispensers
D Ensure that safe disconnection can be carried out by a second person at any
time.
D Secure the range of action for any moving parts.

Also read the chapter on ”Safety”.

Special dangers involved in troubleshooting:

D If energy sources are switched on unintentionally this may cause serious
damage to property or life-threatening injury to people.
D Unsecured manual operation means a higher risk of injury due to
crushing/shearing/being pulled in/...
D Electrostatic processes may damage electronic components.
Note!
Only touch the edge of the printed circuit board and avoid static
caused for example by clothing.

D Special dangers may arise from direct contact with the animal (crushing, risk
of being kicked or trodden on)

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Operating faults
Fault messages and troubleshooting help

8.3 Fault messages and troubleshooting help

Fault reported Possible cause Remedy

Animal is given the wrong D Wrong animal identified D Check data,
feed quantity D Data in DP incorrect D check identification
Warning message Fault in feed dispensing Check wiring, feed motors
and feed dispenser power
supply

Fault message on the PC (DPAlarm)

Double click on message and the window

”Message Details” will open

Fault reported Possible cause Remedy

Milking parlour feeding D no feedback or incorrect D Check switching disk
system, motor problem feedback from the D Test cabling and
”Time expired” switching disk
connections
Milking place ”X”, motor ”X”
D Cabling not correct
Milking parlour feeding D Motor current D Check whether or not the
system, motor problem consumption too motor start-up is blocked.
”Hardware fault” high/too low
D Check the power supply
Milking place ”X”, motor ”X”
D Cabling not correct for the motor
D Test cabling and
connections
If necessary both faults will be displayed in a single message.

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 Maintenance
Safety instructions for maintenance

9 Maintenance
If necessary, please contact your nearest authorised technical dealer.

9.1 Special personnel qualification required for maintenance work

Maintenance work may only be performed by specially qualified personnel in

accordance with the safety instructions.

Also see the section on ”Personnel qualification”

9.2 Safety instructions for maintenance

In order to prevent damage to property and/or life-threatening injury to people,
the following points must always be observed:
D Immediately replace any components that are not in perfect condition.
D Only use original spare parts / original wearing parts / original accessories.
With parts from other manufacturers that have not been authorized by GEA
WestfaliaSurge Deutschland GmbH, it cannot be guaranteed that they have
been suitably designed and manufactured from the point of view of the
application and safety.

Also read the chapter on ”Safety”.

Before carrying out any maintenance work, make sure of the following:
D The area for the maintenance work and access to the working area should
be secured over a wide area and there should not be any unauthorized
people in the working area.
D Before performing any work on electrical installations or equipment
(components, housing, etc.) switch off all sources of voltage and make sure
they cannot be switched back on again. Put up a sign warning against
switching them back on again.

Obey the safety rules:

- Isolate.
- Ensure devices cannot be switched back on again.
- Verify safe isolation from supply.
- Earth and short circuit if necessary.
- Cover or enclose any nearby live parts.

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Maintenance
Safety instructions for maintenance

Special risks involved in maintenance work:

D Serious damage to property may occur if incorrect replacement or wearing

parts are installed.
D If energy sources are switched on unintentionally, this may lead to serious
bodily injury or damage to property.
D There is a risk of injury from components/tools... with accessible sharp
edges.
D Lines which are not laid properly (eg bending radius too small) can cause
scorching and electrical fires
D Electrostatic processes can cause damage to electronic components.
Note!
Only touch the edge of the printed circuit board and avoid static
caused for example by clothing.

D Connections that have been mixed up will cause the motor to run in the
wrong direction - which may cause serious damage to property and/or
life-threatening injury to people.
D Incorrectly wired connections may destroy electrical/electronic
components.
D Serious injury to personnel or damage to property can be caused if the
incorrect torque is applied when tightening screws.
D Unsecured manual operation means a higher risk of injury due to
crushing/shearing/being pulled in/...
Hazards caused by residual energies:
Note that, even after the product has been switched off or has stopped, there
may still be various forms of energy present, for example:
- in components that run on
- in live electricity lines (from accumulators, capacitors, etc.)

After completing the maintenance work, check the following:

D The installation values set before the work are not altered by the work
(report).
D Any screwed connections that were loosened earlier have been tightened.
D Any guards, cover, lids, sieves, filters, ... that were removed earlier have
been put back again correctly.
D All safety equipment is working perfectly again.
D Have all of the tools, materials and other equipment that were used been
removed from the working area again?
D The working area has been cleaned.
(possibly to remove any fluids or similar substances that came out of the
machine)
D Operation has been checked after maintenance work has been completed
or parts replaced. Produce a full test report if necessary.

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 Maintenance
Scheduled maintenance responsibilities

9.3 Scheduled maintenance responsibilities

D Never clean electrical equipment with water or similar fluids.

9.3.1 Feed dispenser

The feed dispenser should be cleaned as necessary. Encrusted feed residue

must be removed.

Automatic start!
The feed dispenser should be separated from the power supply before
any maintenance or repair work!

Dismantling the feed dispenser

4
Remove lower split pin 2 from the
shaft. The feed dispenser can then
2
be further dismantled and cleaned. 14
Re-assembling the feed 3
dispenser
13 5
Mount upper split pin 2, washer 3,
cover 5, housing 6 on shaft 4. Insert 16
straight pin 7 in the shaft. Then push
dispensing wheel 8 onto the shaft. 6

Place the assembled parts on base 7

10. One of the dispensing chambers
10
of dispensing wheel 8 must coincide
8
with the opening of the base 10 (fine
setting). Base 10, housing 6 and 15
cover 5 must be in the locked 9
position. 3 17
Then fit the lower washer 3 and the 18
2
other split pin 2. Compensate for
any play by placing more washers 11,12
underneath. 1

Note!
In the subsequent test run it must always been ensured that, once the
motor is switched off, the dispensing chamber of dispensing wheel 8
and the opening of the base 10 still coincide with each other.

If this is not the case, re-adjust by loosening fastening nut 15 and turning
toothed wheel 9 until the dispensing chamber and the opening coincide.

9.3.2 Feed dropper tube

Clean the feed dropper tube regularly. If a milled feed is used the insert in the
oval dropper tube may be removed. If pellets are used as the feed, the insert
prevents pellets from jumping out of the feed bowl.

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Maintenance
Scheduled maintenance responsibilities

9.4 Scheduled maintenance responsibilities

Carry out regular checks on electrical equipment:
D Retighten any loose connections
D Replace damaged lines or cables immediately
D Close off any cable openings that are not being used

Attention!
Replace the wearing parts indicated in the chapter on ”Spare parts”
during the regular service after the specified number of hours in
operation!

Attention!
Check all fastening screws after 50 hours of operation to ensure they
are securely seated!

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 Decommissioning
Temporary decomissioning

10 Decommissioning
10.1 Special personnel qualification required for decommissioning

Decommissioning may only be performed by specially qualified personnel in

accordance with the safety instructions.

Also see the section on ”Personnel qualification”

10.2 Safety instructions for decommissioning

In order to prevent damage to property and/or life-threatening injury to people
when decommissioning, the following points must always be observed:
D First of all, make the operating area for decommissioning completely safe.
D Make sure that operating media are disposed of without harming the
environment.

Also read the chapter on ”Safety”.

Special dangers involved in decommissioning:

D Components which have not been removed correctely may fall off or twist.
D There is a risk of injury from open components / tools /.... with sharp edges.

10.3 Temporary decomissioning

Disconnect all parts of the installation from the power supply.

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Spare parts
Feed dispenser with accessories

11 Spare parts
11.1 Feed dispenser with accessories

See assembly materials specified in the section entitled ”Installation”.

11.2 Feed dispenser with accessories

Pos. Part No. Description

7071-5609-010 Feed dispenser with accessories
001 7160-5610-100 Feed dispenser, compl. 160ml
002 0018-5825-810 Spiral hose 102x600
003 7071-5576-020 Pipe compl.
004 Pipe 200x3 according to job
005 7071-2165-010 Set of fasteners

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 Spare parts
Feed dispenser with accessories

Feed dispenser complete

10

160
60
230 230 280
70
150 20

250 80
30
40
50
70
130,140
60

A-A 270
280

180
100

110
300
120

240

290

310

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Spare parts
Feed dispenser with accessories

Pos. Part No. Description

7160-5610-100 Feed dispenser complete
0010 7160-5415-000 Shaft, welded
0020 7071-5746-030 Lid
0030 7160-2459-000 Housing
0040 7160-3498-000 Dispensing wheel 160ml
0050 7160-5771-000 Welded bottom
0060 0026-1006-300 Peg DIN 94 3,2x32
0070 0026-1374-400 Washer DIN 433 17
0080 0026-1089-400 Cylindrical pin ISO 2338 B-6x28
0100 7160-3498-010 Cog wheel M=3 / Z=16
0110 0019-6105-400 Cylindrical head screw ISO 4762 M 6 x 12
0120 0026-1382-300 Washer DIN 125 6,4
0130 0026-2210-400 Washer 17x26x1
0150 0024-5220-000 Decal, ”arrow” 40
0160 0019-9342-300 Self-tapping screw DIN 7981 St3,5x9,5-F-H-Sb
0170 7160-2347-000 Cap
0180 7160-2244-000 Lock nut M8
0220 0024-6060-000 Warning sign Automatic start
0230 0024-6063-000 Warning sign Injury to hands
0240 7160-9926-020 Set of felt rings (25x 0004-3133-830)
0250 0024-5939-000 Sticker No sprayed water
0260 7160-9000-169 Installation instructions
0270 7160-2655-000 Rubber section
0280 7071-5648-030 Rubber plate
24V / 40 upm
0290 7160-2206-079 Drive motor complete
for dispenser (packed)
dispenser motor/connector
0300 7160-6933-150 Cable complete
5x0,5, 2m
0310 7160-5017-010 Sticker

Tube complete

Pos. Part No. Description

7071-5576-020 Pipe compl.
0020 7071-2015-000 Insert
0030 0019-9362-300 Self-tapping screw ST4,8x16-C-H

Set of fasteners

Pos. Part No. Description

7071-2165-010 Set of fasteners
0010 0019-6933-300 Hexagon head bolt ISO 4017 M10 x 20
0020 0013-0279-300 Hexagon head nut ISO 4032 M10
0030 0026-0356-300 Washer 11x27x2
0040 0007-1931-750 Gasket 7,3 x 2,4
0050 0019-5325-050 Wood screw DIN 571 10x70
0060 0026-1348-300 Washer DIN 125 10,5
0070 0026-2305-890 Anchor Insert 12 x 60
0080 0018-3804-300 Hose clip As71-114

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 Spare parts
Electrical control unit

11.3 Feed bowl complete

See assembly materials specified in the section entitled ”Installation”.

11.4 Electrical control unit

See assembly materials specified in the section entitled ”Installation”.

Electronic control unit

20

50

70

10

Pos. Part No. Description

7300-2680-010 Electronic control unit 150x200x75
0010 7300-4444-050 Drilled housing 150x200x75
0020 7300-9047-020 Electronics card DairyFeed
0030 0005-4503-000 Sub-unit terminal block Tmstbp 2,5/ 4-St-5,08
0040 0005-3301-000 Sub-unit terminal block Mstb2,5-2-St-5,08
0050 0005-4342-000 Sub-unit terminal block Mc 1,5/ 4-St-3,8
0070 0024-6311-000 Rating plate
0090 0005-4329-820 Cable bushing 5,0
0100 0013-0130-630 Nut DIN 46319 M16x1,5 Sw19
0110 0005-4442-900 Screw plug M16x1,5
0120 7300-6017-040 Sticker
0005-0534-040 Fuse block assembly 10 off

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Spare parts
Animal Identification System

11.5 Gate control unit

Part No. Description

7070-5900-070 Electrical gate control unit (for 4 gates)
(only for feeding system
7065-5910-000 Pushbutton complete
DairyFeed)
0005-0420-048 Oelflex cable (piece goods) 2 x 0.75
0005-3999-048 Cable (piece goods) DPNet 2x1 + 2x0.5

11.6 Animal Identification System

Part No. Description

7160-5530-040 Identification frame, neck
7160-5530-050 Identification frame, foot
7160-2379-420 Transceiver ISO/VC4
7160-5513-070 Fuse strip

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 Appendix
Abbreviations

12 Appendix

12.1 Specialist terms

Term Explanation
Basic ration Minimum feed quantity. It can be dispensed at any milking place regardless
of the identification or feed entitlement of an animal.
DairyPlan Herd management program
DP
DPNetInstall Sub-program in DairyPlan (for transferring software and settings to DPNet
components)
DPSetup Sub-program in DairyPlan (for entering settings)
Electronics card Controls feeding from up to 6 feed motors
DairyFeed
Feed entitlement Feed quantity which the animal may receive at the time of identification
calculated by DairyPlan.
Feed ration Feed quantity for one day.
Portion Feed quantity for each dispensing chamber of the feed dispenser
Portion weight Weight of the feed quantity for each dispensing chamber of the feed
dispenser
Wizard Function in DPSetup (for simplified entry of settings). Goes through all
relevant milking parlour settings.

12.2 Abbreviations

Explanation
Ø Phase
Units
° Degrees (angles)
°C Degrees Celsius/ Centigrade
s Second
min Minute
” (in) Inch (= 25.4 mm)
mm Millimeters
cm Centimeters
m Meter
mm2 Square millimeter
mm3 Cubic millimeter
g Gram
kg Kilograms
kPa Kilopascal
kW Kilowatt
A Amp (current)
V Volt (voltage)
 Ohm (resistance)

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 Appendix
Abbreviations

GEA Farm Technologies

The right choice.

GEA Farm Technologies

GEA WestfaliaSurge Deutschland GmbH

Siemensstraße 25--27, D--59199 Bönen (Germany)
Tel. +49 (0) 2383 / 93--70, Fax. +49 (0) 2383 / 93--80
www.gea--farmtechnologies.com 7300-9001-007
60 11-2009