LELY COSMIX S Installation And Operator's Manual

5.2309.8509.0 A EN – English Original LELY COSMIX S Concentrate Feeder

1 TRADEMARKS, COPYRIGHT AND DISCLAIMER Lely, Astronaut, Astri, Atlantis, Attis, AWS, C4C, Calm, Caltive, Commodus, Compedes, Cosmix, Discovery, F4C, Fertiliner, Gravitor, Grazeway, Hibiscus, Hubble, Juno, L4C, Lely Center, Lelywash, Lotus, Luna, Nautilus, Orbiter, Quaress, Qwes, SAE, Shuttle, Splendimo, Storm, T4C, Tigo, Vector, Viseo, Voyager, Walkway and Welger are registered trademarks of the Lely Group. The right of exclusive use belongs to the companies of the Lely Group. All rights reserved. The information given in this publication is provided for information purposes only and does not constitute an offer for sale. Certain products may not be available in individual countries and products supplied may differ from those illustrated. No part of this publication may be copied or published by means of printing, photocopying, microfilm or any other process whatsoever without prior permission in writing by Lely Holding S.à r.l. Although the contents of this publication have been compiled with the greatest possible care, Lely cannot accept liability for any damage that might arise from errors or omissions in this publication. The English language manual is the original manual. Translations into other languages use the English language manual as the source document. Lely accepts no liability for discrepancies between the original English language manual and versions in other languages. If there is a conflict over the content and accuracy of any translated manual, the English language manual is the authority document. Copyright © 2015 Lely Industries N.V. All rights reserved Lely Industries N.V. Cornelis van der Lelylaan 1 3147 PB Maassluis the Netherlands Phone: +31 (0)88 1228221 Fax: +31 (0)88 1228222 Website: www.lely.com

1 LIST OF INCLUDED AMENDMENTS No: Issue Date (yy/mm) Chapter(s) Remarks 3 15/07 All • Long distance (LD) tag functionality added: machine 5.2309.0040.x • Installation of the rear fences changed • Adjustment of the photocell (H/HR models) added • Feed presence sensor removed • Pressure reducer added to control unit • Several other minor updates 2 11/06 3 Capacity adjusted 1 11/01 3 Dimensions adjusted 4 Descriptions feed presence sensor and Qwes leg ID reader added Operation section rewritten 5 Installation procedures feed presence sensor and Qwes leg ID reader added 8 Adjustment procedures Qwes leg ID reader added Glossary of Terms Terms added 10/04 Initial issue

• Abnormal use of the equipment which is not according to the specifications stated in the Operator Manual or handled during the Operators Service and Maintenance Certification program. • The result of any intervention by technicians other than Lely service technicians or technicians who have Lely’s approval to perform certain duties. • Incidents such as freezing, ice, fire, flood, inundation or any other form of excessive water, lightning. • Defect of the electrical system or grounding. • Use of compressed air that does not meet the quality standards set by Lely Industries. • Damage to the electrical system as a result of vermin or the like. • For USERS that have followed the Operators Maintenance and Service Certification: Any damage resulting from abnormal use of the equipment which is not according to the specifications stated in the Operator Technical Training Manual is not covered by the warranty scheme. Warranty does not apply to consequential damage which does not involve the machine itself. All systems are tested. However in the event of a malfunction Lely cannot be held responsible for consequential damage.

installation and operation of a COSMIX S Concentrate Feeder. Study and understand this information thoroughly before configuration of the COSMIX S. Failure to do so could result in damage to equipment. Please consult your local Lely service provider if you do not understand the information in this manual, or if you need additional information. All information in this manual has been compiled with care. Lely shall not be liable for errors or faults in this manual. The recommendations are meant to serve as guidelines. All instructions, pictures and specifications in this manual are based on the latest information that was available at the time of publication. Your COSMIX S may comprise improvements, features or options that are not covered in this manual. Applicability The table below shows the type numbers of COSMIX S for which this manual is applicable. Model designation Model Type number COSMIX S Concentrate Feeder Qwes ISO ACT neck 5.2309.0000.X COSMIX S Concentrate Feeder Qwes H/HR 5.2309.0010.X COSMIX S Concentrate Feeder Qwes ISO ACT leg 5.2309.0020.X COSMIX S Concentrate Feeder Qwes H/HR-LD 5.2309.0040.X Software version The description, operation and procedures in this manual are based on the following software versions: • T4C version 3.1.3 or higher • E-Link version 1.08R or higher • ADS 3830 pcb; CMv01.05.25 or higher. Standard Torque Loading of Parts All the nuts, bolts and screws used on the COSMIX S Concentrate Feeder are torque tightened to standard torque loadings applicable to the construction materials used. If a part has a non-standard torque loading, it is specified in the applicable part of the manual.

COSMIX S Concentrate Feeder, on the top. Always include the type and serial number of your concentrate feeder when you contact your local Lely service provider or order spare parts. Figure 1. Type and Serial Number Plate We suggest you complete the table below with the type and serial numbers of your concentrate feeder. This makes sure you can easily find the information. Type number Serial number Maintenance Authorization Only technicians certified by Lely Industries are authorized to do maintenance on the COSMIX S, except for the maintenance done by the operator as indicated in the Operator Manual.If people who are not certified by Lely Industries do maintenance on the COSMIX S, the warranty on the COSMIX S becomes invalid. Before a technician does maintenance on a COSMIX S, the owner must examine the service pass of the technician and make sure the technician is currently certified to do maintenance on the COSMIX S. At the end of each visit, all work done on the COSMIX S must be written in the logbook and the logbook must be signed by the certified technician. The logbook must always be kept near the COSMIX S for the entire life of the product. The information in the logbook must include: • The maintenance done • The date of the maintenance • The name of the technician • The certification number of the technician.

approved training program, and passed written and practical examinations during and at the end of the training program. The training is given by a product specialist. The examinations are done under supervision of a master product specialist and include troubleshooting and corrective maintenance of the COSMIX S. There are five certification levels: • Installation Technician (certification valid for two years) • Service Engineer (certification valid for two years) • Senior Service Engineer (certification valid for two years) • Product Specialist (certification valid for one year) • Master Product Specialist (certification valid for one year). During training, a trainee is permitted to work for up to a maximum of six months under close supervision of a certified technician. A trainee can do work on the milking robot can only in the presence of a certified technician. When the training program is completed successfully, Lely issue a certificate and a service pass to the technician. The service pass contains the following information: • The name of the technician • A photograph of the technician • The certification number of the technician • The date of expiry of the certification. Contact Number Local Service Provider We suggest you write the telephone number and email address of your local service provider contact in the table below. This makes sure you can easily find the information. Telephone number email address

v Table of Contents 1 INTRODUCTION ........................................................................................1-1 2 SAFETY .................................................................................................2-1 2.1 Introduction .................................................................................... 2-1 2.2 Signal Icons ..................................................................................... 2-1 2.3 Safety Instructions ............................................................................. 2-2 2.3.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.3.2 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.3.3 Installation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.3.4 Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.3.5 Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.4 Safety Decals ................................................................................... 2-4 2.4.1 Safety Decal Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.4.2 Installation of Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.4.3 Maintenance of Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 3 SPECIFICATIONS .......................................................................................3-1 3.1 Dimensions and Weight ....................................................................... 3-1 3.2 Control Unit .................................................................................... 3-1 3.3 Cow Identification Readers ................................................................... 3-1 3.4 External Requirements ........................................................................ 3-1 4 DESCRIPTION AND OPERATION .....................................................................4-1 4.1 Introduction .................................................................................... 4-1 4.2 Component Description ....................................................................... 4-5 4.2.1 Frame and Fencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.2.2 Feed Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.2.3 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.2.4 Cow Identification (ID) Readers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.3 Operator Interface ........................................................................... 4-13 4.3.1 T4C Farm Management Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 4.4 Service Interfaces ............................................................................. 4-14 4.4.1 The E-Link Manual Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 4.4.2 Menu Structure E-Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 4.4.3 Cosmix Service Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 4.5 Operation ..................................................................................... 4-20 4.5.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 4.5.2 Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 4.5.3 Interaction between the COSMIX S Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 5 INSTALLATION .........................................................................................5-1

5.1 Introduction .................................................................................... 5-1 5.2 Preparation ..................................................................................... 5-1 5.2.1 List of Supplied Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2.2 Preparation by the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2.3 Preparation by Lely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.2.4 Position of the Cosmix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.3 Install the COSMIX S ........................................................................... 5-4 5.3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.3.2 Install the Side Fences on the Portals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5.3.3 Level, square and tighten the Fences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.3.4 Install the Portals on the Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.3.5 Install the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5.3.6 Install the Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 5.3.7 Install the Feed Bin and the Feed Hopper on the Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.3.8 Install the Rear Fences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 5.3.9 Install the Restraining Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 5.3.10 Install a Qwes leg ID Reader and a Floor Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 5.4 Connect the COSMIX S ....................................................................... 5-25 5.4.1 Connect the Air Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 5.4.2 Connect the ID-Reader Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 5.4.3 Install the Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 5.4.4 Prepare the Network Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 5.4.5 Install a Type 1 Network Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 5.4.6 Install a Type 2 Network Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 5.4.7 Install the Network Cable on an Earthing Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 5.4.8 Remove or install the Covers from the Feed Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 5.5 Setup the COSMIX S ......................................................................... 5-35 6 OPERATING INSTRUCTIONS .........................................................................6-1 6.1 List Details about the Rest Feed .............................................................. 6-1 6.2 List a Feed Overview ........................................................................... 6-1 6.3 List a Device Intake Overview ................................................................. 6-2 7 MAINTENANCE ........................................................................................7-1 8 TEST AND ADJUSTMENT .............................................................................8-1 8.1 Introduction .................................................................................... 8-1 8.2 Connect or Remove the E-Link Manual Controller .......................................... 8-1 8.3 Set the Network Settings ...................................................................... 8-1 8.3.1 Set Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.3.2 Set the Device Address of the Cosmix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8.3.3 Set the T4C Device Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8.3.4 Set the IP-address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

vii 8.4 Make Basic Software Settings ................................................................. 8-3 8.4.1 Display the Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8.4.2 Reset to the Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8.4.3 Set the Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 8.4.4 Make the Photocell Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.4.5 Calibrate the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.4.6 Set the Portion Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8.4.7 Adjust the Portion Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8.4.8 Clear all Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8.5 Test the Operation of the COSMIX S ......................................................... 8-6 8.5.1 Test the Time Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8.5.2 Display Real Time Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8.5.3 Test the Tag-ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8.5.4 Test the Dosing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 8.6 Adjust the Floor Antenna Signal (Qwes leg models only) .................................. 8-7 8.7 Adjust the Photoelectric Sensor ............................................................ 8-10 8.8 Adjustments in the T4C Software ........................................................... 8-13 8.8.1 Add the COSMIX S to T4C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 8.8.2 Add a Feed Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 8.8.3 Set the Feed Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 8.9 Adjustments with the Service Interface .................................................... 8-14 8.9.1 Calibrate the Valves with the Service Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 9 TROUBLESHOOTING ..................................................................................9-1 9.1 Troubleshooting Table ......................................................................... 9-1 9.2 Recovery Procedures ........................................................................... 9-1 9.2.1 Make Sure the Cow has Feed Credit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.2.2 Make Sure the Cow Number is less than 32000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.2.3 Clean the Dosing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 10 DIAGRAMS ........................................................................................... 10-1 10.1 Overview COSMIX S with One or Two Feed Hoppers ..................................... 10-1 GLOSSARY OF TERMS

to cows to realize their maximum milk production. The feed portion can be a mixture of up to four different types of concentrates. An electronic tag on each cow enables the system to identify the cow via an unique number. There are three tag types: • Qwes H/HR for identification with an infrared ID reader • Qwes ACT for identification with an ISO ID reader • Qwes leg for identification with an ISO ID reader The T4C (Time for Cows) farm management software has information about each cow and adjusts the use quantity and mixture of the feed based on this information. In combination with the Astronaut milking robot a closed system of milking and allocation of concentrates can be created. The information in this manual is for farmers and technicians. • Farmers use the information to test and adjust the COSMIX S or to list overviews • Technicians use the information to install and setup the COSMIX S.

COSMIX S Concentrate Feeder and in the manual. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instruction of the safety message. Figure 2. Safety Alert Symbol 2.2 Signal Icons Note the use of the signal words DANGER, WARNING and CAUTION with the safety messages. The signal word for each message uses the following guidelines: Danger: indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. Warning: indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. Caution: indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury or product or property damage. Note: this shows extra information that may help the reader.

concentrate feeder. YOU must make sure that you and anyone else who is going to operate, maintain or work in the vicinity of the concentrate feeder knows all the related SAFETY information in this manual. YOU are the key to safety. Good safety practices protect you and the people around you. Make these practices a working part of your safety program. Make sure EVERYONE who operates, maintains or works near the concentrate feeder obeys the safety precautions. Do not risk injury or death by ignoring good safety practices. • COSMIX S owners must train operators before they operate the concentrate feeder. This training must be repeated at least annually • The operator must read, understand and obey all safety and operating instructions in the manual • A person who has not read and understood all safety and operating instructions is not permitted to operate the concentrate feeder • Do not modify the equipment in any way. Unauthorized modification may impair the function and/or safety and could affect the life of the equipment, and persons • Only use approved spare parts, and make sure they are only installed by authorized technicians. 2.3.1 General Safety • Read and understand the manual and all safety signs before you connect power supplies to operate, maintain or adjust the COSMIX S Concentrate Feeder • Only trained persons are permitted to operate the COSMIX S Concentrate Feeder • A first-aid kit must be available near the COSMIX S Concentrate Feeder. Store in a highly visible place • A carbon dioxide or foam fire extinguisher must be available near the COSMIX S Concentrate Feeder. Store the fire extinguisher in a highly visible place • Install all protective covers and guards before you operate the COSMIX S Concentrate Feeder • Wear the correct protective clothing and equipment • Disconnect and isolate the electrical power supply, release pneumatic pressure and wait for all moving parts to stop before you clean or do maintenance on the concentrate feeder • Know the emergency medical center number for your area • Contact your nearest Lely service provider if you have any questions • Review safety related items with all operators frequently (annually).

for the COSMIX S Concentrate Feeder • Make sure the electrical grounding of the electrical system and all parts of the COSMIX S Concentrate Feeder meet the local rules and regulations • Replace any damaged electrical lines, conduits, switches and components immediately • Isolate the electrical power supply before you open the PCB box to work on the electrical system. 2.3.3 Installation Safety • Read and understand the instructions in this manual • The concentrate feeder is not stable until it is correctly installed • Make sure it is correctly supported at all times during movement and installation • Make sure the concentrate feeder is correctly installed. 2.3.4 Operating Safety • Read and understand the applicable manual and all safety signs before you connect power supplies to operate, maintain or adjust the COSMIX S Concentrate Feeder • Only trained persons are permitted to operate the COSMIX S Concentrate Feeder • Disconnect and isolate the electrical power supply, release pneumatic pressure and wait for all moving parts to stop before you clean or do maintenance on the COSMIX S Concentrate Feeder • Install all covers and guards before you operate the COSMIX S Concentrate Feeder • Keep hands, feet, hair and clothing away from all moving parts • Keep unauthorized persons, especially small children away from the COSMIX S Concentrate Feeder at all times • Before the pneumatic pressure is supplied to the COSMIX S Concentrate Feeder, make sure all parts are tight and that all hoses and fittings are in good condition • Always be alert for unexpected movement of the cow. Cows can transmit large forces to parts of the machine • Contact your nearest Lely service provider if you have any questions • Review safety related items with all operators frequently (annually). 2.3.5 Maintenance Safety • Read and understand the applicable manual and all safety signs before you connect power supplies to operate, maintain or adjust the COSMIX S Concentrate Feeder

Concentrate Feeder • Disconnect and isolate the electrical power supply, release pneumatic pressure before you do work on the COSMIX S Concentrate Feeder • Take extreme care when you work near or with high-pressure pneumatic systems. If possible, depressurize the system before you do work on it • Wear protective clothing and safety goggles when you do work on the pneumatic system • Make sure all covers and guards are installed when maintenance work is complete. 2.4 Safety Decals 2.4.1 Safety Decal Messages General safety messages appear in this safety messages section. Specific safety messages are in applicable parts of this manual when potential hazards may occur if the instructions or procedures are not followed. 2.4.2 Installation of Safety Decals 1. Make sure that the installation surface is clean and dry. 2. Make sure that the temperature of the mounting surface is not less than 5 °C (41 °F). 3. Find the correct position for the decal before you remove the backing paper. 4. Remove a small part of the cover paper. 5. Put the decal in the correct position on the installation surface and carefully push the small part of exposed adhesive surface of the decal onto the installation surface. 6. Slowly remove the cover paper and attach the rest of the decal to the installation surface. 7. Puncture small air pockets in the decal with a pin and use the cover paper to smoothen the decal. 2.4.3 Maintenance of Safety Decals Safety decals show important and useful information that will help you to safely operate and maintain the machine. Obey the instructions below to make sure that all the decals stay in the correct position and condition. • Keep the safety decals clean and legible at all times. Clean the safety decals with soap and water. Do not use mineral spirits, abrasive cleaners or other similar agents that may damage the safety decals. • Replace safety decals that are missing or that are illegible. • Safety decals can be purchased from your local Lely service provider.

• Height: 208.5 cm (82.1 in) • Length: 267.2 cm (105.2 in) • Width: 102.2 cm (40.2 in) • Weight: approx. 248 kg (547 lb) • Capacity feed hopper: 25 l (6.6 gal) • Portion size: approx. 60 g (2.1 oz), depending on the feed type Refer to the Diagrams in chapter 10 for the complete dimensions of the COSMIX S. 3.2 Control Unit • Pcb: ADS3830 • Software version: CMv01.05.25 or higher 3.3 Cow Identification Readers Life tags are not supported. • Qwes H/HR for identification with an infrared ID reader • Qwes ACT for identification with an ISO ID reader • Qwes leg for identification with an ISO ID reader 3.4 External Requirements Pressurized air • Output pressure: 6 - 7,5 bar (87 - 109 psi) • Connection: 6 mm tube Electrical power • 100 - 240 VAC Earthing • Earthing of the COSMIX S must comply with current earthing regulations for barns (obey local rules and standards) • The earth wire must be connected to the earth point • An authorized electrician must approve the final electrical installation (including earthing) and supply an official report that is given to the Lely service provider before the installation is used

correctly installed. T4C network Network connection: • LAN CAT.5e Network cable, S-FTP 200 MHz (foil-screened twisted pair with overall screening (copper braiding)) with steel RJ-45 connector • Maximum cable length: 100 m (109 yd) (use a switch if the distance is more than 100 m (109 yd))

4-1 4 DESCRIPTION AND OPERATION 4.1 Introduction The COSMIX S has the following main parts: • Frame and fencing • Feed hopper(s) (1 - 4) • Feed bin • Control unit • Cow identification reader. The COSMIX S is installed in the barn. The COSMIX S is connected to the T4C network. The COSMIX S gets input from and sends output to the T4C Farm Management software. The following figures show the main components of the COSMIX S with Qwes ACT, Qwes H/HR and Qwes leg identification.

Figure 4. Main components COSMIX S with Qwes ACT identification KEY: 1. Feed hopper - 2. Control box - 3. Rear portal - 4. Restraining bracket - 5. Rear fences - 6. ID-reader - 7. Front portal - 8. Feed bin - 9. Side fence

4-3 Figure 5. Main components COSMIX S with Qwes H/HR identification KEY: 1. Feed hopper - 2. Control box - 3. Rear portal - 4. Restraining bracket - 5. Rear fences - 6. Front portal - 7. Feed bin - 8. Side fence

Figure 6. Main components COSMIX S with Qwes H/HR-LD identification KEY: 1. Feed hopper - 2. IR reader (External IDU 530) - 3. Control box - 4. Rear portal - 5. Restraining bracket - 6. Rear fences - 7. Front portal - 8. Feed bin - 9. Side fence

4-5 Figure 7. Main components COSMIX S with Qwes leg identification KEY: 1. Feed hopper - 2. Control box - 3. Rear portal - 4. Side fence - 5. Restraining bracket - 6. Rear fences - 7. EWA transformer - 8. Floor antenna mat - 9. Front portal - 10. Feed bin - 11. Side fence 4.2 Component Description 4.2.1 Frame and Fencing The COSMIX S has the following frames and fences: • Front portal • Rear portal • Side fence (2×) • Restraining bracket. The two side fences are connected to the front and the rear frame. The restraining bracket prevents cows from being hindered by other cows while eating.

4.2.2 Feed Unit The feed unit is an assembly that has the following parts: • Feed hopper • Dosing unit • Feed funnel • Feed bin. The feed unit can have 1 - 4 feed hoppers, each with a dosing unit. All parts are installed on a plate. 4.2.2.1 Feed Hoppers The COSMIX S has up to four feed hoppers. Each feed hopper has a feed dosing unit that provides portions of concentrates. In most cases the feed hoppers are filled by tube feeders that are connected to silos. Lely does not supply tube feeders and silos. 4.2.2.2 Dosing Unit The dosing unit gives exactly the same (calibrated) volume each feed portion. It has a cylinder that opens and closes the unit. The amount of concentrate to be fed to a cow is based on calculations made in the T4C farm management software. The proportion of each feed type and the total amount that is fed can be set per cow, group or herd. 4.2.2.3 Feed Funnel The feed is dropped through the feed funnel into the feed bin. 4.2.2.4 Feed Bin The feed bin is made of stainless steel. 4.2.3 Control Unit The control unit controls the identification of cows and the supply of feed. The control unit on top of the COSMIX S has the following parts: • ADS 3830 pcb • Air valves • Photoelectric sensor (Qwes H/HR models only) • Infrared ID reader (Qwes H/HR models only) • Velos box (Qwes leg models only)

4-7 • Power supply with safe life switch • Network switch (optional). • Air pressure reducer 4.2.3.1 ADS 3830 pcb The ADS 3830 pcb (see figure 8 on page 4-8) controls the valves that supply air to the cylinders of the feed dosing unit. The pcb is installed in the control unit. The control software that runs on the pcb communicates with the T4C farm management software. Connector J604 (9) is connected to the valves for the cylinders that move the feed dosing units. Connector J602 (11) is connected to the photoelectric sensor, if applicable. The following table shows the connector/pin - cylinder combinations: Connector Pins Cylinder J604 Out1, gnd Dosing Unit 1 Out2, gnd Dosing Unit 2 (optional) Out3, gnd Dosing Unit 3 (optional) Out4, gnd Dosing Unit 4 (optional) J602 In4, gnd Photoelectric sensor (Qwes H/HR models only)

Figure 8. ADS 3830 pcb KEY: 1. Not used - 2. Not used - 3. Ethernet connector - 4. Infrared ID reader (Qwes H/HR models only) or Velos box (Qwes leg models only) - 5. E-Link - 6. 24V power supply - 7. Valves dosing unit 5 (optional) - 8. Status indicator - 9. Valves dosing units 1–4 - 10. FSK pcb (Qwes ACT models only) - 11. Photoelectric sensor (Qwes H/HR models only) 4.2.3.2 Velos Box In Qwes leg models, a velos box is installed to convert the analog antenna signal to a digital signal that is appropriate for the ADS 3830 pcb. The velos box is installed in the control unit. 4.2.3.3 Air Valves Block The air valves are solenoid valves and supply pressurized air to the cylinders of the feed dosing unit(s). The air valves are installed on a valve terminal. A standard configuration has one solenoid valve and five blanking plates. If an additional feed funnel is installed, an additional air valve is also installed. The valves are controlled by the ADS 3830 pcb. 4.2.3.4 Photoelectric Sensor The photoelectric sensor has a housing that contains an emitting element (infrared LED) and a receiving element (photodiode). It is installed on a bracket on the base plate of the control unit. The photoelectric sensor gets input when a cow is in the COSMIX S. The photoelectric sensor sends output to the ADS 3830 pcb.

4-9 Figure 9. Control unit (Qwes ACT) KEY: 1. Pressure reducer - 2. ADS 3830 pcb - 3. Network switch (optional) - 4. Power supply (ADS 3830 pcb) - 5. Safe life switch (optional) - 6. Air valve - 7. E-Link connection - 8. Air valve block

Figure 10. Control unit (Qwes H/HR) KEY: 1. Pressure reducer - 2. ADS 3830 pcb - 3. Network switch (optional) - 4. Infrared ID reader - 5. Photoelectric sensor - 6. Power supply (ADS 3830 pcb) - 7. Safe life switch (optional) - 8. Air valve - 9. E-Link connection - 10. Air valve block

4-11 Figure 11. Control unit (Qwes H/HR-LD) KEY: 1. Pressure reducer - 2. ADS 3830 pcb - 3. Network switch (optional) - 4. Photoelectric sensor - 5. Power supply (ADS 3830 pcb) - 6. Safe life switch (optional) - 7. Air valve - 8. E-Link connection - 9. Air valve block

Figure 12. Control unit (Qwes leg) KEY: 1. Pressure reducer - 2. ADS 3830 pcb - 3. Velos box - 4. Network switch (optional) - 5. Power supply (ADS 3830 pcb) - 6. Safe life switch (optional) - 7. Air valve - 8. E-Link connection - 9. Air valve block 4.2.4 Cow Identification (ID) Readers 4.2.4.1 Qwes ACT Cow ID Reader The Qwes ACT cow identification system has two components: • The cow tag (Qwes ACT) • The ID reader (ISO). The cow tag is installed on a collar on the neck of the cow. The cow ID reader is a sealed plastic box with an internal antenna (MIMI). The box is installed on a mounting plate that is installed on the front plate under the feed bin. The data cable of the ID reader is connected to the FSK pcb (10)(see figure 8 on page 4-8) on the ADS 3830 pcb. 4.2.4.2 Qwes H/HR Cow ID Reader The Qwes H/HR cow identification system has two components: • The cow tag (Qwes H or Qwes HR)

4-13 • The infrared ID reader. The cow tag is installed on a collar on the neck of the cow. The ID reader can be installed on two places: 1. In the control unit (4)(see figure 11 on page 4-11) on top of the COSMIX S 2. In a metal housing (3)(see figure 6 on page 4-4) under the Control unit on top of the COSMIX S. It has the following components: • Xenon flash light • Infrared transmitter and receiver • Indicator LEDs for cow presence and data transfer • Pcb. The transmitter, receiver and indicator LEDs are connected to the pcb, the pcb is connected to the ADS 3830 pcb(see figure 8 on page 4-8). 4.2.4.3 Qwes ISO Leg Reader The Qwes ISO leg reader has three components: • Floor antenna • EWA transformer • Velos box (VP1001) The floor antenna mat (8)(see figure 7 on page 4-5) is installed on the floor in between the front portal (9). The EWA transformer (7) is installed on the front portal. The Velos box (VP1001) (3)(see figure 12 on page 4- 12) installed in the Qwes ISO leg control box on top of the COSMIX S. On the side of the control box are cable glands. The CAN-bus cable of the Velos box is connected to connector J608 on the ADS2412 PCB. The floor antenna mat detects the signal from the Qwes ISO ACT leg tag. The EWA transformer filters the identification signal from the antenna signal and sends it to the Velos box. The Velos box converts the analog signal to a digital (CAN-bus) signal for the ADS2412 PCB. 4.3 Operator Interface The settings of the COSMIX S are made in the T4C Farm Management software (T4C). 4.3.1 T4C Farm Management Software The T4C software is used to: • Setup the COSMIX S • Get information about the food consumption • Set the amount of concentrate the COSMIX S supplies. The T4C software receives data requests from the COSMIX S.

The T4C software sends data (new and updated) to the COSMIX S. 4.3.1.1 The T4C Window Explained The T4C software is displayed in a Google Chrome window. The window has the following parts: • Header • Navigation bar • Data page. Figure 13. The T4C screen overview KEY: 1. Header - 2. Navigation bar - 3. Data page 4.4 Service Interfaces The COSMIX S has the following service interface: • E-Link Manual Controller • T4C Farm Management software • Cosmix Service Interface (web browser). 4.4.1 The E-Link Manual Controller The E-Link Manual Controller controls and monitors the COSMIX S. The E-link Manual Controller has an LCD display and nine buttons that enable the user to give commands and change values in the COSMIX S. The LCD display also shows reports and alarms. The connector of the E-Link Manual Controller is on the front side of the control unit.

4-15 The E-Link has the following buttons: • Soft buttons (1): confirm the action on the LCD display above the applicable button • Start/Stop button (2): starts or stops an action • Enter button (4): open the selected function or the next menu screen • Menu button (5) • Arrow buttons (3 and 7): move the selector up/down, increase/ decrease a value by one • Escape button (6): return to the previous screen. Figure 14. The E-Link Manual Controller KEY: 1. Soft buttons - 2. Start or stop button - 3. Arrow down button - 4. Enter button - 5. Menu button - 6. Escape button - 7. Arrow up button - 8. LCD display 4.4.2 Menu Structure E-Link The main menu on the E-Link has the following items: • Version info • Settings • Network Settings • Testing • Setup. An input selection on the E-Link is shown as a grey cross-hatched block.

Figure 15. The E-Link menu structure 4.4.2.1 Version info 'Version info' displays information about the software installed on the ADS 3830 pcb. The menu displays the following items: • Software version • Time when the software was compiled • Date when the software was compiled • Version info of the ID-reader. The software version is the current version number of the software installed on the ADS 3830 pcb.

4-17 4.4.2.2 Settings The menu 'Settings' is used to define basic settings that are necessary for correct operation. The menu has the following items: • Set defaults • Time • Imperial Units • Keep blocker open (Not used) • Photocell active • Weigh unit on (Not used) • Portion size1 • Portion size2 • Portion size3 • Portion size4 • Portion size5 (Not used) • CalibrateTagsActive • Cal. Tag1 • Cal. Tag2 • Cal. Tag3 • Cal. Tag4 • Cal. Tag5 • Feedsensor Present (Not used). Menu item 'Set defaults' resets the value of all items in this sub-menu to the default values. The menu item 'Time' displays the current time and date. The time and date are automatically synchronized with the T4C software. The menu item 'Imperial Units' is used to switch from display of metric units to imperial units. The menu item 'Keep blocker open' is only applicable for service engineers. In the IR version of the COSMIX S a photocell is installed to support the ID-detector. The setting Photocell active is used to switch ON the photocell (value 0 is OFF, value 1 is ON). The menu item 'Weigh unit on' is not used. The menu items 'Portion size1', 'Portion size2', 'Portion size3' or 'Portion size4' are used to set the portion size of each dosing unit. By default the portion sizes for feed types 1 to 4 are 61, 62, 63 and 64 grams. Menu item 'Portion size5' is not used.

The last portions fed can be less than the set ‘Dose portion’ to feed exactly the actual balance of a cow. The menu item 'CalibrateTagsActive' is used to switch ON or OFF the calibration procedure. The menu items 'Cal. Tag1' - 'Cal. Tag4' can be used to introduce a new tag in T4C. 'Cal. Tag5' is not used. 4.4.2.3 Network Settings The menu 'Network settings' is used to define basic network settings that are necessary for correct operation. The menu has the following items: • Set defaults • Dev addr Cosmix • Dev addr T4C • Dev addr CRS+ • IP Address • ETH address. The menu 'Set defaults' is used to restore all default network settings. When the default settings are restored, the network address is also reset. The correct network address must be set to use the COSMIX S. The menu 'Dev addr Cosmix' is used to identify the COSMIX S in the T4C network. The recommended value is 11 for the first COSMIX S, 12 for the second, and so on. Menu item 'Dev addr T4C' sets the identification number of the T4C- server. The default setting is 001. Menu item 'Dev addr CRS+' sets the identification number of the CRS+. The default setting is 151. Menu item 'IP Address' sets the IP address of the COSMIX S, as used in the T4C network. Menu item 'ETH address' displays the ethernet (MAC) address of the ADS 3830 pcb.This address is fixed and can not be changed. 4.4.2.4 Testing Menu 'Testing' displays information about the use of the COSMIX S, real- time or non-real-time, and enables testing of some functions. The menu has the following items: • Time

4-19 • RealTimeInfo • Tag id • Valves/Blocker • IDC Power level • mbox testing (Not used). The menu item 'Time' displays the internal processor time and date, the time and date of the T4C network and the elapsed time, in seconds, starting from the year 2000 (see page 8-6). The menu item 'RealTimeInfo' displays the tag ID from the identified cow, the content of the feed bin, the cows credit and the quantity of food the cow has already eaten. The menu item 'Tag id' displays the tag ID when a cow is present in the COSMIX S and the value 1 if the cow is detected by the (optional) photocell (see page 8-6). The menu 'Valves/Blocker' is used to test the correct operation of the valves (see page 8-7). • 'Valve 1', to supply one portion of feed type 1 • 'Valve 2', to supply one portion of feed type 2 (if present) • 'Valve 3', to supply one portion of feed type 3 (if present) • 'Valve 4', to supply one portion of feed type 4 (if present) • 'Valve 5' is not applicable • 'Blocker' is not applicable. The menu-item 'IDC Power level' is used to set the threshold value for detection of the antenna signal (only Qwes Leg/Ear reader). If the distance between the tag and the reader is too large and therefore the signal is too low for correct identification, the signal is suppressed; 2 is most sensitive, 0 less sensitive. The default value is 1 (approx. 30 cm or 11.8 in). 4.4.2.5 Setup Menu 'Setup' has the following submenus: • Calibrate weigh unit • Clear All Tables • Calibrate Valves • Empty Feedbin Value. The menu 'Calibrate weigh unit' is not applicable. The menu 'Clear All Tables' is used to clear the memory on the ADS 3830 pcb. Information about visiting cows and their indications is primarily stored on the ADS 3830 pcb (see page 4-7). The data is also synchronized

with the data in T4C (see page 4-13). If you install the COSMIX S or a new ADS 3830 pcb, the data on that board should be replaced by the data in T4C. The menu 'Calibrate Valves' is used to adjust the supplied feed doses to the indicated amount (see page 8-4). 4.4.3 Cosmix Service Interface 4.4.3.1 Cosmix Service Interface The COSMIX S service interface is the web interface of the ADS 3830 pcb. The interface is accessible with an internet browser. The service interface enables changes to be made to all the device settings except the IP-address. The COSMIX S service interface has the following worksheets: • Version • Settings • Table data • Raw data • Help • Test. The worksheets 'Table data', 'Raw data', 'Help' and 'Test' are only used by service engineers. 4.5 Operation 4.5.1 Identification A cow enters the COSMIX S. Qwes ACT tags When the cow moves her head to the feed bin, the antenna in the ID reader reads the tag. The ID reader sends the data of the tag to the ADS 3830 pcb. Qwes H/HR tags The photoelectric sensor on the control unit detects the presence of a cow and activates the ID reader. The Xenos flash light in the ID reader starts to flash. The infrared reader reads the data from the cow's tag and sends the data to the ADS 3830 pcb. Then the flash light and the reader is switched OFF. Qwes leg tags The floor antenna from the ID reader reads the tag of the cow. The ID reader sends the data of the tag to the ADS 3830 pcb. The cow ID is verified by the database present on the ADS 3830 pcb.

4-21 4.5.2 Feeding The control system identifies the cow and synchronizes its information with the T4C computer. Based on the information for the specific cow, the feed credit is calculated. If the cow has feed credit the control system opens the lock from the dosing unit(s) to provide the specific mix of concentrates for the cow. Before the COSMIX S starts feeding, two conditions must be met: • The cow has feed credit for the connected feed types • The cow is allowed to eat concentrates in the COSMIX S (No block time). Feed credit The amount to be fed must be higher than 0 kg (0 lb) for at least one of the connected feed types. Also, the amount must be higher than the minimum portion size set in T4C. Allowance to eat Cows are allowed to eat if: • The visit is not in one of the blocking periods set in T4C • Robot feeding is switched on • The cow is not due to be milked, which means that it is not necessary to attract the cow to go to the milking robot (and to eat her portion of concentrates in the robot). End of visit At the end of the visit, the amount eaten is stored in the local database and sent to T4C. 4.5.3 Interaction between the COSMIX S Components The COSMIX S is connected to the T4C network. After installation, the COSMIX S is given a device ID and an IP address. These settings are used in the T4C software. The T4C software In the T4C software the feeding criteria are set. The T4C software supplies the ADS 3830 pcb database with the necessary data. When a cow enters the COSMIX S for the first time, the ADS 3830 pcb requests the cow data from the T4C software. The first time the cow data request takes longer. Once the cow is in the database on the ADS 3830 pcb, T4C automatically synchronizes the cow data after each change of data. The E-Link Manual Controller The E-Link Manual Controller is used by the service technician to set the initial settings (after installation) and to test and monitor the COSMIX S. The COSMIX S Service Interface The COSMIX S Service Interface is used by the service technician to set the initial settings (after installation) and to test and monitor the COSMIX S.

• Prepare the installation • Install the COSMIX S • Connect the COSMIX S • Setup the software. The network and power supply cables must not be installed next to each other to prevent electromagnetic interference (EMI). 5.2 Preparation 5.2.1 List of Supplied Parts The COSMIX S package must contain the parts listed below. Make sure all these items are present before you start the installation. If items are missing, contact your local Lely service provider. The COSMIX S is supplied with either one, two, three or four feed hoppers. • 1× Feed unit with one feed hopper • 1× Control unit • 1× Cardboard box with small parts • 2× Pipe with open T-clamps • 2× Side fence • 1× Front portal • 1× Rear portal • 1× Restraining bracket • 1 - 3× Additional feed hopper(s) with parts for installation (optional) • 2× Pipe (for transport only) • 1× EWA transformer (Qwes leg models only) • 1× Floor antenna mat (Qwes leg models only). 5.2.2 Preparation by the Owner Before the installation can be done, some tasks must be done by the owner of the COSMIX S with support from the Lely service provider.

equipment necessary to use the COSMIX S. Example tasks are: • Install a PC with T4C software in demo mode (if not already done) • Make sure that USB data storage space for making backups is available • Make sure all cows have a collar with a tag and a number on both sides • Make sure all cows are entered in T4C • Make sure all responder numbers are entered in T4C • Make sure a feed quantity for each cow is entered in T4C • Have the electrical supply installed and have it approved by the energy company • Have the air compressor installed • Install the earth wire and get it approved by the energy company • Install an external feed delivery system • Consult the local Lely service provider for the correct position of the COSMIX S in the barn. • Read and understand the COSMIX S Installation and Operator Manual. 5.2.2.1 Recommendations for Installation of an External Feed Delivery System Please consult your Lely service provider for advice about the installation of the tube feeder(s). • If possible install the tube feeder(s) with an angle above the COSMIX S. This prevents contamination of the COSMIX S with dust. • If you do: • Install a screen between the tube feeders and the COSMIX S • Make sure the distance between the floor and the bottom of the feed system is at least 215 cm (85.7 in). • Make holes in the cover of the feed funnel to attach the drop pipes from the tube feeders. The holes in the cover of the feed funnel must be the correct size for the drop pipes so that dust does not contaminate the COSMIX S. • Lely recommends that you install level switches in the feed funnels to control the tube feeder system to ensure that the feed funnels stay full. • Make sure the tube feeder(s) do not apply any additional weight to the dosing units.

decrease milk production of the cows. 5.2.2.2 Install the Air Compressor This section only applies when an air compressor is not installed. 1. Refer to the manual of the air compressor and install the compressor in the compressor room. 2. Connect the pneumatic hose to the compressor. 5.2.3 Preparation by Lely Make sure the owner is familiar with the T4C software. 5.2.4 Position of the Cosmix 5.2.4.1 General Rules and Recommendations The correct position of the COSMIX S will depend on the operational management of the farm. Analyze the operational requirements of the farm before you install the COSMIX S. This will make sure the COSMIX S is installed in the correct position. Please contact your Lely service provider for help with your specific requirements. • The COSMIX S must be installed on a solid, and correctly constructed foundation • The cows should have easy access to the COSMIX S • The cows must not be able to lay down in the exit route from the COSMIX S.

KEY: 1. Spare room - 2. Cosmix concentrate feeder - 3. Walk alley - 4. Barn 5.3 Install the COSMIX S Wear safety shoes. 5.3.1 Preparation This procedure requires a minimum of two persons. Hold the side fences while unpacking the parts. 1. Unpack all parts. 2. Remove the two pipes with the text "For transport only" and the four T-clamps from the portals.

Parts • 2× Side fence • 1× Front portal • 1× Rear portal • 4× Bracket set (1.5 in×1.5 in) • 16× Bolt, washer, nut • 4× T-clamps. Installation This procedure requires a minimum of two persons. 1. Put the front portal (1) (see figure 17 on page 5-6) on the floor, hold it. The front portal has a small mounting strip on top of it. 2. Loosely install both side fences (6) with the four bracket sets (5) on the front portal with the bolts, washers and nuts. 3. Loosely install the four T-clamps (4) on the side fences with a 8 mm Allen key (2). 4. Remove the four bolts (3)(see figure 18 on page 5-7) from the T- clamps. 5. Lift both side fences and put screwdrivers or pins (5) in the holes in the front portals to secure the position of the side fences. 6. Put the rear portal (1) on the floor, hold it. Do not fully tighten the T-clamps

with the four bolts (2). Figure 17. Install the portals and fences KEY: 1. Front portal - 2. Allen bolt - 3. Bolt - 4. T-clamps - 5. Brackets - 6. Side fences

KEY: 1. Rear portal - 2. Bolt - 3. Allen bolt - 4. Allen bolt - 5. Screw driver 5.3.3 Level, square and tighten the Fences Special tools • Level Installation 1. Make sure the distance between the front and rear portal is 101.5 cm (40.0 in), move the front portal (1) if necessary. 2. Make sure the side fences are level (2), move the T-clamps (3) up or down if necessary.

fences and the opposite brackets (1) (see figure 20 on page 5-9) are equal (A = B). 4. Tighten the bolts and nuts on the four brackets (1) on the front portal. 5. Tighten the bolts on the four T-clamps (4) (see figure 19 on page 5- 8) with a 8 mm Allen key. 6. Remove the screwdrivers or pins from the front portal that keep the fences in place. Figure 19. Level the side fences KEY: 1. Front portal - 2. Level - 3. T-clamp - 4. Allen bolt

KEY: 1. Front portal A: Distance between front side of side fence and opposite bracket B: Distance between front side of side fence and opposite bracket 5.3.4 Install the Portals on the Floor Parts • 8× Expander bolt M12×120×80 Installation Use the supplied expander bolts on concrete floors, otherwise use suitable M12 installation hardware. 1. Install the front and rear portal on the floor, at least 3 cm (1.2 in) from the wall (wall to outside pipe).

5.3.5.1 Install the Control Unit - General For installation of a COSMIX S with Qwes H/HR-LD identification refer to Install the Control Unit - Qwes H/HR-LD Identification (see page 5-20) Parts • 1× Control unit • 4× Carriage bolt M8×16, washer and cap nut Installation 1. Put the control unit (2) (see figure 21 on page 5-11) on the brackets between the front portal and the rear portal, with the CE-plate (1) on the rear and the cable throughput on the front. 2. Open the cover of the control unit. 3. Loosen the bolts that tighten the two strips on the cable throughput. 4. Feed the earthing cable, from the control box, through the cable throughput. 5. Install a carriage bolt (3) (see figure 21 on page 5-11) through the hole in the bottom of the control box and the strip on the front portal. 6. Install the cable shoe (4) from the earthing cable with a washer (5) and a cap nut (6) on the carriage bolt. 7. Install the control unit on the bracket on the portals with four carriage bolts, washers and cap nuts. 8. Close the cover of the control unit.

KEY: 1. CE-plate - 2. Control unit - 3. Carriage bolt - 4. Cable shoe - 5. Washer - 6. Cap nut 5.3.5.2 Install the Control Unit - Qwes H/HR-LD Identification Parts • 1× Control unit • 4× Carriage bolt M8×16, washer and cap nut • 1x Reader-bracket assembly Installation 1. Put the control unit (6)(see figure 22 on page 5-12) on the brackets (3 and 7) between the front portal and the rear portal, with the CE- plate (5) on the rear and the cable throughput on the front. 2. Open the cover of the control unit (6). 3. Loosen the bolts that tighten the two strips on the cable throughput (11)(see figure 35 on page 5-26). 4. Feed the earthing cable (12), from the control box, through the cable throughput. 5. Install a carriage bolt (3)(see figure 21 on page 5-11) through the hole in the bottom of the control box and the strip on the front portal.

bolt. 7. Install the reader-bracket assembly (8)(see figure 22 on page 5-12) and the control unit (6) on the brackets (3 and 7) on the portals with four carriage bolts (4), washers (2) and cap nuts (1). 8. Close the cover of the control unit (6). Figure 22. Install the Control unit — Qwes H/HR-LD KEY: 1. Cap nut - 2. Washer - 3. Support bracket - 4. Carriage bolt - 5. CE plate - 6. Control unit - 7. Support bracket - 8. Reader bracket assembly 5.3.6 Install the Front Plate Parts • 1× Front plate • 4× Bolt M12×80 and washer • 8× Nut M12

• 4× T-clamp This procedure requires a minimum of two persons. Installation 1. Loosely install the four T-Clamps (8)(see figure 24 on page 5-14) on the two mounting pipes (1) with an 8 mm Allen key. 2. Install the four bolts (9) and eight nuts (7) on the mounting pipes. The mounting pipes can be installed on three different heights on the back plate (3) and (4) 3. Install the two mounting pipes on the rear plate with the four nuts (5) and washers (6). 4. Remove the four bolts (3)(see figure 25 on page 5-15) from the four T-clamps (1) with an 17 mm wrench. Figure 23. Do not fully tighten the T-clamps 5. Install the front plate on the side fences with the four bolts (3)(see figure 25 on page 5-15). 6. Fully tighten the bolts in the T-clamp (2)(see figure 25 on page 5- 15) with an 8 mm Allen key.

KEY: 1. Mounting pipe - 2. Front plate - 3. Lower mounting pipe installation holes - 4. Upper mounting pipe installation holes - 5. Nut - 6. Washer - 7. Nuts - 8. T-clamp - 9. Bolt

KEY: 1. T-clamp - 2. Allen bolt - 3. Bolt 5.3.7 Install the Feed Bin and the Feed Hopper on the Front Plate Parts • Dosing units (1-4) • Feed bin • Feed funnel cover • Feed hopper cover Installation 1. Install the feed bin (4)(see figure 26 on page 5-16) on the front plate with the four bolts, nuts and washers (3), (1) and (2). 2. Install the dosing unit(s) (1)(see figure 27 on page 5-17) on the front plate. 3. Install the feed funnel cover (2) on the front plate and the feed bin.

clamping spring (4). Figure 26. Install the feed bin KEY: 1. Bolt - 2. Washer - 3. Nut - 4. Feed bin

KEY: 1. Dosing unit - 2. Feed funnel cover - 3. Feed hopper cover - 4. Clamping spring 5.3.8 Install the Rear Fences Parts • 2× Rear fence • 4× Bolt M10×70, washer and cap nut • 4 x Clamp M8, nuts and cap nuts Preparation 1. Determine the installation position of the rear fences: longest (1) (see figure 28 on page 5-18), middle (2) or shortest (3). Installation 1. Loosely install the upper side of one of the rear fences on a side fence with a 70 mm bolt (3)(see figure 29 on page 5-19), a washer (2) and a cap nut (1). 2. Loosely install the U-bolt (4) with the clamp (5), the nuts (6) and the cap nuts (7) to the upper side of the fence.

fence on the side fence with a 70 mm bolt (3) a washer (2) and a cap nut (1). 4. Loosely install the U-bolt (4) with the clamp (5), the nuts (6) and the cap nuts (7) to the lower side of the fence. 5. Support the rear fence and tighten all nuts 6. Repeat steps 1 to 5 for the other rear fence. Figure 28. Rear fence position KEY: 1. Longest position - 2. Middle position - 3. Shortest position

KEY: 1. Cap nut - 2. Washer - 3. Bolt (70 mm) - 4. U-bolt - 5. Clamp - 6. Nut - 7. Cap nut 5.3.9 Install the Restraining Bracket Parts • 1× Restraining bracket • 2× Bolt M10×60 and nut Installation 1. Loosely install the restraining bracket (3)(see figure 30 on page 5- 20) on top of the rear fences, with the bolts (2) and nuts (1).

KEY: 1. Cap nut - 2. Bolt - 3. Restraining bracket 5.3.10 Install a Qwes leg ID Reader and a Floor Antenna This section only applies when you have a COSMIX S with Qwes leg identification. Parts • 1× Floor antenna mat • 1× EWA transformer box with pcb • 1× EWA transformer housing • 2× Bolt M8×20, washer, nut • 3 m (9.8 ft) coax cable. Installation 1. Install the floor antenna mat (1)(see figure 31 on page 5-22) on the floor, between the two piles of the front portal.

frame (3) to the hole in the front frame (2). Connect the EWA transformer 1. Remove the cover (2) (see figure 32 on page 5-23)from the EWA transformer box. 2. Loosen four bolts that attach the pcb on the EWA transformer box. 3. Route the coax cable through the gland nut (1) into the EWA transformer box. 4. Use a wire stripper to remove approximately 5 cm (2 in) from the insulation. 5. Unbundle the woven shielding. 6. Use a wire stripper to remove approximately 1 cm (0.4 in) from the inner insulation. 7. Insulate the shielding. 8. Connect the shielding to the connector (6) (see figure 33 on page 5- 24) on the EW transformer pcb. 9. Connect the inner wire to the connector (7) on the EWA transformer pcb. 10. Make sure the antenna connectors (3) and (4) are connected to the connectors on the EWA transformer box. 11. Make sure the two jumper wires are connected to the connectors (1) and (2). 12. Install the EWA transformer pcb in the EWA transformer box with the four bolts. 13. Tighten the gland nut on the EWA transformer box. 14. Install the cover on the EWA transformer box. 15. Feed the two antenna wires through the two holes in the EWA transformer housing (3)(see figure 34 on page 5-25). 16. Connect the cable shoes from the antenna cables to the connectors on the EWA box with two washers, toothed washers and nuts (see figure 34 on page 5-25). Do not install the EWA transformer housing on the front portal, before you adjust the floor antenna signal (see page 8-8).

KEY: 1. Floor antenna mat - 2. Hole (front frame) - 3. Hole (upper side frame)

KEY: 1. Coax cable through gland nut - 2. Cover - 3. Potentiometer - 4. Wire - 5. Terminal strip

KEY: 1. Jumper wire connector - 2. Jumper wire connector - 3. Antenna wire connector - 4. Antenna wire connector - 5. Trimmer coil - 6. Shielding connector - 7. Inner wire connector

KEY: 1. EWA transformer box - 2. Upper cover EWA transformer housing - 3. Lower cover EWA transformer housing - 4. Nut - 5. Washer - 6. Cable shoe - 7. Washer 5.4 Connect the COSMIX S Use a cable channel to protect the cables and tubes against external mechanical effects. Use a separate cable channel for the network cable to protect it from electromagnetic interference (EMI). 5.4.1 Connect the Air Tubes 1. Find the air tubes that are connected to the dosing unit. Each feed dosing unit has a black and a blue air tube. 2. Feed the air tubes into the control unit. 3. Connect the black air tube to the tube connector (9)(see figure 35 on page 5-26) on the valve unit.

unit. 5. Feed the compressed air supply tube into the control unit. 6. Connect the air supply tube to the air coupling of the pressure reducer (1)(see figure 9 on page 4-9). Figure 35. Connect the control unit KEY: 1. Air coupling - 2. FSK pcb - 3. Network connector - 4. Earth connector - 5. Antenna connector Velos box - 6. Not used - 7. 24V power supply - 8. Earthing clamp - 9. Tube connector - 10. Tube connector - 11. Cable feed - 12. Earth cable 5.4.2 Connect the ID-Reader Cable 1. Find the cable to the ID reader. 2. Route the ID reader cable into the control unit. 3. Remove approximately 7 cm (2.8 in) from the outer insulation with a wire stripper. 4. Remove approximately 6 cm (2.4 in) from the shielding. 5. Turn the shielding back. 6. Remove approximately 1 cm (0.4 in) from the inner insulation with a wire stripper. Qwes ACT ID reader 1. Remove the bolts and the clamp from the FSK pcb (2)(see figure 35 on page 5-26).

3. Install the cable with the clamp and the two bolts on the pcb. 4. Make sure the clamp and the shielding are connected. Qwes leg ID reader 1. Insulate the wire shielding with a piece of heat shrink. 2. Connect the wire shielding to the - antenna connector (5) on the Velos box (bottom-right). 3. Connect the inner wire to the + antenna connector (5) on the Velos box. 5.4.3 Install the Earthing 1. Find the external earthing wire. 2. Feed the cable into the control unit. 3. Connect the earthing wire to the earth connector (4)(see figure 35 on page 5-26). 5.4.4 Prepare the Network Cable Use a Network Switch if the length of the network cable is more than 100 m (109 yd). 5.4.4.1 Introduction A type 1 or a type 2 network connector can be installed to a network cable.

KEY: 1. a) Type 1 network connector (T-568A) - 1. b) Type 1 network connector (T-568B) - 2. Type 2 network connector (T-568A) 5.4.5 Install a Type 1 Network Connector Special tools • Ethernet crimping tool Preparation 1. Make sure the network cable is of type S-FTP 200MHz CAT5e. 2. Cut a piece of network cable to the correct length. 3. Feed the network cable into the control unit. Installation 1. Install the connector cover and the cap on the network cable (1) (see figure 37 on page 5-30). 2. Remove approximately 5 cm (1.96 in) of the insulation (2) of one side of the cable. 3. Slide the screen backward (3). 4. Fold the wire backward (4). 5. Peel the metal shield from the cable (4). The inside of the metal shield is covered with an insulating film (often blue colored). If the metal shield is turned backward, the cable cannot make a ground connection with the connector. 6. Remove the plastic shield from the cable (5).

8. Sort the wires by color according to one of the tables. A Type 1 Network Connector can be configured accordingly a Type A or Type B wiring scheme. Use the same scheme (A or B) on both cable ends. T-568A T-568B 1 Green/White 1 1 Orange/White 1 2 Green 2 2 Orange 2 3 Orange/White 3 3 Green/White 3 4 Blue 4 4 Blue 4 5 Blue/White 5 5 Blue/White 5 6 Orange 6 6 Green 6 7 Brown/White 7 7 Brown/White 7 8 Brown 8 8 Brown 8 9. Cut the wires to a length of 1.3 cm (0.51 in) (9). 10. Put the wires and the cable fully in the RJ-45 plug (10). 11. Make sure the wire is on the left or right side of the plug (11). 12. Put the plug in the crimp tool until it clicks (12). 13. Squeeze the crimp tool until it clicks (13). 14. Push the plug tab and remove the plug from the crimp tool (14). 15. Remove the shielding and the wire (15). 16. Repeat the installation procedure for the other side of the network cable.

5.4.6 Install a Type 2 Network Connector Special tools

Preparation 1. Make sure the network cable is of type S-FTP 200MHz CAT5e. 2. Cut a piece of network cable to the correct length. 3. Feed the network cable into the control unit. Installation 1. Install the connector cover and the cap on the network cable (1) (see figure 38 on page 5-33). 2. Remove approximately 5 cm (2 in) of the insulation (2). 3. Slide the screen backwards (2). 4. Install the metal shielding tape on the screen (2). 5. Cut the remaining screen (2). 6. Remove the plastic shield from the cable. 7. Splice the wires. The blue and red wires on one side, the yellow and green wires on the other side (3). A Type 2 Network Connector can only be configured accordingly a Type A wiring scheme. Use scheme (A) on both cable ends. Type A 1 Green/white 1 2 green 2 3 Orange/white 3 4 Blue 4 5 Blue/white 5 6 Orange 6 7 Brown/white 7 8 Brown 8 8. Install the connector on the cable with the metal contact on the metal shielding tape (4). Make sure the wire order in the network connector is the same as the network connector on the other side of the network cable. 9. Put the wires in the correct position (3) and (4) 10. Cut the wire to length (5). 11. Install a plate on both sides of the connector (6).

13. Push the connector cover on the connector until you hear a click (8). 14. Install the cap on the cover (8).

Installation 1. Remove one of the earthing clamps (8)(see figure 35 on page 5-26). 2. Connect the network connector to the ADS 3830 pcb (3). 3. Mark the position of the earthing clamp on the network cable. 4. Remove the network connector from the ADS 3830 pcb. 5. Strip approximately 1.5 cm (0.4 in) of the marked insulation of the (1) and (2)(see figure 39 on page 5-34). 6. Attach the network cable to the earthing connector with the (8) (see figure 35 on page 5-26). 7. Make sure the shielding and the earth connector make good contact. Do not tighten the clamp too firmly (less than finger tight about 30 nm), to prevent damage to the cable (wires and the metal shield). 8. Tighten the clamp with a screw driver. Figure 39. Install a network cable to a ground rail

Removal 1. Pull the springs on both sides of the feed hopper cover (1)(see figure 40 on page 5-35), remove the feed hopper cover (2). 2. Lift the feed funnel cover (3) and remove it. Installation 1. Install the feed funnel cover (3) on the feed unit. 2. Install the feed hopper cover (2) on the feed unit. Figure 40. Remove or install the covers KEY: 1. Clamping spring - 2. Feed hopper cover - 3. Feed funnel cover 5.5 Setup the COSMIX S 1. Make sure the E-Link is connected and the main switch is switched On. 2. Set the IP-address. The IP-address for the first COSMIX S is 10:4:1:11 for the second 10:4:1:12 and so on.

the Cosmix (see page 8-2). The device address for the first COSMIX S is 11, for the second 12 and so on. 4. Set the device address T4C (see page 8-2). The device address for the T4C server is 1. 5. Make sure the feed blocker is set to 'open'. 6. Make sure the weight unit is set to 'off'. 7. Add the COSMIX S device to the T4C software . 8. Add the feed types to each feed hopper (see page 8-13). 9. Calibrate the valves (see page 8-4). 10. Set the portion size (see page 8-5). 11. Set the feed speed (see page 8-14). 12. Clear all tables (see page 8-5). 13. Test the correct operation of the COSMIX S (see page 8-6). 14. Disconnect the E-Link Manual Controller.

Make sure the connection with T4C is still working properly if: • Two or more Cosmix machines are installed and • The amount of rest feed in T4C raises quickly. The T4C report ''Feeding - Rest Feed' displays only information about cows that have rest feed. 1. Go to the page Analysis/Reports > Reports 2. Select the report 'Feeding - Rest Feed'. Make sure feed types in the COSMIX S have a unique name. This makes it possible to report feeding details from the COSMIX S apart from the milking robot. 3. Select the feed types to be added to the report. 4. Select button [Open]. 6.2 List a Feed Overview The report ''Feed Overview' displays information about all cows. 1. Go to the page Analysis/Reports > Reports 2. Select the report 'Feed Overview'. Make sure feed types in the COSMIX S have a unique name. This makes it possible to report feeding details from the COSMIX S apart from the milking robot. 3. Select the feed types to be added to the report. 4. Select button [Open].

The report ''Feeding - Device Intake Overview' displays the total feed intake per device (milking robot and COSMIX S) and per feed type in a given period. 1. Go to the page Analysis/Reports > Reports 2. Select the report 'Feeding - Device Intake Overview'. 3. Enter the reporting period: • Enter the number of days (start and end), or • Select a specific start and end date. 4. Select button [Open].

8-1 8 TEST AND ADJUSTMENT 8.1 Introduction This chapter contains the following test and adjustment procedures for the COSMIX S Concentrate Feeder: • Set the network settings (see page 8-1) • Make basic software settings (see page 8-3) • Test the operation of the COSMIX S (see page 8-6) • Adjustments in the T4C software (see page 8-13) • Adjustments with the service interface (see page 8-14). 8.2 Connect or Remove the E-Link Manual Controller Block the cow traffic to the COSMIX S before you do this procedure. Connect 1. Loosen the cap until you can remove it from the connector on the control unit (7)(see figure 9 on page 4-9). 2. Connect the connector of the E-Link Manual Controller to the connector on the control unit. 3. Fully turn the ring on the connector. Removal 1. Loosen the ring until you can remove the connector of the E-Link Manual Controller. 2. Install the cap on the connector on the control unit. 8.3 Set the Network Settings 8.3.1 Set Defaults Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu, select 'Network settings' and push button [ ]. 2. Select 'Set defaults' and push button [ ]. 3. Push soft button [OK] to confirm.

After a few seconds you return to the main menu. 8.3.2 Set the Device Address of the Cosmix Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu, select 'Network settings' and push button [ ]. 2. Select 'Dev addr Cosmix' and push button [ ]. 3. Use soft buttons [<] or [>] to select the position you want to change. 4. Use buttons [ ] or [ ] to change the value. 5. Push soft button [OK] to confirm. After a few seconds you return to the main menu. 8.3.3 Set the T4C Device Address Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu, select 'Network settings' and push button [ ]. 2. Select 'Dev addr T4C' and push button [ ]. 3. Use soft buttons [<] or [>] to select the position you want to change. 4. Use buttons [ ] or [ ] to change the value. 5. Push soft button [OK] to confirm. After a few seconds you return to the main menu. 8.3.4 Set the IP-address Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu, select 'Network settings' and push button [ ]. 2. Select 'IP Address' and push button [ ].

8-3 3. Use soft buttons [<] or [>] to select the position you want to change. 4. Use buttons [ ] or [ ] to change the value. 5. Push soft button [OK] to confirm. After a few seconds you return to the main menu. 8.4 Make Basic Software Settings 8.4.1 Display the Software Version Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu, select 'Version info' and push button [ ]. 2. Push button [ ]. After a few seconds you return to the main menu. 8.4.2 Reset to the Default Settings Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu of the (UI name), select Settings and push [ ]. 2. Select 'Set defaults' and push button [ ]. 3. Push soft button [OK] to confirm. After a few seconds you return to the main menu. 8.4.3 Set the Time Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu of the (UI name), select Settings and push [ ]. 2. Select 'Time' and push button [ ]. 3. Use soft buttons [<] or [>] to select the position you want to change.

4. Use buttons [ ] or [ ] to change the value. 5. Push soft button [OK] to confirm. After a few seconds you return to the menu 'Settings'. 8.4.4 Make the Photocell Active Block the cow traffic to the COSMIX S before you do this procedure. Only applicable for Qwes - H/HR readers. Use the E-Link manual controller for this procedure. 1. In the main menu, select ‘Settings’ and push button [ ]. 2. Select 'Photocell active' and push [ ]. 3. Use the buttons [ ] or [ ] to change the value. 4. Push button [OK] to confirm. After a few seconds you return to the menu 'Settings'. 8.4.5 Calibrate the Valves Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu, select 'Setup' and push button [ ]. 2. Select 'Calibrate Valves' and push button [ ]. 3. Select 'Valve' and push button [ ]. 4. Push the buttons [ ] or [ ] to select the number of the dosing unit (see page 4-6) and push [ ]. 5. Select 'Portions' and push button [ ]. 6. Push the buttons [ ] or [ ] to select 10 feed portions. 7. Push button [ ] to confirm. 8. Push button [START]. The valve opens and closes to dose each of the 10 feed portions. The software counts down the amount of feed portions. 9. Use a balance to weigh the feed. 10. Calculate the portion size (total weight/10).

8-5 11. Set the correct portion size (see page 8-5). 8.4.6 Set the Portion Size Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu, select ‘Settings’ and push [ ]. 2. In the menu 'Settings' select 'Portion size1', 'Portion size2', 'Portion size3' or 'Portion size4' and push button [ ]. 3. Use soft buttons [<] or [>] to select the position you want to change. 4. Use buttons [ ] or [ ] to change the value. 5. Push soft button [OK] to confirm. After a few seconds you return to the menu 'Settings'. 8.4.7 Adjust the Portion Size Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. Make sure the feed bin is empty. 2. Use the E-Link to drop five portions for feed type 1 (see page 8-7). 3. Remove the food from the feed bin. 4. Use a balance to weigh the food. 5. Calculate the portion size by dividing the total weight by five. 6. Set the portion size for feed type 1 (see page 8-5). 7. Repeat the procedure for other feed types. 8.4.8 Clear all Tables Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu of the (UI name), select ‘Setup’ and push [ ]. 2. Select 'Clear All Tables' and push button [ ].

The E-Link displays the message "Remove Local Data!!!". 3. Push soft button [OK] to confirm. After a few seconds you return to the menu 'Setup'. 8.5 Test the Operation of the COSMIX S 8.5.1 Test the Time Setting Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu, select 'Testing' and push button [ ]. 2. Select 'Time' and push button [ ]. 3. Make sure the values are correct. 1. If the settings are correct, push button [ ]. 2. Else, set the time (see page 8-3). 8.5.2 Display Real Time Information Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. In the main menu, select 'Testing' and push button [ ]. 2. Select 'RealTimeInfo' and push button [ ]. The display shows: • the tag ID of the identified cow • the content of the feed bin • the cows credit • the amount food the cow has already eaten 8.5.3 Test the Tag-ID Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure.

8-7 1. In the main menu, select 'Testing' and push button [ ]. 2. Select 'Tag id' and push button [ ]. The display shows: • the tag ID of the identified cow • a value 1 if the cow is detected by the (optional) photocell. 3. Push button [ ]. 8.5.4 Test the Dosing Units Block the cow traffic to the COSMIX S before you do this procedure. Use the E-Link manual controller for this procedure. 1. Make sure the feed funnels are not empty. 2. In the main menu, select 'Testing' and push button [ ]. 3. Select 'Valves/Blocker' and push button [ ]. 4. Select 'Valve 1' and push button [ ]. 5. Make sure the dosing unit gives the correct food type. 6. If the COSMIX S has two or more feed types: 1. Select 'Valve 2' and push button [ ]. 2. Make sure the dosing unit gives the correct food type. 7. If the COSMIX S has three or more feed types: 1. Select 'Valve 3' and push button [ ]. 2. Make sure the dosing unit gives the correct food type. 8. If the COSMIX S has four feed types: 1. Select 'Valve 4' and push button [ ]. 2. Make sure the dosing unit gives the correct food type. 9. If one or more dosing units do not give the correct food type, assign the correct feed type to the dosing unit (see page 8-13). 8.6 Adjust the Floor Antenna Signal (Qwes leg models only) Special tools • Non-metal screwdriver (e.g. plastic) Preparation 1. Open the control unit. 2. Find the indication LEDs (4)(see figure 41 on page 8-9) on the Velos box (3).

3. Open the EWA transformer box (see page 5-23). 4. Find the trimmer coil (2) on the EWA transformer pcb (1). Adjust 1. Turn the trimmer coil on the EWA transformer pcb clockwise until it is completely in the coil housing with a non-metal screwdriver. 2. Turn the trimmer anti-clockwise until the green LED (4) lights up. 3. If the green LED does not light up: 1. Remove the jumper on connector B1 on the EWA transformer pcb (1)(see figure 33 on page 5-24). 2. Connect the jumper to connector B2 on the EWA transformer pcb. 3. Repeat the adjustment procedure. Attach the EWA transformer housing to the front portal 1. Install the cover on the EWA transformer box. 2. Install the EWA transformer box in the EWA transformer housing. Make sure not to damage the cables. 3. Connect the rear sides of the parts of the housing. 4. Slide the assembly over the front portal. 5. Attach the EWA transformer on the front portal with two M8 bolts, washers and nuts (1)(see page 8-10).

8-9 Figure 41. Adjust the EWA transformer KEY: 1. EWA transformer pcb - 2. Trimmer coil - 3. Velos box - 4. Indication LEDs - 5. Terminal strip

Figure 42. Remove/Install the Qwes leg ID reader KEY: 1. Cap nut - 2. Washer - 3. Bolt A: Open the EWA transformer housing B: Close the EWA transformer housing C: Attach the EWA transformer housing to the front portal D: Install the EWA transformer housing with M8 bolts, washers and nuts. 8.7 Adjust the Photoelectric Sensor Special tools • Screwdriver. Preparation 1. Open the control unit. 2. Find the photoelectric sensor. 3. Find the detection distance adjuster on the photoelectric sensor.

8-11 Adjust To set the cow detection area (see figure 43 on page 8-11): 1. Turn the detection distance adjuster (4)(see figure 44 on page 8-12) completely counterclockwise with the screwdriver to the minimum detection distance (I)(see figure 45 on page 8-13). 2. Put a matt black object at approximately 120 cm (47.2 in) above the ground. 3. Slowly turn the detection distance adjuster (4) clockwise with the screwdriver until the detection LED (1) comes on and the stability LED (3) goes out. 4. Make a mark of the position (A)(see figure 45 on page 8-13) on the adjuster indicator (II). 5. Remove the object. 6. Slowly turn the detection distance adjuster (4)(see figure 44 on page 8-12) further clockwise with the screwdriver until the detection LED (1) comes on again (either the floor is scanned or the maximum detection distance is reached). 7. Make a mark on the position (B)(see figure 45 on page 8-13) on the adjuster indicator (III). 8. Turn the detection distance adjuster (4)(see figure 44 on page 8-12) counter clockwise with the screwdriver until the adjuster indicator is exactly in the middle of the positions A and B (IV). Figure 43. Cow detection area

Figure 44. Photocell LEDs and detection distance adjuster KEY: 1. Detection LED (red) - 2. Adjuster indicator - 3. Stability LED (green) - 4. Detection distance adjuster