WELBA WTS-300, WTS-300 G1 Installation And Operating Instructions Manual

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Universal tank control WTS-300 Firmware V2.0

Installation and operating instructions for plant engineering companies, installers and service engineers

Measuring - Controlling - Regulating

All from the same source

welba.de

Programmable via configuration software WELBA „KONSOFT"

105204 WTS-300 V2.0 - 11.01.2019

WTS-300 G1

Contents

1 Introduction

1.1 Information about this operating instructions Page 4

1.2 Limitation of liability Page 5

1.3 Device description Page 6

1.4 Type designation Page 6

1.5 Items supplied Page 7

1.6 Dimensions Page 7

1.7 Technical data Page 8

1.8 Sensor dimensions and technical data sensor Page 9

2 Safety

2.1 General Information Page 10

2.2 Intended use Page 12

2.3 Wiring, screening, earthing Page 13

2.4 Electrical safety Page 13

3 Installation

3.1 Location and climatic conditions Page 14

3.2 Unpacking and storage Page 14

3.3 Installation of housing Page 14

3.4 Fitting the sensor Page 15

4 Electrical connection

4.1 Safety during installation Page 16

4.2 Procedure Page 16

4.3 Wiring Page17

4.4 Connection diagram Page 18

4.5 Wiring the digital inputs Page 19

4.6 Connection robot Page 19

4.7 Connection of external pressure sensor (optional) Page 19

5 Operation

5.1 Function overview Page 20

5.2 The configuration software KONSOFT Page 23

5.3 Guideline for the initial installation / parameterization Page 24

5.4 Setting the date and time Page 26

5.5 Operation in levels Page 27

5.6 Operation of working level Page 28

5.6.1 Button functions Page 29

5.6.2 Meaning of the LEDs Page 30

5.6.3 Operation modes Page 32

6 Cleaning

6.1 Cleaning methods (cooling tank-configurations) Page 36

6.1.1 Circulation cleaning with a beaker Page 36

6.1.2 Circulation cleaning with two dosing pumps Page 36

6.1.3 Displacement cleaning with feed container, dosing pumps in circulation line Page 37

6.1.4 Displacement cleaning with feed container and dosing pumps Page 37

6.2 Page 38Cleaning programme diagram

6.3 Explanation and programming of the cleaning process Page 39

6.3.1 Service functions for testing the cleaning cycle Page 46

7. Tank monitor and general fault handling

7.1 Description of tank monitor operation Page 48

7.2 Tank monitor: Milk removal YES or NO Page 50

7.3 Tank monitor: Handling multiple faults Page 53

7.4 Tank monitor: Display fault memory Page 53

7.5 Listing fault codes and their description Page 54

7.5.1 Critical tank monitor alarms (red) Page 54

7.5.2 Informative tank monitor alarms (green) Page 55

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Contents

7.5.3 System alarms cleaning Page 56

7.5.4 System alarms cooling Page 58

7.5.5 System alarms external sensors Page 59

7.5.6 Test alarm Page 59

8. Setting of parameters

8.1 Change and save parameter values Page 60

8.2 Level „General cooling parameters“ c-parameter Page 62

8.3 Level „Extended cooling parameters“ P-parameter Page 64

8.4 Level „General cleaning parameters“ n-parameter Page 69

8.5 Level „Extended cleaning parameters“ r-parameter Page 72

8.6 Level „Service parameters“ E-parameter Page 77

8.7 Level „General tank monitor parameters“ h-parameter Page 78

8.8 Level „Extended tank monitor parameters“ H-parameter Page 80

8.9 Level „Alarm -> Event assignment“ F-parameter Page 82

8.10 Level „Hardware assignment“ A-parameter Page 84

8.11 Level „I-/O- test parameters“ o-parameter Page 90

9. Other information

9.1 Butterfly valve (manual or pneumatic) Page 92

9.2 Safety switch for manual butterfly valve Page 93

9.3 Robot control Page 94

9.3.1 Cleaning release by robot Page 95

9.4 Different variants for cooling start delay Page 96

9.5 Compressor switch-on delay / pre-agitating Page 98

9.6 Emergency cooling / sensor failure Page 98

9.7 Sensor correction procedure Page 98

9.8 Function second temperature sensor Page 99

9.9 Alarm level during cooling Page 98

9.10 Automatic / convenience functions Page 98

9.10.1 Autom. start to cont. agitating mode after exiting cooling mode Page 98

9.10.2 Automatic start to cooling mode after successful cleaning Page 98

9.11 Heating control Page 100

9.12 Function of pressure switch – Effect on pump and heater Page 100

9.13 Air in the cleaning pump -> automatic venting Page 101

9.14 Level control setting Page 102

9.15 Detergent injection position Page 103

9.16 Configuration of the different stages Page 103

9.17 Setting of a break in the cleaning programme Page 104

9.18 Page 104Function test alarm

9.19 Activation delay tank monitor Page 105 . Procedure following power failure9 20 Page 106

9.21 Power pack (optional) Page 106

9.22 Agitator monitoring module (optional) Page 107

9.23 Connection /Param. external analogue pressure sensor Page 108

9.24 Tank overflow protection Page 108

9.25 Tanks with various cooling levels Page 109

9.26 Anti-freezing protection by means of low pressure monitoring Page 109

9.27 General measures when using electronic control systems Page 110

Circuit diagram is stored in the control box

Publisher: WELBA GmbH Electronic Control Engineering Gewerbepark Siebenmorgen 6 D-53547 Breitscheid

Tel: Fax: E-mail: Internet:

+49 (0)2638 / 9320-0 +49 (0)2638 / 9320-20 info@welba.de www.welba.de

1. Introduction

1.1 Information about this operating instructions

These operating instructions are intended for the use by plant engineers, installers or service technicians of the WTS-300 universal tank control. This manual contains all necessary suggestions, Information, recommendations and advice for the safe and proper installation and commissioning of the tank control. It is only with the knowledge of this operating instruction that errors in the tank control system can be avoided and a trouble-free operation is guaranteed.

Read the assembly instructions carefully and adhere to the recommendations described in order to ensure proper operation. In addition, the local accident prevention regulations and general safety regulations are to be observed for the field of application of the tank control.

When delivered, the parameterization of the WTS-300 does not necessarily correspond to the intended use. This must be adjusted accordingly during the installation.

Basically, the installer of the system is responsible for the commissioning of the control.

Operation instruction for the operator

The plant engineers, the installer or the service technician must prepare operating instructions for the operator of the tank control (farmer). In this case the parameterization of the delivery state must be clearly documented.

We recommend to only document those parameters which the operator of the tank control needs.

When preparing the operating instructions for the operator the local regulations have to be observed – see chapter “Safety”.

These operating instructions include important technical and safety information. It is vital to carefully study all these instructions before the installation of the control or in case of any other work with the control!

These instructions have been prepared with the utmost care. However, the information contained herein is not an assurance of product characteristics.

NOTICE for storing the operating instructions

This instruction manual is part of the product and must always be readily available for the service technician.

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1.2 Limitation of liability

The proper function of the WTS-300 depends on many external factors on which the manufacturer has no influence. The manufacturer accepts no liability for any damages on the milk cooling tank, the connected components or the milk. The integrated tank monitor supports only the control of the milk quality and does neither absolve the farmer (as operator of the milk tank) nor the driver of the milk collecting truck from the duty of care. Both parties have to ensure that the milk is transportable before it is removed from the tank.

All information and instructions in this manual have been compiled taking into account the applicable standards and regulations, the state of the art and our long-term experiences.

WELBA GmbH does not assume any liability for damages due to:

! Non-observance of the installation instruction ! Improper use ! Installation by unqualified staff ! Non-professional installation by third parties ! Unauthorized modifications ! Technical modifications ! Use of unapproved spare parts (e.g. batteries)

1. Introduction

Otherwise, our general terms and conditions as well as the terms of delivery of WELBA GmbH and the legal regulations valid at the time of conclusion of the contract are applicable.

We reserve the right to make technical changes in the context of improving the properties of use and further developments,

1. Introduction

These operating instructions contain important technical and safety information. Please read carefully before installation and before any work on or with the regulator.

These instructions have been compiled with maximum care and attention. However, their content does not constitute an assurance of product features.

1.3 Device description

The WTS-300 is an universal tank control unit that combines various basic functions in one unit

, a milk cooling thermostat , an extensive cleaning control , an extended robot interface , an extended tank monitoring system

All functions can be parameterised separately and universally.

1.4 Type designation

The control unit has various operating modes:

, OFF mode (tank is empty) , Cooling mode , Continuous stirring mode , Cleaning mode

WELBA KONSOFT

The free of charge configuration Software KONSOFT provides a simple parameterization and updating of the WTS-300 as well as a comfortable evaluation of the determined data.

See section 5.2

NOTE: The KONSOFT PC-Software has been thoroughly tested and has proven itself hundreds of times in customer use. Despite all care, we point out that the use of the free PC-Software is at your own risk. WELBA does not accept any liability for damages or loss of data resulting from the installation or use of the Software.

The type designation of your controller is attached to the holder frame.

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1.5 Items supplied

1.6 Dimensions

1. Introduction

! Controller WTS-300 ! Holder ! Rubber seal ! Sensor ! Fixing screws

106

177

°C

Mode

Robot Stop

Valve open

RESET

Robot STOP

1. Introduction 1. Introduction

1.7 Technical data of control unit

Operating voltage 230V AC +/-10%, 50/60 Hz Relay contact 12 performance relays max. switching current 6 x each 6A AC1 - 250V AC

4 x each 10A AC1 - 250V AC 2 x each 12A AC1 - 250V AC

max. current per terminal 12A - 250V AC max. switching voltage 250V AC - 50..60 Hz Display 13 mm LED-Display, 4 digits Display range -999 ... 9999 LED switching status displays 3 mm Number of sensor inputs 1 or 2 Measurement range -5° ... +95°C Temperature resolution 0.1°C Sensor input KTY 81-210 (optionally PT-100) Control mode two-step controller Hysteresis* 0.1 K .. 99,9 K (standard adjusting 0.7 K) Water detection via 2 independent level monitors Target temperature T1* standard adjusting 8°C Target temperature T2* standard adjusting 4°C Digital inputs 8 (via optocoupler) Interface 2x RS 485 Connection Plug-in screw connections

for cables up to 2.5 mm² Housing

- Front dimension 177 x 106 mm

- Front panel cut out 157 x 97 mm

- Insertion depth 45 mm Protection The control is open on the rear, as it is designed for

installation in a closed housing

- Housing front IP 64

- Rear IP 20 Electrical safety Protection class II,

Overvoltage category III, pollution degree I Environment specifications:

- Operation temperature 0° .. +50°C

- Storage temperature -20° .. +70°C

- max. humidity 75% (no dew)

Technical data subject to change

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1.8 Sensor dimensions and technical data

6,1 mm

40 mm

Order no. TF1A-2

6,0 mm

Sensor element Bush material Bush length Bush diameter Cable material Measurement range Cable length Protection type

Sensors other than our standard type are available on request (different bush form or cable length).

Some of the options are shown here.

KTY sensor

1.4301 (V2A) 40 mm

6.0 mm +/- 0.1 PVC

-10 .. 70° C standard 2 metres IP 65

2. Safety

2.1 General Information

The plant engineering company, the installer or the service engineer must prepare operating instructions for the operator, taking account of the controller's parameters as supplied.

We recommend referring only to the parameters which the end user needs for safe operation.

In preparing the operating instructions for the end user, especially the chapter on “Safety”, account must be taken of local regulations.

The parameter settings of the WTS-300 as supplied do not correspond to the intended use. This can lead to undefined behaviour by individual components when the system is commissioned.

For this reason, no actuators should be connected when starting operation. Load circuits should be separated.

The general principle is that the plant constructor is responsible for putting the controller into operation.

IMPORTANT NOTICE ON LIABILITY The faultless function of the WTS-300 depends on many external fac-

tors, which the manufacturer has no influence on. The manufacturer assumes no liability for damage to the milk cooling tank, the connected components or the milk. The integrated tank monitor thus only supports the milk quality and does not release the farmer (as operator of the milk cooling tank) or the driver of the milk collecting truck from the duty of care. These must ensure, before withdrawing from the tank, that the milk is transportable.

IMPORTANT NOTICE ABOUT THE ACCUMULATORS (only if installed) The life of the accumulators is limited. The built-in accumulators must

be replaced by new ones every two years at the latest. Only (!) charged accumulators of the following specification may be

used: 1.2 V NiMh - size AA (min. 2.000 mAh)

DO NOT USE BATTERIES !!! EXPLOSIVE !!!

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2. Safety

These operating instructions contain important technical and safety information. Please read carefully before installation and before any work on or with the regulator.

It is the duty of the party commissioning the system to ensure compliance with the following guidelines.

The universal tank controller may only be installed by an authorised specialist, observing all local safety requirements.

Access to the environment when connected must be restricted to specialised personnel.

Universal tank controllers contain live components. They must be built into the plant in such a way that contact with such live components is impossible.

The controller is not suitable for use in explosive atmospheres. Danger of explosion. Use only outside areas subject to explosive atmospheres.

The device must not be used if the housing or connection terminals are damaged.

No fluids must penetrate the housing.

The universal tank control may not be exported to the USA without the manufacturer's express permission.

2. Safety 2. Safety

2.2 Intended use

These operating instructions contain important technical and safety information. Please read carefully before installation and before any work on or with the regulator.

Universal tank controllers WTS-300 are designed to control heating systems, condensing units, alarms, fans, etc. in milk cooling tanks as well as to monitor milk quality. Furthermore, connected milking robots can be controlled. Any other use of the device is permitted only with prior written permission from the manufacturer.

The controller is intended only for incorporating into machinery, display panels or switchboxes etc. and when fitted corresponding to protection class 2 (double or reinforced insulation) It is only allowed to be put into operation in installed state. The use . of the control is permitted in devices of protection class 1 and 2. The controller must not be modified or converted in any way.

The universal tank controller is ready for use only when the parameters have been set appropriately. Its use before this has been done would have no benefits and could also damage the equipment or adversely affect the milk to be temperature-controlled.

Responsibility for the faultless functioning of the connected devices lies with the plant engineer or the installer or the service engineer who has installed and commissioned the WTS-300.

The device is fitted with a resistance temperature sensor. The controller is not suitable for use in explosive atmospheres. Danger of explosion.

Use only outside areas subject to explosive atmospheres. The WTS-300 fulfils the EC requirements for electromagnetic compatibility (EMC)

and the Low Voltage Directive (LVD). The safety components meet the VDE regulations.

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2.3 Wiring, screening, earthing

When selecting wiring materials and installing and connecting the temperature controller to the electricity supply, account must be taken of DIN VDE 0100 “Erection of power installations with rated voltages below 1000” or the relevant national regulations (e.g. based on IEC 60364).

! Wherever possible, keep input, output and supply leads and sensor cable physically

separate from each other and do not lay them parallel to each other.

! Mains voltage cables and low-voltage cables must not be laid in one cable. ! Use screened and twisted interface and sensor cables. ! Earth the screening of temperature sensors unilaterally in the switchbox. ! Ensure correctly wired potential equalisation.

2.4 Electrical safety

! The controller itself and the associated control circuits and load circuits must be pro-

tected separately and in accordance with the local regulations.

! The separate protection of the control- and load circuit must be carried out according

to local conditions!

! In order to prevent destruction of the relay or semiconductor relay outputs in the event

of a short-circuit, the load circuit should be fused to the maximum permissible output current.

! As well as incorrect installation, wrong parameter settings can also adversely affect

the correct functioning of the controller. For this reason, safety devices that are independent of the controller should always be used, e.g. high and low pressure valves or temperature limiters. Account should be taken of the local safety regulations in this connection.

! The load circuit (relay outputs K1 to K12) must be fused in accordance with the con-

nected components.

! The connection of external voltages to the digital inputs can lead to the destruction of

the control.

! Caution: All cables to the digital inputs must be shielded and kept as short as possible.

EMC.

Important note concerning the external fuse

! The transformer, which is installed in the WTS-300, has a two-chamber safety wind-

ing, which is only short-circuit-proof due to the built-in thermal protection. If the temperature exceeds 145 ° C, there is a risk of damage!

Protect control unit with an external fuse of 160mA!

3. Installation 3. Installation

3.1 Location and climatic conditions

It is essential not to install the device under the following conditions:

" severe jolting, vibration or magnetic fields " permanent contact with water " relative humidity of more than 90% " sharply fluctuating temperatures (condensation) " dust, flammable gases, vapours, solvents, " operation in an aggressive atmosphere (ammonia or sulphur fumes) - risk of oxi-

dation

" operation in the immediate vicinity of radio transmitters with high levels of spuri-

ous radiation.

A physical separation between the device and inductive consumers is recommended.

3.2 Unpacking and storage

If the packaging is damaged or something is missing, do not fit the temperature controller. In this case please contact Welba.

If you keep the temperature controller for a period before using it, store it in a clean dry place at a temperure of between -20°C and +70°C.

3.3 Installation of housing

For fixing the housing please follow the instructions:

Place the seal carefully in the groove. Ensure it is not twisted.

! Insert the housing from the front through the switchboard cut-out. ! Attach the holding frame in the rear position as shown by the picture. ! Fasten the housing by using the screws provided.

166 157

all drillings ø 4 mm

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3.4 Fitting the sensor

The sensor cable must not be chafed or kinked.

There must be no substantial mechanical pressure on the sensor tube.

Do not place the sensor and the high-voltage cable in the same cable conduit (not even within the switchbox).

Temperature range sensor cable -10°C .. +70°C

The WTS-300 has been designed for connection to various types of sensor (see technical data). It can function properly only if one of those sensor types is installed and the parameters are correctly set.

When setting the temperature controller parameters (and whenever the sensor is replaced) the “actual value correction” [Parameter C91] must be adjusted so that the temperature measured corresponds to that shown on the display. A reference thermometer should be used for this purpose.

6,1 mm

40 mm

See the section 9.7

6,0 mm

Pay attention to the permitted temperture range for sensor cable exposure.

Changing the sensor cable length

lf it is necessary to shorten or lengthen the sensor cable on installation (or if a sensor other than the one supplied is to be fitted), the "actual value correction" parameter must be adjusted accordingly. See the section 9.7

4. Electrical connection

4.1 Safety during installation

Before connecting ensure that the mains voltage is the same as indicated on the device's type plate.

Incorrect electrical connection can cause damage to the regulator and to the equipment.

The temperature controller should be disconnected from the mains voltage while connecting plant components or the sensor.

No appliances with current levels in excess of the maximum values indicated in the technical data should be connected to the relay contacts.

No other consumers may be connected to the controller's mains terminals.

4.2 Procedure

In order to avoid injury to persons or damage to connected components, connections must in all cases be undertaken in the following order.

Pull out all the controller's plug-in terminals.

Put the controller in position in the housing or switchboard.

Connect all components and sensors in accordance with section 4.4 (Circuit diagram) to the plug-in terminals. (Do not yet plug the terminals into the controller!)

Connect the mains cable to plug-in terminal A1 / A2.

Plug terminal A1/ A2 into the controller.

Close the switchbox and turn on the mains voltage.

Switch on the controller and set the parameters (possibly using the optional WELBA-KONSOFT configuration software).

Plug the pre-cabled plug-in terminals of the components into the controller.

Close the switchbox.

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4.3 Wiring

4. Electrical connection

Correct wiring in accordance with the information in the accompanying description and local regulations is essential. Take particular care to ensure that the AC supply is not connected to the sensor input or other low-voltage inputs or outputs.

The various relay contacts may only be connected with uniform tension. Use copper wire (except for the sensor connection) and ensure that all supply leads

and connection terminals are dimensioned to suit the relevant current rating. When connecting the controller and selecting the wiring materials to be used, it is

essential to comply with the provisions of DIN VDE 0100 “Erection of power installations with rated voltages below 1000” or the relevant national regulations.

Furthermore, all connections must comply with the relevant VDE regulations or corresponding national regulations.

, Within the two relay groups (K3 to K6) and (K9 to K12), the respective relays are

connected with each other on one side. They connect the respective voltage which has been connected at the feed point (terminals 8 and 17) to the load.

, Compressor, cleaning pump and heater must not be connected directly to the relays

on the control unit. These must be switched by additional contactors. In individual cases, it must be checked whether additional motor protection switches or other safety devices are to be installed.

, Contactors are to be fitted with an RC protective circuit. , Connection of the digital inputs:

Only the output signal of the control provided at terminal 38 must be connected to the digital inputs (via potential-free switching contacts)!

4. Electrical connection 4. Electrical connection

4.4 Connection diagram

! Electrical connections must be as shown in the diagram

below.

! Use cable bushes. ! Make sure that cables cannot chafe. ! Observe relay current rating. ! In all cases use contactors for pump, compressor and

heater.

! Do not feed digital inputs with external voltage! Use

potential-free switches.

Default configuration

The assignment of components to the relay outputs is set in the A parameters (A1 to A12). See section 8.10

The assignment of components to the digital inputs is set in the A parameters (A21 to A28). Section 8.10

RX/TX-

RX/TX+

Alarm horn

interface

PC programming

external

RS485

Interface

(Tank monitoring alarm)

10A

Robot STOP

54321

6 10987 11 12 13 14 15NC16 17 18 19 20

10A

Safety switche

Dry protection heating

Thermal protection pump

Remote start cooling

3736 3938 4140 4342 44 4645

RX/TX- 2

RX/TX+ 2

Digital inputs

Acid detergent

L1 - Supply

Water pressure switch

Thermal protect. compres.

Release cleaning

Drain valve

Cleanig pump

Heater

10A

12A

Impulse milk pump

Connect digital inputs with potential-free contacts!

Butterfly valve

Alkaline detergent

Warm water valve

L1 - Supply

Cold water valve

K10

ONLY Welba-

Power pack

(50-60)Hz(50-60)Hz

(50-60)Hz

Compressor

Agitator

10A

12A

K11

K12

(8x AA)

230V AC230V AC

230V AC

22 21A2 A1NC

3435 3233 3031 2829 27

GND

Output. +12 V

Sensor 1

Sensor 2

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Input. 0..20 mA

(optional)

Connection

pressure sensor

26 2425 23

GND*

Lev1

Lev2

Level 1

Level 2

GND * = capacitively decoupled from GND

GND*

If the tank housing is to be used as one of the two level poles, this pole must be connected to GND*.

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4.5 Wiring the digital inputs

Terminals 39 to 46 are digital optocoupler inputs. These are used to monitor and process external switching contacts. These switching contacts must be potential-free! The signal provided by the controller at terminal 38 must be fed separately to each individual switching contact.

Parameter assignment

A21

A22

A23

A24

A25

A26

3938 4140 4342 44 4645

Digital inputs

A27

A28

Connect digital inputs with potential-free contacts!

4.6 Connection robot

If the WTS-300 and the robot have a separate power supply, the robot can still be stopped (by corresponding connection) in the event of power failure.

10A

4 5 6

[A41] = 0

[A41] = 2

from the robot

Robot requires an active signal to stop (high-active)

, [A41] = 0: In the event of a power failure, the robot is not stopped

(Connection to terminal 6 / 4)

, [A41] = 2: In the event of a power failure, the robot is stopped

(Connection to terminal 6 / 5)

10A

4 5 6

[A41] = 1

[A41] = 3

from the robot

Robot needs to lose the signal to stop (low active)

, [A41] = 1: In the event of a power failure, the robot is stopped

(Connection to terminal 6 / 4)

, [A41] = 3: In the event of a power failure, the robot is not stopped

(Connection to terminal 6 / 5)

4.7 Connection of external pressure sensor (optional)

Terminals 27 to 29 must be used only for the connection of an external pressure sensor. See section 9.23

Connection pressure sensor two-wire Connection pressure sensor three-wire

signal

4..20 mA

2829 27

Pressure sensor

two-wire

4..20 mA

signal

2829 27

Pressure sensor

three-wire

Maximum load terminal 27 = 100 mA

5. Operation

5.1 Function overview

Working level

for normal daily operation

The WTS-300 is a universal tank control unit which combines all the basic functions in one device:

- milk cooling control

- comprehensive cleaning control

- an extended robot interface

- an extended tank monitor

All basic functions can be selected and operated from the working level. The control unit can also be adapted to a wide range of different system types and sizes. This takes place through the thematically organised parameter levels.

General cooling parameters

Extended cooling parameters

General cleaning parameters

Extended cleaning parameters

Service parameter

General tank monitor parameter

Extended tank monitor parameter

Parameter levels

Alarm configuration

Configuration

I/O test parameter

Within the working level the control unit differentiates between various operating modes:

! OFF mode (stand-by)

Shows the current time

, All LEDs are out

(Exceptions: robot, outlet valve and tank monitor LEDs may be lit)

, All output relays are deactivated

(Exceptions: robot, outlet valve and tank monitor alarms may be active)

The other operating modes can only be selected from OFF mode. It is not possible to switch directly between the different modes.

CAUTION: The control unit is live even when switched off.

! Cooling mode

Two freely definable target temperatures can be selected by pressing a button. If the milk temperature exceeds the selected target temperature (T1 or T2) by

the hysteresis value, the compressor contactor and agitator are switched on automatically. Once the target temperature is attained, the compressor contactor switches off, while the agitator continues to run for the set “afterstirring“ period.

During cooling breaks the agitator switches on periodically, in accordance with the set 'pause time', in order to ensure an even temperature throughout the milk.

Independently of this, during cooling, short or long “intermediate stirring” can be switched on by pressing a button.

Cooling can be triggered in different ways:

, manually using the “START COOLING“ button , via digital input “Remote start to cooling“

(by robot or external button)

, automatically following cleaning (only in conjunction with robot)

Cooling now starts in accordance with the pre-set starting mode: Immediately or after a cooling start delay, with periodic cooling boosts, etc.

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5. Operation

! Continuous stirring mode

From OFF mode, the agitator can be switched on by pressing a button and then switched off again by pressing the OFF button.

Parameter [C25] can be used to set the time after which the agitator is to switch off automatically.

The countdown can be interrupted at any time using the OFF button. If [C25] is set to '0', the agitator will run continuously, but can be switched off at

any time using the OFF button.

! Cleaning mode

The cleaning timer controls the water intake by time or level, as desired. All running times (heater, pump, detergent injection) can be set separately. The automatic switchover from acidic to alkaline detergent is also adjustable.

The WTS-300 controls the different processes and times fully automatically.

RESET

Following a power failure the control unit will restart in the mode it was in before.

Robot interface

Depending on the parameter settings, the control unit includes a built-in robot interface with the following functions:

- „Robot start / stop“ and

- “Butterfly valve open / closed“

These functions are controlled via the keypad.

Tank monitor function

During the entire cooling and cleaning process, the built-in tank monitor keeps check on the correct operation of all components, in order to guarantee the perfect state of the milk.

In particular, the following are monitored:

- minimum and maximum milk temperatures during cooling

- power failure (optionally power pack required!)

- agitator function (optionally agitator monitoring module required

- minimum and maximum temperatures during cleaning

- etc.

Any faults are indicated by two LEDs, and associated fault codes flash in the display.

In the case of errors which may jeopardise the milk quality, the red LED “Don't add milk” lights up.

5. Operation 5. Operation

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5.2 The configuration software KONSOFT

For software description see separate instructions

The user-friendly configuration software “KONSOFT" for the WTS-300 can be used for

, configuration , parameter setting , visualisation , storage , updating

Configuration

All setting parameters can be entered and stored, with reference to levels, on your PC using a clearly designed template. A description is available for every parameter.

Once all parameters are entered, the complete configuration can be transferred to the control unit via USB interface

Visualisation

Also by USB transfer, values and status or error reports can be obtained from the control unit, displayed on screen graphically or in tabular form, and stored. This allows rapid analysis in the event of a fault.

Bootloader function

This allows control units to be updated to any new software by pressing a button, without changing parameter settings.

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5. Operation 5. Operation

5.3 Guideline for the initial installation / parameterization

Before setting parameters you should decide the following:

, Which components (pump, compressor, heater, robot, butterfly

valve, alarm, etc.) do you wish to control or regulate with the control unit?

, Which external signal transmitters (sensors, safety switches, pres-

sure switches, robot signals etc.) are decisive for the control of the connected devices?

, Are alarm functions to be defined? , Which occurrences (temperature, time) shall affect the control

processes?

, Which cleaning processes are appropriate to the system?

Step 1 Connect all hardware components acc. to connecting diagram. See

section 4.4

When using the tank monitor, connect optionally extra modules such as

USB module and / or stirring unit monitoring module.

Step 2 Assign hardware components to the corresponding relay outputs (A1 to

A12). See section 8.10

Step 3 Assign external signal transmitters to the digital inputs (A21 to A28). See

section 8.10.

Step 4 Check the wiring of all connected components. See section 8.11

IF ROBOTS IS SHALL BE USED:

Step 5 Adjust parameter A40 and A 41

IF TANK MONITORS SHALL BE USED:

Step 6 A-parameter, H-parameter, adapt H-parameter according to conditions.

Step 7 Assign occurrences to the various alarms in the F-parameters (alarm horn,

LED-display, SMS-message, etc.)

Step 8 Adjust cooling and cleaning parameter. See sections 8.2 to 8.5

Step 9 Test cleaning sequence on proper function. See section 6.3.1.

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105204 WTS-300 V2.0 - 11.01.2019

TIP

For the parameterization and the commissioning of the WTS-300 use the free Software “Welba KONSOFT”.

Advantages:

Fast and comfortable parameterization of the WTS-300.

Clear presentation of the parameter-settings of your tank.

Fast transfer of an existing configuration onto identical or similar tanks.

Use the „monitoring function“ of the Software when commissioning the WTS-300.

Here all occurrences can be graphically displayed and recorded.

Store your configurations so that in case of a spare parts delivery the parameterization can be loaded onto the new device. Only the actual value correction has to be entered newly

In case of the initial installation the display shows after the application of the mains voltage

- 4 circulating bars,

- then briefly the Firmware-version

- then the time

Information: If only 4 blinking horizontal bars are displayed after the application of the mains volt-

age, the time has to be reset. See section 5.4. Note: For data evaluation, the Software Konsoft uses the entered date of the WTS-300. If

date and time are not entered correctly, the evaluation is also incorrect!

Now the control unit's parameters must be properly set in line with the features of your system.

Incorrectly set parameters can lead to serious malfunctions and damage to the milk-cooling tank.

When setting the control unit parameters, please bear in mind the consequences of malfunctions. For example, a continuously operating compressor can result in damage to the system. Protect yourself and your system by additional safeguards.

NB: The control unit offers more application functions than the number of relays and digital inputs available on the printed circuit board. When starting configuration please give careful consideration to how you want to allocate all the various components to the relays and digital inputs.

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5. Operation

5.4 Setting the date and time

Robot Stop

°C

Mode

Valve open

RESET

Robot

STOP

When the power is connected ...

... there are two possible displays:

1.) Time is lost: 4 dashes are shown: The date and time must be re-entered. Proceed as follows:

Press one of the arrow keys: the year appears, flashing.

Set the time as described below.

In the event of a power cut, the date and time are retained for up to 5 days. After that they must be re-entered.

Year

Date

Time

Robot STOP

2.) Time is still preserved: During initialisation, 4 rotating bars are shown, then the current firmware appears briefly, then the time is displayed. If it is not correct, adjust it as follows.

Setting the time during normal operation

Press the OFF button: a time is displayed.

Hold the SET button down until the year appears, flashing. (in between, the tank temperature is shown briefly)

Use the arrow keys to set the correct year

Press the SET button: the month appears, flashing.

Use the arrow keys to set the correct month.

Press the SET button: the day appears, flashing.

Use the arrow keys to set the correct day.

Then set the hour and minute displays in the same way.

When finished press the SET button. Setting is completed, and the actual time is displayed.

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5.5 Operation in levels

5. Operation

Working level

General cooling parameters C parameter code: C212

The working level is used for operation and control in everyday operation.

The WTS-300 is parameterized in 10 different parameter levels.

The subordinate parameter levels are only entered after entering a code in order to avoid inadvertent adjustment of the parameters.

Extended cooling parameters P parameter code: D345

General cleaning parameters n parameter code: B454

Extended cleaning parameters r parameter code: C567

Service parameters E parameter code: EA03

General tank monitor parameters h parameter code: 4711

Extended tank monitor parameters H parameter code: F94A

Alarm configuration F parameter code: FFFF

Configuration A parameter code: A384

Parameter level

General cooling parameters - (c parameter)

Parameters such as setpoints, hysteresis etc. can be set here.

Extended cooling parameters - (P parameter) Setting of plant-specific functions such as agitator function, cooling start variant,

milk removal option, etc.

I/O test parameters o. parameter code: 10E5

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General cleaning parameters - (n parameter) Parameters such as the run times of the rinses etc. can be set here.

Extended cleaning parameters - (r parameter) Setting of plant-specific functions such as configuration of safety elements, level

detection, number of passes of individual cleaning stages etc.

Service parameters - (E parameter) Displays the tank monitor parameters and counters

General tank monitor parameters - (h-parameter) Determine whether and when informative alarms are triggered

Extended tank monitor parameters - (H parameter) Determine whether and when critical alarms are triggered

Alarm configuration - (F parameter) Here an individual behaviour can be assigned for each fault.

Configuration - (A parameter) Determination / Parameterisation of the hardware configuration

I / O test parameters - (o parameter) Is intended for commissioning the control system.

5. Operation

5.6 Operation of working level

Working level

for normal daily operation

General cooling parameters code: C212

Extended cooling parameters code: D345

General cleaning parameters code: B454

Extended cleaning parameters code: C567

Service parameter code: EA03

General tank monitor parameter code: 4711

Extended tank monitor parameter code: F94A

Alarm configuration code: FFFF

Configuration code: A384

I/O test parameter code: 10E5

The working level is used for operation and control in everyday operation:

, OFF mode = switch off the control (Stand-by) , Start cooling mode , Start continuous stirring , Start cleaning mode , Robot operation , Milk removal via the butterfly valve , Observe tank monitor

°C

Mode

Robot Stop

Valve open

RESET

Robot STOP

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5.6.1 Button functions

5. Operation

„OFF“ button

To change to a different mode, always first press the “OFF” button. active modes are closed down when the OFF button is pressed.

Switch control unit to STAND-BY

Close down cleaning mode or continuous stirring mode prematurely

Acknowledge error

Change to programming mode (hold down button for 3 seconds)

„SET“ button

in OFF mode = press briefly: Display of critical faults (if available) Hold down for 3 seconds: set date and time

in cleaning mode = “Cleaning stage” or “Tank temperature” is displayed (see Parameter [r97]) and current error

Parameter setting = the current value entered is displayed in cooling mode = Display of various information such as time, fault,

litre display (see section 9.23)

Robot

STOP

“COOL” button

in OFF mode = start cooling press 2x = bypass the cooling start delay (if set) press long = new start of the cooling-start-delay (see section 9.4) in cooling mode = change target temperature T1 / T2

„AGITATOR” button

in OFF mode = start continuous stirring mode in cooling mode = press for 1 second: "Intermediate stirring SHORT"

press for 3 seconds: "Intermediate stirring LONG”

See also at the end of section “5.6.3 Cooling mode”

“WASHING” button

in OFF mode = start cleaning

“ARROW KEYS”

To select and adjust parameters.

Operation by the driver of the milk truck

RESET

Robot STOP

„RESET“ button

press briefly = Confirmation of the message “do not load”. See section 7.2 hold 5 seconds = Test of the red alarm-LED

„ROBOT STOP“ button (if parameterized) Starts or stops both the robot and the cooling mode as well.

„PNEUMATIC OUTLET VALVE“ button (if parameterized) Opens / closes the pneumatic outlet valve.

5. Operation

5.6.2 Meaning of the LED‘s

LEDs in cooling mode

LED "AGITATOR”

during cooling mode Agitator is switched on

°C

Mode

Robot Stop

Valve open

RESET

Robot STOP

LED "COMPRESSOR“

on Compressor contactor is switched on

off Compressor contactor is switched off flashing Pause time compressor (pendulum protection)

LED "T1” or „T2"

T1 on Set target temperature for "T1" is active

T2 on Set target temperature for "T2" is active

LEDs in cleaning mode

LED “ERROR”

flashing The control is in error mode and must be acknowledged with the "OFF" button.

LED “END OF CLEANING / TANK EMPTY”

permanent Cleaning successfully finished tank is ready for further filling.

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Display of operation mode

5. Operation

Mode

Robot / Drain valve

Robot Stop

Valve open

LED operating mode "COOLING”

flashing „cooling start delay“ is active permanent „cooling mode“ is active

LED operating mode "AGITATING”

permanent „continuous stirring“ is active

LED operating mode "CLEANING”

permanent „cleaning mode“ is active flashing no cleaning release from the robot (see section 9.3.1)

LED "ROBOTER STOP”

permanent Roboter is stopped flashing "CLEANING" button was pressed before the

robot was stopped

Robot Stop

Valve open

Tank monitoring

LED "PNEUMATIC OUTLET VALVE” opened

permanent pneumatic outlet valve is open flashing Cleaning button has been pressed before the

pneumatic outlet valve has been opened.

LED (green) "MILK COLLECTION OK”

permanent everything ok - milk can be loaded. flashing informative alarm is on

LED (red) "DON‘T ADD MILK !”

flashing critical alarm is on. permanent critical alarm is on - has already been

acknowledged off everything ok - milk can be loaded.

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5. Operation

5.6.3 Operation modes

OFF mode

°C

Mode

Robot Stop

Valve open

RESET

Robot STOP

The current time is displayed. (see also section 5.4) The control unit is on stand-by

, All mode LEDs are out. , All output relays are deactivated

(Exceptions: robot, butterfly valve and tank monitor alarms may be active)

The other operating modes can only be selected from OFF mode. It is not possible to switch directly between the different modes.

Mode

CAUTION: The control unit is live even when switched off.

Cooling mode

Cooling mode is started in all cases from the OFF mode. Starting takes place:

, MANUALLY by pressing the COOL button , DIGITALLY via digital input “Remote start to cooling “

(by robot or external button)

, AUTOMATICALLY following cleaning (if programmed)

Subject: Cooling start delay.

If “Cooling start delay” [P60] is programmed, the compressor starts after a delay, in order to prevent a small amount of milk in the tank from freezing. During the cooling-start-delay LED “operation mode “COOLING” is blinking.

This delay applies only for the first milking after cleaning. Note: If you push the button “COOLING” twice (double click), cooling will start

immediately without a delay - the LED will be lit continuously. There are various cooling start delay options. See section 9.4

After the start of the cooling mode

, The COOLING mode LED is lit

Robot Stop

Valve open

Page 32 Page 33

, The robot is enabled (LED off). , The butterfly valve is closed (LED off).

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5. Operation

, The “Agitator” LED lights up , The “Compressor” LED lights up only when the compressor is actually running.

- it is not lit if the milk temperature is lower than the target value

- it flashes for the duration of the min. pause time for the compressor [P71]

, The “T1” or “T2” LED (for target temperature 1 or 2) lights up. , The pre-set target temperature T1 or T2 flashes three times in the display, then

the current temperature of the milk is shown. If you wish to change to the other target temperature: press the COOL button again. (Switching over from T1 to T2 may be blocked via parameter [P80]).

The milk is now cooled down to the set target temperature, and the agitator runs continuously during cooling. If the milk temperature is already below the target, just the agitator runs for the time being.

, When the target temperature is reached, the compressor switches off.

, At the end of the set “after-stirring” period [c20], the agitator also switches off. , During cooling breaks the agitator switches on periodically, in line with the set

“pause time” [c21] for the “after-stirring” period [c20], in order to ensure an even temperature throughout the milk.

, If the milk temperature rises again, and exceeds the selected target tempera-

ture by the hysteresis value [c10 or c11], the compressor and agitator are switched on again automatically.

Stirring in cooling mode = INTERMEDIATE STIRRING

(only if released in parameter [P22])

In cooling mode, briefly press the AGITATOR button:

A “short intermediate stirring” is triggered [duration = c23]. The indication “Sho” is displayed.

In cooling mode, press the AGITATOR button for 5 seconds:

A “long intermediate stirring” is triggered [duration = c24]. The indication “Lon” is displayed.

Continuous stirring mode

if parameter [c25] = '0'

Press the “AGITATOR” button: (from OFF mode)

Switches on continuous stirring mode (revolving bar in the display).

Press “OFF” button:

Switches off continuous stirring mode.

if parameter [c25] > '0'

Press the “AGITATOR” button: (from OFF mode)

If parameter [c25] is set higher than '0', when the button is pressed the agitator runs for the set number of minutes.

Press “OFF” button:

Switches off continuous stirring mode prematurely.

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5. Operation

5.6 3 Operation of working level

Cleaning mode

Press the “WASH” button: (from OFF mode)

Cleaning proceeds automatically in line with your settings. Depending on the setting in [r97], the display indicates the current cleaning stage or the temperature. Exception: During the heating stages the current water temperature is displayed.

To stop cleaning manually

Press OFF button for 3 seconds: The cleaning programme switches to the stop

phase. “ABL” and “F43” flash alternately in the display, indicating “outlet valve open”.

, All currently active relays are de-energised

(apart from “Cleaning active” and “Robot stop”)

, The outlet valve opens for a pre-set time and then closes again. , The red “WASHING” LED blinks - code F43 flashes in the display. , The control unit switches to OFF mode only when the OFF button is pressed

again.

Cleaning does not start

There are various possible causes – depending on parameter settings:

, The robot has not been stopped -> Stop. , The butterfly valve is still closed -> Open. , The safety switch is in the wrong position. , No cleaning release from the robot (see section 9.3.1)

Displays during main wash

, during intake of alkaline detergent: "ALC“ , during intake of acidic detergent: "ACI“ , during disinfecting: “dESI“ , during heating the temperature alternates with "HEAt“

Robot operation

Robot STOP

Robot Stop

Valve open

Using the ROBOT STOP button, the operation of a connected robot is either stopped or enabled.

With the start / stop of the robot, the cooling mode of the milk tank is simultaneously started / stopped.

Hold down the ROBOT STOP button for approx. 3 seconds: robot operation is

either enabled or stopped (Toggle function) The current switching status is indicated by LED.

only if the robot is configured

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5.6 3 Operation of working level

Milk collection

Robot Stop

Valve open

5. Operation

Complete emptying of tank into collection tanker

Ensure that the green LED of the tank monitor indicator is lit

Press the OFF button

To stir the milk for a short period: briefly press the AGITATOR button. After the

desired stirring time, stop the agitator by pressing the OFF button.

Connect the milk pipe from the tanker.

Open the tank outlet. (depending on the system, either manually or by means of

the BUTTERFLY VALVE button)

If the tank has a pneumatic butterfly valve:

Press the “BUTTERFLY VALVE” button for approx. 3 seconds:

The butterfly valve opens – the milk is transferred to the tanker. The “Valve open“ LED is lit.

When the tank is empty

Disconnect the tanker's milk pipe .

Connected the cleaning hose to the tank outlet.

Press the WASH button.

To draw off a small quantity of milk (tanks with pneumatic butterfly valve)

If milk is to be taken from the tank while cooling mode is running, proceed as follows

Parameter [P32] Setting 1 -> Button function

The butterfly valve opens immediately and remains open for as long as the button is held down. When the button is released, the valve closes immediately.

Parameter [P32] Setting 2 -> Toggle function

Press the BUTTERFLY VALVE button for 3 seconds - Outlet opens. Briefly press the button again - Outlet immediately closes.

For both settings a time limit can be programmed via parameter [P33].

Observe the tank monitor

RESET

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The “Tank monitor” function indicates whether the milk quality is guaranteed or whether a fault has occurred during cleaning.

LED shows green: milk can be taken out.

LED shows red: DO NOT LOAD MILK!

The fault is indicated in the display. A detailed description of the tank monitor function may be found in section 7.1 of

these operating instructions.

6.1 Cleaning methods (cooling tank-configurations)

6.1.1 Circulation cleaning with a beaker

K12

Agitator

Heater

Drain valve

Hot

water

K9 K3

Hot water

valve

alcaline /

or acid

detergent

Cold

water

K10

Cold water

valve

Pump

Cleaning method for milk cooling tanks, where alkaline and acidic detergents are supplied either by a drawer or a fixed beaker.

6.1.2 Circulation cleaning with two dosing pumps

Hot

Heater

K12

Agitator

Pump

Drain valve

Cleaning method for milk cooling tanks, where alkaline and acidic detergents are supplied by separate dosing pumps.

water

K9 K10

Hot water

valve

Metering pump

for alcaline

Cold

water

K8 K3

Cold water

valve

detergent

Metering pump

for acid

detergent

Page 36 Page 37

6. Cleaning6. Cleaning

6.1.3 Displacement cleaning with feed container, dosing pumps in circulation line.

K12

Agitator

Heater

Drain valve

Hot

water

Cold

water

K9 K10

K8 K3

Hot water

valve

Cold water

valve

Pump

K8 = Metering pump

for alcaline detergent

K3 = Metering pump

for acid detergent

Level 2

Level 1

Feed container

Cleaning method for milk cooling tanks, where hot and cold water are dosed levelcontrolled in a feed container, before pumped out for tank cleaning. The detergent is filled into circulation line.

6.1.4 Displacement cleaning with feed container and dosing pumps

K12

Agitator

Heater

Drain valve

Hot

water

K9 K10

Hot water

valve

Metering pump

K8 K3

for alcaline

detergent

Level 2

Pump

Level 1

Cleaning method for milk cooling tanks, where water and detergent are dosed levelcontrolled in a feed container, before pumped out for tank cleaning.

Cold

water

Cold water

valve

Feed container

Metering pump

for acid

detergent

105204 WTS-300 V2.0 - 11.01.2019105204 WTS-300 V2.0 - 11.01.2019

6. Cleaning

6.2 Cleaning programme diagram

Cleaning cycle

agitator

compressor

cold water valve

warm water valve

alk. detergent

acid detergent

drain valve

cleaning pump

heater

cleaning active

disinfection

Clean. stg 0

Rinse out Pre-rinse 1 Pre-rinse 2 Main rinse 1 Intermediate rinse 1

n1n2n3

Cleaning stage 1

Level 2 Level 1

n10

n11

n12

n13

n14

n15

Cleaning stage 2 Cleaning stage 3 Cleaning stage 4

n16

n20

Level 2 Level 1

n21

n22

n23

n24

n25

n26

n30

Level 2 Level 1

n31

n32D1n33D2H

n34

n35

n36

n40

programme step

Level 2 Level 1

n41

n42

n43

n44

n45

n46

During the cleaning process the current

programme step is displayed.

The flashing point indicates activity.

Only available when activated in parameters

Switch-on delay for heater

Post-heating temperature during main circulation

Cleaning pump venting (if set in parameter [r80])

Only required in case of cleaning method ‚green' (see section 6.1.3 and 6.1.4).

n11

Designation of the n-parameters, with which the corresponding times are set

For the first parameter of each cleaning stage the following can be parameterised: Water intake by level

Adjustment of dosing times for detergents

Heat-up time (variable - until the set temperature is reached)

Cleaning cycles, cleaning stages

°C

Mode

and programme steps:

A cleaning cycle consists of different "cleaning stages".

Each cleaning stage consists of several 'programme steps'.

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Cleaning stage

6. Cleaning

n50

Level 2 Level 1

n51

Cleaning stage 5 Cleaning stage 6

Main rinse 2 Intermediate rinse 2

Level 2 Level 1

n52D1n53D2H

n54

n55

n56

n60

n61

n62

n63

n64

n65

n66

n70

Level 2 Level 1

n71

Cleaning stage 7

Disinfection

n72D1n73D2H

n74

n75

Cleaning stage 8

n76

n80

After-rinse

Level 2 Level 1

n81

n82

n83

n84

n85

Clean. stg 9

Rinse out

n86

n91

n92

n93

Abort

n100

nXX

Feed

container

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Explanation of the setting of alkaline / acid cleaning:

, If main cleaning stages 1 + 2 are activated, both alkaline and acid detergents are

used for each cleaning cycle.

, If a cycle with acidic detergent is to be carried out after x cleaning cycles with

alkaline detergent only, the main cleaning stage 2 must be deactivated. Parameter [r21] is used to set the number of alkaline cycles, after which one cycle with acid detergent will be carried out.

, The intake of the detergent is always time-controlled.

During dosing the display shows:

- ALC - alkaline detergent is dosed

- ACI - acid detergent is dosed

, Here you can select whether the detergent is to be dosed in programme step D1

or D2 or in the feed container. Parameter [r20]

6. Cleaning

6.3 Explanation and programming of the cleaning process

Cleaning methods

In section 6.1, 4 cleaning methods for different cooling tank configurations are described. In the following all 4 methods are described, whereby the specific differences are marked in colour.

Only reasonable for

yellow and pink

Circulation cleaning

with beaker

Circulation cleaning

with dosing pumps

Displacement cleaning

with dosing pumps and feed container

6.1.1 6.1.2 6.1.3 + 6.1.4

A cleaning cycle consists of up to nine different cleaning stages. The frequency of each stage during a cycle can be set by the user. See parameter [r40 to r48].

During the cleaning cycle the current programme step is displayed.

Cleaning stage 0: RINSE OUT Parameter [r40] = 0 ‘Cleaning stage 0’ disabled

Parameter [r40] = 1..5 ‘Cleaning stage 0’ execute x-times

+ Water is taken in.

The parameter [r50] is used to stipulate whether cold, hot or mixed water is to be taken in.

Furthermore, for "Cleaning stage 0", the water intake time was set [n01].

+ Agitator and pump start to run, the outlet valve will open.

The water circulates for the pre-set time [n02].

+ Agitator and pump switch off. + Drain valve opens for the pre-set time [n03]. The drain valve is assigned to the

respective cleaning stage via the parameters [r60 to r68]. Parameter [r24 / r25] determines whether the drain valve is normally open or normally closed. Applies to all cleaning stages.

Cleaning stage 1: PRE-RINSE 1 Parameter [r41] = 0 ‘Cleaning stage 1’ disabled

Parameter [r41] = 1..5 ‘Cleaning stage 1’ execute x-times

+ In case of cleaning method 'green' – it is set in programme step [n10] how often

the feed container is filled with water up to level 2 and water is pumped back up to level 1. As long as the rinsing pump is running, the drain valve is open.

+ Water is taken in.

In case of green

n11 and n12 have to be

parameterized on „0“

The parameter [n11] is used to stipulate whether water will be taken by level or time. If time-controlled, the water intake time is defined in parameter [n12].

If, in the event of intake by level, the level is not reached after a pre-set time [r32], the cleaning cycle is interrupted. See section 7.5.3 - F44 The cleaning parameter [r51] is used to stipulate whether cold, hot or mixed

In case of green

n13 have to be

parameterized on „0“

Page 40 Page 41

water is to be taken in.

+ Agitator and pump start to run.

Another option is to select an 'additional water intake time' using [n13].

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6.3 Explanation and programming of the cleaning process

6. Cleaning

In case of green

n14 have to be

parameterized on „0“

In case of green

n21 and n22 have to be

parameterized on „0“

In case of green

n23 and n24 have to be

parameterized on „0“

+ The water circulates for the pre-set time [n14].

An additional time can be defined in parameter [n15], in which the drain valve opens (agitator and cleaning pump continue to run)

+ Agitator and pump switch off. + Outlet valve opens for the pre-set time [n16]. See also [n15].

Cleaning stage 2: PRE-RINSE 2 Parameter [r42] = 0 ‘Cleaning stage 2’ disabled

Parameter [r42] = 1..5 ‘Cleaning stage 2’ execute x-times

+ In case of cleaning method 'green' – it is set in programme step [n20] how often

the feed container is filled with water up to level 2 and water is pumped back up to level 1. As long as the rinsing pump is running, the drain valve is open.

+ Water is taken in.

The parameter [n21] is used to stipulate whether water will be taken by level or time. If time-controlled, the water intake time is defined in parameter [n22].

The cleaning parameter [r52] is used to stipulate whether cold, hot or mixed water is to be taken in.

If, in the event of intake by level, the level is not reached after a pre-set time [r32], the cleaning cycle is interrupted. See section 7.5.3 - F44

+ Agitator and pump start to run.

Another option is to select an 'additional water intake time' using [n23]. The water circulates for the pre-set time [n24]. An additional time can be defined in parameter [n25], in which the drain valve

opens (agitator and cleaning pump continue to run)

+ Agitator and pump switch off. + Drain valve opens for the pre-set time [n26]. See also [n25].

In case of green

n31 and n32 have to be

parameterized on „0“

In case of green

n33 have to be

parameterized on „0“

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Cleaning stage 3: MAIN WASH 1 Parameter [r43] = 1 not changeable

+ In case of cleaning method 'green' – it is set in programme step [n30] how often

the feed container is filled with water up to level 2 and water is pumped backup to level 1. The drain valve remains closed up to cleaning step [n35/n36].

Settings for version 6.1.4 (dosing in pre-hopper)

Parameter [r20 = 0] and parameter [n30 = min. 2] since the detergent is added when water is taken from the pre-hopper for the second time.

+ Water is taken in.

The parameter [n31] is used to stipulate whether water will be taken by level or time. If time-controlled, the water intake time is defined in parameter [n32].

If, in the event of intake by level, the level is not reached after a pre-set time [r32], the cleaning cycle is interrupted. See section 7.5.3 - F44

The cleaning parameter [r53] is used to stipulate whether cold, hot or mixed water is to be taken in.

+ Agitator and pump start to run. Water circulates in the tank.

Another option is to select an 'additional water intake time' using [n33].

* (D1 or D2 in cleaning programme diagram)

6. Cleaning

6.3 Explanation and programming of the cleaning process

In case of green

n32 and n33 have to be

parameterized on „0“

Cleaning agent dosing: (see also explanation two pages before)

+ Depending on the setting of the parameter [r20], detergent is injected at the end

of the water intake time [n32] or the subsequent water intake time [n33] as follows:

, If ‚cleaning stage 5' is activated [r45=1] only alkaline detergent is injected here

for duration [n101*].

, If 'cleaning stage 5' is deactivated [r45=0] alkaline detergent is injected x times

for duration [n101*] before acidic detergent is injected once for duration [n102*].

, The number of alkaline cleaning cycles is set in [r21].

+ If a heater is present [r35], this is switched on. When the heating temperature

[n106] is reached, the heater is switched off again.

If the temperature is not reached within the pre-set time [r37], the control unit continues with the program, but a fault report is displayed at the end. See section 7.5.3 - F44

If a switch-on delay [r36] has been parameterized for heating, heating starts only after this time has elapsed. (This is to ensure that water is in the heater.)

+ Main circulation time: The water circulates for the pre-set time [n34]. During the

main circulating time, a post-heating temperature [n109] can be defined.

+ An additional time can be defined in parameter [n35], in which the drain valve

opens (agitator and cleaning pump continue to run)

+ Agitator and pump switch off. + Drain valve opens for the pre-set time [n36]. See also [n35].

In case of green

n41 and n42 have to be

parameterized on „0“

In case of green

n43 and n44 have to be

parameterized on „0“

Cleaning stage 4: INTERMEDIATE RINSE 1 Parameter [r44] = 0 ‘Cleaning stage 4’ disabled

Parameter [r44] = 1..5 ‘Cleaning stage 4’ execute x-times

+ In case of cleaning method 'green' – it is set in programme step [n50] how often

the feed container is filled with water up to level 2 and water is pumped back up to level 1. As long as the rinsing pump is running, the drain valve is open.

+ Water is taken in.

The parameter [n41] is used to stipulate whether water will be taken by level or time. If time-controlled, the water intake time is defined in parameter [n42]. The cleaning parameter [r54] is used to stipulate whether cold, hot or mixed water is to be taken in.

If, in the event of intake by level, the level is not reached after a pre-set time [r32], the cleaning cycle is interrupted. See section 7.5.3 - F44

+ Agitator and pump start to run.

Another option is to select an 'additional water intake time' using [n43]. The water circulates for the pre-set time [n44]. An additional time can be defined in parameter [n45], in which the drain valve opens (agitator and cleaning pump continue to run)

+ Agitator and pump switch off. + Drain valve opens for the pre-set time [n46]. See also [n45].

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6.3 Explanation and programming of the cleaning process

Cleaning stage 5: MAIN WASH 2 Parameter [r45] = 0 ‘Cleaning stage 5’ disabled

Parameter [r45] = 1 ‘Cleaning stage 5’ execute one time

+ In case of cleaning method 'green' – it is set in programme step [n30] how often

the feed container is filled with water up to level 2 and water is pumped backup to level 1. The drain valve remains closed up to cleaning step [n55/n56].

Settings for version 6.1.4 (dosing in pre-hopper) Parameter [r20 = 0] and parameter [n50 = min. 2] since the detergent is added when water is taken from the pre-hopper for the second time.

In case of green

n51 and n52 have to be

parameterized on „0“

+ Water is taken in.

The parameter [n51] is used to stipulate whether water will be taken by level or time. If time-controlled, the water intake time is defined in parameter [n52].

If, in the event of intake by level, the level is not reached after a pre-set time [r32], the cleaning cycle is interrupted. See section 7.5.3 - F44 The cleaning parameter [r54] is used to stipulate whether cold, hot or mixed

In case of green

n53 have to be

parameterized on „0“

water is to be taken in.

+ Agitator and pump start to run. Water circulates in the tank. + Another option is to select an 'additional water intake time' using [n53]. + Depending on the setting of the parameter [r20], acidic detergent is injected at

the end of the water intake time [n52] or the subsequent water intake time [n53]. The duration of the detergent dosing is set in parameter [n102].

+ If a heater is present [r35], this is switched on. When the heating temperature

[n107] is reached, the heater is switched off again.

If the temperature is not reached within the pre-set time [r37], the control unit continues with the program, but a fault report is displayed at the end. See section 7.5.3 - F44

If a switch-on delay [r36] has been parameterized for heating, heating starts only after this time has elapsed. (This is to ensure that water is in the heater.)

+ Main circulation time: The water circulates for the pre-set time [n54]. During the

main circulating time, a post-heating temperature [n110] can be defined.

+ An additional time can be defined in parameter [n55], in which the drain valve

opens (agitator and cleaning pump continue to run)

+ Agitator and pump switch off. + Drain valve opens for the pre-set time [n56]. See also [n55].

6. Cleaning

In case of green

n61 and n62 have to be

parameterized on „0“

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Cleaning stage 6: INTERMEDIATE RINSE 2 Parameter [r46] = 0 ‘Cleaning stage 6’ disabled

Parameter [r46] = 1..5 ‘Cleaning stage 6’ execute x-times

+ In case of cleaning method 'green' – it is set in programme step [n60] how often

the feed container is filled with water up to level 2 and water is pumped back up to level 1. As long as the rinsing pump is running, the drain valve is open.

+ Water is taken in.

The parameter [n61] is used to stipulate whether water will be taken by level or time. If time-controlled, the water intake time is defined in parameter [n62]. The cleaning parameter [r55] is used to stipulate whether cold, hot or mixed water is to be taken in.

If, in the event of intake by level, the level is not reached after a pre-set time [r32], the cleaning cycle is interrupted. See section 7.5.3 - F44

6. Cleaning

6.3 Explanation and programming of the cleaning process

In case of green

n63 and n64 have to be

parameterized on „0“

In case of green

n71 and n72 have to be

parameterized on „0“

In case of green

n73 have to be

parameterized on „0“

+ Agitator and pump start to run.

Another option is to select an 'additonal water intake time' using [n63]. The water circulates for the pre-set time [n64]. An additional time can be defined in parameter [n65], in which the drain valve opens (agitator and cleaning pump continue to run)

+ Agitator and pump switch off. + Drain valve opens for the pre-set time [n66]. See also [n65].

Cleaning stage 7: disinfection Parameter [r47] = 0 ‘Cleaning stage 7’ disabled

Parameter [r47] = 1 ‘Cleaning stage 7’ execute x-times

+ In case of cleaning method 'green' – it is set in programme step [n30] how often

the feed container is filled with water up to level 2 and water is pumped backup to level 1. The drain valve remains closed up to cleaning step [n75/n76].

Settings for version 6.1.4 (dosing in pre-hopper) Parameter [r20 = 0] and parameter [n70 = min. 2] since the detergent is added when water is taken from the pre-hopper for the second time.

+ Water is taken in.

The parameter [n71] is used to stipulate whether water will be taken by level or time. If time-controlled, the water intake time is defined in parameter [n72].

If, in the event of intake by level, the level is not reached after a pre-set time [r32], the cleaning cycle is interrupted. See section 6.5.3 - F44

The cleaning parameter [r57] is used to stipulate whether cold, hot or mixed water is to be taken in.

+ Agitator and pump start to run. Water circulates in the tank.

Another option is to select an 'additional water intake time' using [n73].

+ Depending on the setting of the parameter [r20], acidic detergent is injected at

the end of the water intake time [n72] or the subsequent water intake time [n73]. The duration of the detergent dosing is set in parameter [n103].

+ If a heater is present [r35], this is switched on. When the heating temperature

[n108] is reached, the heater is switched off again.

If the temperature is not reached within the pre-set time [r37], the control unit continues with the program, but a fault report is displayed at the end. See section 7.5.3 - F44

If a switch-on delay [r36] has been parameterized for heating, heating starts only after this time has elapsed. (This is to ensure that water is in the heater.)

+ Main circulation time: The water circulates for the pre-set time [n74]. During the

main circulating time, a post-heating temperature [n111] can be defined.

+ An additional time can be defined in parameter [n75], in which the drain valve

opens (agitator and cleaning pump continue to run)

+ Agitator and pump switch off. + Drain valve opens for the pre-set time [n76]. See also [n75].

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6.3 Explanation and programming of the cleaning process

Cleaning stage 8: AFTER RINSE Parameter [r48] = 0 ‘Cleaning stage 8’ disabled

Parameter [r48] = 1..5 ‘Cleaning stage 8’ execute x-times

+ In case of cleaning method 'green' – it is set in programme step [n80] how often

the feed container is filled with water up to level 2 and water is pumped back up to level 1. As long as the rinsing pump is running, the drain valve is open.

In case of green

n81 and n82 have to be

parameterized on „0“

+ Water is taken in.

The parameter [n81] is used to stipulate whether water will be taken by level or time. If time-controlled, the water intake time is defined in parameter [n82].

If, in the event of intake by level, the level is not reached after a pre-set time [r32], the cleaning cycle is interrupted. See section 7.5.3 - F44 The cleaning parameter [r58] is used to stipulate whether cold, hot or mixed

In case of green

n83 and n84 have to be

parameterized on „0“

water is to be taken in.

+ Agitator and pump start to run.

Another option is to select an 'additional water intake time' using [n83]. The water circulates for the pre-set time [n84].

+ An additional time can be defined in parameter [n85], in which the drain valve

opens (agitator and cleaning pump continue to run)

+ Agitator and pump switch off. + Drain valve opens for the pre-set time [n86]. See also [n85].

6. Cleaning

Only reasonable for

yellow and pink

Cleaning stage 9: RINSE OUT Parameter [r49] = 0 ‘Cleaning stage 9’ disabled

Parameter [r49] = 1..5 ‘Cleaning stage 9’ execute x-times

+ Water is taken in. + The parameter [r50] is used to stipulate whether cold, hot or mixed water is to

be taken in.

+ Furthermore, for "Cleaning stage 0", the water intake time was set [n01]. + Agitator and pump start to run, the outlet valve will open. + The water circulates for the pre-set time [n02]. + Agitator and pump switch off. + Drain valve opens for the pre-set time [n03]. The drain valve is assigned to the

respective cleaning stage via the parameters [r60 to r69].

+ Parameter [r24 / r25] determines whether the drain valve is normally open or

normally closed. Applies to all cleaning stages.

Abort of cleaning cycle Aborting can occur:

, Manually (by pressing the OFF button) , Due to mains failure , An abort criterion was met

(e.g. predetermined time for reaching the level exceeded)

If cleaning has been completed without errors, the control unit switches to "OFF mode" or "cooling mode" depending on the parameter setting.

6. Cleaning

6.7.1 Service functions for testing the cleaning cycle

Start cleaning with the desired cleaning stage (0 to 8)

! Set the desired cleaning stage (0 to 8) in parameter [r92]. ! Press CLEANING button: A cleaning cycle starts with the selected cleaning

stage and then runs through to the end. The next cleaning cycle starts again with the first cleaning stage.

Switch on the cleaning cycle with single step function (up to 3 times) In order to be able to test a cleaning cycle more quickly, it is possible to switch the cycle

manually from one programme step to the next without having to wait until it has been completely processed.

! In parameter [r93], set the number of cleaning cycles to be executed consecu-

tively with the single step function. NB: An aborted cleaning counts here as a completed cleaning.

! By repeatedly pressing the CLEANING button, the cycle can now be progressed

step by step.

programme step

Can be terminated via OFF button at any time, with drain phase. Tank monitoring function and alarms are deactivated !!!!!

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6. Cleaning

7. Tank monitor and general fault handling

7.1 Description of tank monitor operation

During the entire cooling and cleaning process, the built-in tank monitor keeps check on the correct operation of all processes, in order to guarantee the perfect state of the milk. Faults are displayed flashing in the display via corresponding fault codes. Depending on the type of alarm, two LEDs (red and green) are flashing or lit.

In the case of errors which may jeopardise the milk quality, the problem is indicated by a red LED as a “critical alarm”. In this case milk must not be added to the tank before a careful check has been carried out.

In the "F" parameters (see section 8.9), a system alarm, an informative alarm or a critical alarm is defined for each fault. It is also parameterized, whether a relay function or an SMS message should be carried out. For this to take effect, the relay functions in the "A" parameters (see section 8.10) must be assigned to a relay or the SMS function must be activated.

The tank monitor of the WTS-300 has the following alarm types:

Critical tank monitor alarms (red LED + fault code in the display)

During cooling: - min. and max. milk temperature

- agitator function and stirring intervals

- duration of power failure

- milk temperature too high for too long During cleaning: - cleaning temperatures

- wash duration

Informative tank monitor alarms (green LED + fault code in the display)

During cooling: - milk temperature too high for too long

- milk temperature too low

- agitator failure and stirring times

- max. time till next wash

- duration of power failure

During cleaning: - cleaning temperatures

- detergent injection and acting time

Additional WTS-300 system alarms (only fault code in the display)

(depending on parameter settings, may be both critical and informative)

During cooling: - cooling time for first milking

- broken sensor

- sensor short-circuit, etc.

During cleaning: - monitoring of butterfly valve, cleaning pump, etc.

- water intake and outlet times,

- heating times, etc.

A list of all alarms and a description of how they are configured can be found in section 8.9 “Alarm -> Event assignment”.

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7. Tank monitor and general fault handling

Optical presentation of alarms

Informative alarm

°C

Mode

Robot Stop

Valve open

RESET

Robot STOP

No alarm

Each alarm has its own display code (see section 7.5 for listing)

Informative and critical alarms are also indicated by LED as follows:

active informative alarm (Green permanently again after RESET)

Critical alarm

Informative and

critical alarm

System alarm

active critical alarm

critical alarm after RESET (Turns off when cleaning cycle runs for at least 10 minutes ...)

active critical + informative alarm

critical + informative alarm - 1x RESET

critical + informative alarm - multiple RESET

If several alarms are present, the reset button must be pressed several times. See section 7.3

(Turns off when cleaning cycle runs for at least 10 minutes ...)

Is displayed as a blinking display code only.

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7. Tank monitor and general fault handling

7.2 Tank monitor: Milk removal YES or NO

Examples of use of tank monitor.

CAUTION:

Do not simply cancel a tank monitor alarm. It is essential to investigate and remedy the cause, in order to avoid a harmful effect on the milk.

Even without an alarm message, the plant operator has to convince himself of the transportability of the milk before picking up!

No alarm – Milk may be drawn off.

Green = on Red = off

! The driver goes to the WTS-300 and checks the tank monitor.

If the green LED is on, milk may be drawn off.

! Once the milk has been taken, the driver starts the cleaning process.

Informative alarm - Milk may be drawn off.

Green = flashing Red = off

after RESET

Green = on Red = off

! The driver goes to the WTS-300 and checks the tank monitor.

The green LED is flashing – the warn horn sounds - an error code is displayed. Milk can be drawn off -> The farmer must be informed.

! The farmer investigates (and remedies) the cause of the fault and presses the

"RESET" button -> the warn horn mute.

! The farmer presses the “RESET“ button again -> the green LED is now on con-

tinuously. (The informative alarm is accepted and deleted with the pushbutton.)

! Once the milk has been taken, the driver starts the cleaning process.

No alarm

Informative alarm (Press RESET button)

Informative alarm

RESET RESET

NB: If the informative alarm is not reset, the green LED flashes and the error code con-

tinues to be displayed -> even after the next cleaning cycle.

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7. Tank monitor and general fault handling

Critical alarm - Milk must not be taken out.

Green = off

Red = flashing

critical alarm (press RESET button)

RESET RESET

after RESET

Green = off

critical alarm

Red = on

! The driver goes to the WTS-300 and checks the tank monitor.

The red LED is lit or flashing, an error code blinks in the display and, depending on the circumstances, a horn may sound.

! The driver informs the farmer -> Farmer and driver investigate the cause of the

critical alarm. (The critical alarm codes are taken from the display and identified using the fault table. See section 8.9)

! The farmer and driver then decide together whether the milk can be transferred

to the tanker, despite the alarm.

! The farmer presses the RESET button to cancel the alarm -> The warn horn

mute.

! The farmer presses the RESET button again -> the red LED is lit continuously. ! Once the tank is emptied the washing process must be started

It is only when the cleaning cycle is active for at least 10 minutes that the tank monitor resets all critical alarms.

7. Tank monitor and general fault handling

Critical + informative alarm - Milk must not be taken out.

Green = flashing Red = flashing

critical + informative alarm (press RESET button)

RESET RESET

after RESET

Green = flashing Red = on

critical + informative alarm (press RESET button)

RESET

after second RESET

Green = off

critical + informative alarm

Red = on

! The driver goes to the WTS-300 and checks the tank monitor.

Green and red LEDs are flashing, an error code blinks in the display and, depending on the circumstances, a horn may sound

! The driver informs the farmer -> Farmer and driver investigate the cause of the

critical and informative alarms. (The critical alarm codes are taken from the display and identified using the fault table. See section 8.9)

! The farmer and driver then decide together whether the milk can be transferred

to the tanker, despite the alarm.

! The farmer first presses the RESET button to cancel the critical alarm -> the

horn switches of.

! The farmer presses the RESET button again -> the red LED is lit continuously. ! The farmer then cancels the informative alarm -> the green LED turns off. ! Once the tank is emptied the washing process must be started.

It is only when the cleaning cycle is active for at least 10 minutes that the tank monitor resets all critical alarms.

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7. Tank monitor and general fault handling

7.3 Tank monitor: Handling multiple faults

For every alarm - whether informative (green) or critical (red) – an error code blinks in the display.

If several faults occur simultaneously, the code for the most recently occurring fault blinks in the display.

If both informative and critical faults occur, priority is always given to the critical error code (in the example this would be fault F10)

Exception in cooling mode: sensor faults flash alternately with critical or informative

Informative

alarm

Critical

alarm

alarms.

Cancelling faults: (both LEDs flash alternately)

! The most recently occurring fault (example F10) blinks in the display.

Press RESET button -> The horn switches off, the most recently occurring fault (example F10) continues to blink in the display.

! Identify the fault using the list of faults -> Press RESET button ->

the red LED continues to flash in order to indicate that there are further critical faults.

! The next fault (in the example F11) blinks in the display:

Identify the fault using the list of faults -> Press RESET button -> etc.

When the last critical fault (example F02) has been reset: (red LED permanently lit)

Cance lled critical faults are transferred to the device's internal fault memory and can be consulted at any time.

! The first informative fault (example F34) blinks in the display:

Identify the fault using the list of faults -> Press RESET button -> The green LED continues to flash in order to indicate that there are further informative faults.

! The next informative fault (example F20) flashes in the display...

When the last informative fault has been reset, the green LED goes out, while the red LED stays on permanently.

It is only when the cleaning cycle is active for at least 10 minutes that the tank monitor resets all critical alarms.

7.4 Tank monitor: Display fault memory

If the tank monitor's red LED is permanently lit, it means that critical faults have already been acknowledged, but still exist. These error codes are registered in the device's internal fault memory and can be consulted as follows:

Show the last 5 critical faults from the fault memory

! SET button in OFF mode: the code for the first critical fault is displayed (in

the above example F02).

! SET button again: the next error code is displayed (in the example F05).

If no button is pressed for 3 seconds, the display switches back to the time.

It is only when the cleaning cycle is active for at least 10 minutes that the tank monitor resets all critical alarms.

7. Tank monitor and general fault handling

7.5 Listing fault codes and their description

The display blinks to indicate faults.

Meanings as follows:

7.5.1 Critical tank monitor alarms (red)

°C

Mode

°C

t1 t2 t3+ +

30°

H10

4°

ZEIT

F1 Milk temperature too high for too long 1

If during cooling mode the milk temperature exceeds the temperature limit

value entered in [H10] for longer than the time entered in [H11], fault report F1 appears.

H11 here is the limit value for the sum of all time overshoots (t1, t2, t3 etc.)

F2 Milk temperature too high for too long 2

as F1, but relating to [H12 and H13]

F3 Milk temperature too high for too long 3

as F1, but relating to [H14 and H15]

F6 Power cut alarm

Alarm functions only if optional power pack is installed. Alarm is triggered if power cut lasts longer than the time entered in parameter

[H20].

F11 Minimum washing temperature not reached

Alarm is triggered if, in the main washing stages, the minimum water temper-

ature selected in [H30] is not reached.

F12 Minimum acting time not reached

Alarm is triggered if, in the main washing stages, the minimum water temper-

ature selected in [H30] has not had enough time to act.

Minimum acting time = [H31]

F15 Agitator fault in cooling mode (milk not stirred)

Alarm functions only if optional “Welba agitator monitor” is installed and

parameters set [A71].

Alarm occurs after the cooling mode is started, if a backpressure by the milk

has not been detected on the stirrer within the time [H40].

F16 “No stirring” time exceeded

Alarm functions only if optional “Welba agitator monitor” is installed and

parameters set [A71].

Alarm is triggered if, after the previous stirring, more than the number of

minutes set in [H41] have passed without the agitator restarting.

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7. Tank monitor and general fault handling

7.5.2 Informative tank monitor alarms (green)

F20 Cooling time exceeded for first milking

Alarm is triggered if the temperature set in parameter [h20] is not reached within the time set in parameter [h21].

The time starts when cooling of the first milking starts.

F22 Forgotten to switch on the cooling

At the milking time [h41-h43] entered, the cooling was not switched on.

F23 Milk temperature too high for too long

Same as for faults F1 - F3. Setting in parameter [h23 / h24]

F25 Excess temperature directly

When cooling starts, this alarm remains inactive until the milk temperature falls below the temperature set in [h20] for the first time. It is at this point that milk temperature monitoring starts. If the milk temperature subsequently exceeds the temperature set in [h25], the alarm is triggered.

F27 Milk temperature too low for too long

The alarm is triggered if the milk temperature is too low [h27] for too long [h28]. The timer starts when the temperature falls below [h27] and stops again when the temperature exceeds [h27]. The timer restarts each time the temperature is exceeded.

F29 Low temperature directly

The alarm is triggered as soon as the milk temperature falls below the temperature set in [h29].

F30 Power cut directly

The alarm can function only if the optional power pack is installed. Regardless of the operating mode, the alarm is triggered in the event of a power cut.

F31 Max. time without cooling (starts when cooling manually ends)

Safety function! (This is to prevent that after manual interruption of the cooling mode is forgotten, to reactivate it or to start the cleaning after the milk removal.)

Timer starts as soon as cooling mode is switched off manually. The alarm is triggered if a new cooling period or washing cycle is not started within time [h31].

F32 Max. time without cooling (starts when washing ends)

Safety function! (designed to ensure that the operator does not forget to start cooling mode after washing.)

Timer starts as soon as washing mode ends. The alarm is triggered if a new cooling period or washing cycle is not started within time [h32].

F33 min. cleaning interval

Alarm is triggered, if a new cleaning does not take place within the time [h33]

F34 Time / date not set

The alarm is triggered if the date and time are lost.

F35 Detergent "Empty" alkaline - Alerts empty detergent container

(only if optional float switch is installed and configured [h35])

F36 Detergent "Empty" acid - Alerts empty detergent container.

(only if optional float switch is installed and configured [h36])

F38 Exceeding of temperature difference, monitoring sensor

The alarm can function only if the optional monitoring sensor is installed and parameters set.

The alarm is triggered as soon as the temperatures differ by value [h38].

F39 Battery voltage too low

The alarm can function only if the optional power pack is installed. The alarm is triggered if the battery charge is no longer sufficient.

see also section 9.10.2

0: Auto start deactivated

1: Auto start activated (in case of successful cleaning)

P61 Variations of the cooling start delay 0 .. 7 0 0: deactivated (without cooling start delay)

1: simple cooling start delay 2: Interval cooling boosts (power reduction by cycles) 3: Interval cooling boosts after switch-on delay 4: Start cooling according to number of boosts of milk pump

5: Interval cooling boosts according to number of impulses milk pump 6: Milk-volume-dependent cooling start delay (from start cooling) [P50-55] 7: Milk-volume-dependent cooling start delay (from start cleaning) [P50-55]

P62 Duration of cooling start delay [P61] = 1 or 3 1 .. 999 min. 30

8. Setting of parameters

P63 „ON“ time cooling boost [P61] = 2, 3, 5 1 .. 30 min. 5

P64 „OFF“ time cooling boost [P61] = 2, 3, 5 5 .. 60 min. 20

P65 Number of cooling boosts [P61] = 2, 3, 5 1 .. 10 5

P66 Number of impulses milk pump [P61] = 4 or 5 1 .. 10 10

P67 Timeout delay via milk pump 1 .. 999 min. 60

only if [P61] = 4 or 5 Safety function: In the absence of milk pump impulses

(for example, wire breakage), cooling is started

after [P67] has elapsed.

Compressor settings Range Default

P70 Compressor stop via digital input 0 .. 2 0 Possible control of the cooling start by robot. 0: deactivated

1: Signal at the digital input blocks the compressor 2: no signal at digital input blocks the compressor

INFORMATION: Pay attention to the function assignment [A21 - A28]

P71 Minimum pause time compressor 0 .. 999 sec. 120 Prevents the compressor from running against pressure.

The LED compressor is flashing during the pause time.

P72 Thermal protection monitoring compressor 0 .. 2 0 0: deactivated

1: high-activated (error "F53" when open) 2: low-active (error „F53" when closed)

INFORMATION: Pay attention to the function assignment [A21 - A28]

8. Setting of parameters

8.3 Level “Extended cooling parameters” (P parameters)

P73 Function 2nd and/or 3rd cooling level compressor 0 .. 3 0 Explanations see also section 9.25

0: deactivated 1: Delayed after cooling start delay by the time [P74 / P75] 2: Controlled via level sensor

INFORMATION: Pay attention to the function assignment [A21 - A28]!

3: Filling quantities controlled (litre registration via pressure sensor) P74 Time delay 2nd cooling level 1..999 min 60

From the end of cooling start delay P75 Time delay 3rd cooling level 1..999 min 60

From activation of 2nd cooling level

P76 Min. filling-quantity to switch the 2 cooling level on 0..5000 ltr 2000 P77 Min. filling-quantity to switch the 3 cooling level on 0..5000 ltr 4000

Settings for target temperature switchover T1 / T2 Range Default

P80 Settings for target temperature switchover T1 / T2 0 .. 3 0

0: deactivated (always T1 active) 1: only manual switchover T1 / T2 via button.

Press “Cooling” button in cooling mode to change to

the other target tempepature. The corresponding LED lights up.

2*: manual switchover to T2 with switch-back after a period.

Press “Cooling” button in cooling mode: control unit

switches to T2 for period [P81] and then back to T1.

3*: manual and automatic switchover to T2 at a set time,

with switch-back after a period.

- Automatic switchover to T2 at time [P82] and [P83] with switch-back after period [P81]. (if only one time is to be used, [P82] and P83 must be set to the same time.)

- Manual switchover to T2 for period [P81] by pressing the “Cooling” button.

* In the case of 2 and 3:

- If T1 is active, the LED for T1 is permanently on.

- If T2 is active, the LED for T2 flashes and shows that switch-back to T2 will happen automatically.

P81 Duration until switch-back to T1 0 .. 999 min. 60

[P80] = 2 or 3

P82 Time 1 for automatic switchover to T2 00:00 .. 23:59 4:00 see also [P80]

P83 Time 2 for automatic switchover to T2 00:00 .. 23:59 16:00 see also [P80]

Settings low pressure monitoring Range Default

Explanations see also section 9.26

P85 Pressure trigger limit (pressure too low) 1 .. 99,9 % 20 P87 Monitoring delay after start compressor 10 .. 999 sec. 120 P88 Switch off time compressor in case of too 1 .. 15 min. 10

low pressure

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8. Setting of parameters

8.4 Level “General cleaning parameters” (n parameters)

Working level

for normal daily operation

General cooling parameters code: C212

n parameters

Code: B454

Switch to level “General cleaning parameters” See section 8.1.

Range Default

Running times cleaning stage 0 (rinse out) - hidden, if [r40] = 0

Extended cooling parameters code: D345

General cleaning parameters code: B454

Extended cleaning parameters code: C567

Service parameters code: EA03

General tank monitor parameters code: 4711

Extended tank monitor parameters code: F94A

Alarm configuration code: FFF F

Configuration code: A384

I/O test parameters code: 10E5

For all „water intake by feed container“ the following applies:

0 = deactivated

1..6 = Number of repetitions

Applies to all “Water intake by level 1" situations:'

0 = deactivated 1 = activated

n01 Water intake time 0 .. 999 sec. 10 n02 Rinse out time with water intake 0 .. 999 sec. 120 n03 Drain time 0 .. 999 sec. 30

Running times cleaning stage 1 (pre-rinse 1) - hidden, if [r41] = 0

n10 Water intake by feed container (displacement cleaning) 0 .. 6 0 n11 Water intake by level 1 0 .. 1 0

n12 Water intake by time 0 .. 999 sec. 90 n13 Additional water intake time + circulation 0 .. 999 sec. 0 n14 Main circulation time 0 .. 999 sec. 30 n15 Rinse out time 0 .. 999 sec. 0 n16 Drain time 0 .. 999 sec. 60

Running times cleaning stage 2 (pre-rinse 2) - hidden, if [r42] = 0

n20 Water intake by feed container (displacement cleaning) 0 .. 6 0 n21 Water intake by level 1 0 .. 1 0 n22 Water intake by time 0 .. 999 sec. 90 n23 Additional water intake time + circulation 0 .. 999 sec. 0 n24 Main circulation time 0 .. 999 sec. 30 n25 Rinse out time 0 .. 999 sec. 0 n26 Drain time 0 .. 999 sec. 60

Running times cleaning stage 3 (main rinse 1) - hidden, if [r43] = 0

n30 Water intake by feed container (displacement cleaning) 0 .. 6 0 n31 Water intake by level 1 0 .. 1 0 n32 Water intake by time 0 .. 999 sec. 120 n33 Additional water intake time + circulation 0 .. 999 sec. 0 n34 Main circulation time 0 .. 999 sec. 120 n35 Rinse out time 0 .. 999 sec. 0 n36 Drain time 0 .. 999 sec. 90

8. Setting of parameters 8. Setting of parameters

Running times cleaning stage 4 (intermediate rinse) - hidden, if [r44] = 0

n40 Water intake by feed container (displacement cleaning) 0 .. 6 0 n41 Water intake by level 1 0 .. 1 0 n42 Water intake by time 0 .. 999 sec. 90 n43 Additional water intake time + circulation 0 .. 999 sec. 0 n44 Main circulation time 0 .. 999 sec. 30 n45 Rinse out time 0 .. 999 sec. 0 n46 Drain time 0 .. 999 sec. 60

Running times cleaning stage 5 (main rinse 2) - hidden, if [r45] = 0

n50 Water intake by feed container (displacement cleaning) 0 .. 6 0 n51 Water intake by level 1 0 .. 1 0 n52 Water intake by time 0 .. 999 sec. 120 n53 Additional water intake time + circulation 0 .. 999 sec. 0 n54 Main circulation time 0 .. 999 sec. 120 n55 Rinse out time 0 .. 999 sec. 0 n56 Drain time 0 .. 999 sec. 90

Running times cleaning stage 6 (intermediate rinse 2) - hidden, if [r46] = 0

n60 Water intake by feed container (displacement cleaning) 0 .. 6 0 n61 Water intake by level 1 0 .. 1 0 n62 Water intake by time 0 .. 999 sec. 90 n63 Additional water intake time + circulation 0 .. 999 sec. 0 n64 Main circulation time 0 .. 999 sec. 30 n65 Rinse out time 0 .. 999 sec. 0 n66 Drain time 0 .. 999 sec. 60

Running times cleaning stage 7 (disinfection) - hidden, if [r47] = 0

n70 Water intake by feed container (displacement cleaning) 0 .. 6 0 n71 Water intake by level 1 0 .. 1 0 n72 Water intake by time 0 .. 999 sec. 120 n73 Additional water intake time + circulation 0 .. 999 sec. 0 n74 Main circulation time 0 .. 999 sec. 120 n75 Rinse out time 0 .. 999 sec. 0 n76 Drain time 0 .. 999 sec. 90

Running times cleaning stage 8 (after-rinse) - hidden, if [r48] = 0

n80 Water intake by feed container (displacement cleaning) 0 .. 6 0 n81 Water intake by level 1 0 .. 1 0 n82 Water intake by time 0 .. 999 sec. 120 n83 Additional water intake time + circulation 0 .. 999 sec. 0 n84 Main circulation time 0 .. 999 sec. 60 n85 Rinse out time 0 .. 999 sec. 0 n86 Drain time 0 .. 999 sec. 150

Running times cleaning stage 9 (rinse out) - hidden, if [r49] = 0

n91 Water intake time 0 .. 999 sec. 10 n92 0 .. 999 sec. 120Rinse out time with water intake n93 Drain time 0 .. 999 sec. 30

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Runtime abort for all cleaning stages

n100 Drain time after cleaning has been aborted 0 .. 999 sec. 150

Dosing time settings

n101 Dosing time alkaline detergent 0 .. 999 sec. 30 n102 Dosing time acid detergent 0 .. 999 sec. 30 n103 Dosing time disinfection (hidden if r47 = 0) 0 .. 999 sec. 30

Temperature settings (see also section 9.11)

n106 Pre-heat. temp. main cleaning stage 1 (alkal./acid) 0 .. 99,9 °C 45,0

(hidden if r35 = 0)

n107 Pre-heat. temp. main cleaning stage 2 (acid) 0 .. 99,9 °C 45,0

(hidden if r35 = 0 or 1)

n108 Pre-heat. temp. main cleaning stage disinfection 0 .. 99,9 °C 45,0

(hidden if r35 = 1 or 2)

n109 Post-heating temp. during circulation 0 .. 99,9 °C 40,0

in main cleaning stage 1 [n34] (hidden if r35 = 0)

n110 Post-heating temp. during circulation 0 .. 99,9 °C 40,0

in main cleaning stage 2 [n54] (hidden if r35 = 0 / 1)

n111 Post-heating temp. during circulation 0 .. 99,9 °C 40,0

in cleaning stage disinfection [n74] (hidden if r35 = 0 / 1 / 2)

8. Setting of parameters

8.5 Level “Extended cleaning parameters” (r parameters)

Working level

for normal daily operation

General cooling parameters code: C212

Extended cooling parameters code: D345

r parameters

Code: C567

Switch to level “Extended cleaning parameters” See section 8.1.

Adjustment to safety elements

r10 Safety switch butterfly valve (F40) see section 9.2 (Default 0) Parameter is hidden, if parameter [A40] = 2 or 3 0: no safety switch

1: prevents the start of cooling / cleaning, when switch is not in proper position 2: as 1 + abort of cleaning when switch in the wrong position

General cleaning parameters code: B454

Extended cleaning parameters code: C567

Service parameters code: EA03

General tank monitor parameters code: 4711

Extended tank monitor parameters code: F94A

Alarm configuration code: FFF F

Configuration code: A384

I/O test parameters code: 10E5

r11 Cleaning pump monitoring via pressure switch (Fault F41) (Default 0)

For dry running protection of the cleaning pump (open in case of fault) 0: deactivated

1 .. 20: Stop cleaning after x seconds without pressure

r12 Cleaning pump fault thermo contact switch (Fault F42) (Default 0) To protect the cleaning pump (open in case of fault)

0: no thermo contact switch 1: thermo contact switch active

Detergent options

r20 Dosing position (see section 6.2 and 9.15) (Default 2) 0: dosing in feed container (displacement cleaning)

1: position D1 in cleaning diagram 2: position D2 in cleaning diagram

r21 Detergent sequence in case of 3-cycles (Default 3)

(if second main cleaning stage is deactivated)

0: only alkaline

1..10: x times alkaline, before one time acid

Drain valve settings

r24 Switching mode drain valve 1 (Default 0) 0: normally closed 1: currentless open

r25 Switching mode drain valve 2 (Default 0) 0: normally closed 1: currentless open

Settings to start cleaning (see section 9.3.1)

r27 Cleaning enable via digital input (Default 0)

0: deactivated

1: activated

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8. Setting of parameters

Settings for level detection (see also section 9.14)

r30 Sensitivity level input 1 (Default 0)

-10: less sensitive +10: more sensitive

r31 Sensitivity level input 2 (Default 0)

-10: less sensitive +10: more sensitive

r32 Timeout water intake by level (Fault F44) (Default 5) Maximum time to cleaning abort: 1 .. 60 min.

r33 Level monitoring at the end of the cleaning stages (Fault F45) (Def. 0)

0: deactivated 1: Level 1 monitoring only after the last cleaning stage.

activate alarm message F45 and alarm relays.

2: Level 1 monitoring after each cleaning stage.

activate alarm message F45 and alarm relays.

3: Level 2 monitoring only after the last cleaning stage.

activate alarm message F45 and alarm relays.

4: Level 2 monitoring after each cleaning stage.

activate alarm message F45 and alarm relays.

Setting of heater

r35 Heater activation (Default 1)

0: no heater

1: only in main cleaning stage 1 2: in both main cleaning stages 1+2 3: in both main cleaning stages 1+2 and disinfection

r36 Start delay heater (Default 10)

Range: 0 .. 120 sec.

r37 Max. running time heater (Timeout programme step “H”) (Default 60) Range: 10 .. 999 min. (Fault F48)

r38 Heater protection via pressure switch (Default 0) 0: deactivated

1.. 8 sec.: Switch off the heater after x seconds without pressure

r39 Over temperature protection heater (Fault F49) (Default 0) To protect the heater (open in the event of a fault)

0: No protective contact

1: Protective contact active

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8. Setting of parameters

8.5 Level “Extended cleaning parameters” (r parameters)

Number of passes of seperate cleaning stages Range Default See also section 9.16

r40 Number of passes clean. stage 0: Rinse out 0 .. 5 0 r41 Number of passes clean. stage 1: Pre-rinse 1 0 .. 5 1 r42 Number of passes clean. stage 2: Pre-rinse 2 0 .. 5 0 r43 Number of passes clean. stage 3: Main rinse 1 1 1

(not changeable)

r44 Number of passes clean. stage 4: Intermed. rinse 1 0 .. 5 0 r45 Number of passes clean. stage 5: Main rinse 2 0 .. 1 0 r46 Number of passes clean. stage 6: Intermed. rinse 2 0 .. 5 0 r47 Number of passes clean. stage 7: Disinfection 0 .. 1 0 r48 Number of passes clean. stage 8: After-rinse 0 .. 5 1 r49 Number of passes clean. stage 9: Rinse out 0 .. 5 0

From option 4 onwards, the function A 16 (hot water valve) must additionally be assigned to one of the relays in the A parameters.

In case of selection 2, the function A 15 (drain valve) must additionally be assigned to one of the relays in the A parameters.

Selection of water valve (cold / hot water) Range Default

r50 Valve selection clean. stage 0: Rinse out 1 .. 4 1 r51 Valve selection clean. stage 1: Pre-rinse 1 1 .. 4 1 r52 Valve selection clean. stage 2: Pre-rinse 2 1 .. 4 2 r53 Valve selection clean. stage 3: Main rinse 1 1 .. 4 2 r54 Valve selection clean. stage 4: Intermitt. rinse 1 1 .. 4 1 r55 Valve selection clean. stage 5: Main rinse 2 1 .. 4 1 r56 Valve selection clean. stage 6: Intermed. rinse 2 1 .. 4 1 r57 Valve selection clean. stage 7: Disinfection 1 .. 4 1 r58 Valve selection clean. stage 8: After-rinse 1 .. 4 1 r59 Valve selection clean. stage 9: Rinse out 1 .. 4 1

1: Cold water

2: Warm water 3: Cold and warm water (mixed) 4: Hot water 5: Hot water and cold water 6: Hot water and warm water 7: Hot water and warm water and cold water

Selection of drain valve Range Default

r60 Drain valve select. clean. stage 0: Rinse out 1 .. 2 1 r61 Drain valve select. clean. stage 1: Pre-rinse 1 1 .. 2 1 r62 Drain valve select. clean. stage 2: Pre-rinse 2 1 .. 2 1 r63 Drain valve select. clean. stage 3: Main rinse 1 1 .. 2 1 r64 Drain valve select. clean. stage 4: Intermed. rinse 1 1 .. 2 1 r65 Drain valve select. clean. stage 5: Main rinse 2 1 .. 2 1 r66 Drain valve select. clean. stage 6: Intermed. rinse 2 1 .. 2 1 r67 Drain valve select. clean. stage 7: Disinfection 1 .. 2 1 r68 Drain valve select. clean. stage 8: After-rinse 1 .. 2 1 r69 Drain valve select. clean. stage 9: Rinse out 1 .. 2 1

1: Drain valve 1

2: Drain valve 2

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8.5 Level “Extended cleaning parameters” (r parameters)

Settings cleaning breaks

8. Setting of parameters

Selection 1, 2, 3: If the digital input is to be used to terminate the pause, the function 15 must additionally be assigned to one of the digital inputs A21-A28 in the Aparameters.

r70 Activation of break in cleaning programme (see section 9.17) (Default 0) 0: deactivated 1: activated, finish of break only with button or digital input 2: activated, finish of break after time [r72] or button or digital input 3: activated, finish of break at a certain time [r73] or button or digital input

r71 Position break: (Default 1)

After which cleaning stage is the break integrated

Setting range: after cleaning stage 0….8

r72 Break time 0...999 min. (Default 120)

r73 Finish of the break at time 00:00 … 23:59 00:00

Settings of cleaning pump (see section 9.13)

r80 Cleaning pump venting (Default 0) 0: deactivated

1: On-/off-impulses with a fixed quantity for all cleaning stages 2: as 1, however, premature termination if pressure via pressure switch 3: as 1, however, unlimited impulses when rinsing (cleaning stages 0+9) 4: as 2, however, unlimited impulses when rinsing (cleaning stages 0+9)

r81 Number of on / off impulses cleaning pump

Range: 0 .. 10

r82 ON impulse length cleaning pump (Default 5) Range: 0 .. 10 sec.

r83 OFF impulse length cleaning pump (Default 5) Range: 0 .. 10 sec.

Service settings for commissioning (see also section 6.3.1)

r92 Start cleaning at the beginning of cleaning stages 0..8 (Default 0) Range: 0 .. 8

r93 Number of cleaning cycles with step function (Default 0) Range: 0 .. 3

r97 Display during cleaning (Default 0) 0: Display of programme step

1: Display of temperature 2: Display changes between step and temperature

8. Setting of parameters

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8. Setting of parameters

8.6 Level “Service parameters” (E parameters)

E parameters

Code: EA03

Switch to level “Service parameters” See section 8.1.

These parameters are only used to query ACTUAL states.

Working level

for normal daily operation

General cooling parameters code: C212

Extended cooling parameters code: D345

General cleaning parameters code: B454

Extended cleaning parameters code: C567

Service parameters code: EA03

General tank monitor parameters code: 4711

Extended tank monitor parameters code: F94A

Alarm configuration code: FFF F

Configuration code: A384

I/O test parameters code: 10E5

Display tank monitoring time counter and values Range Default

Display of... E1 ... over- / under time temperature / time 1 0…900 min. - - - E2 ... over- / under time temperature / time 2 0…900 min. - - - E3 ... over- / under time temperature / time 3 0…900 min. - - -

Based on the error messages F1 - F3, it can be

read here how long the milk temperature has already been above the respectively set limit value.

E6 ... the last cleaning temperature reached 0…99,9 °C - - Displays the maximum temperature during the

last cleaning cycle.

E15 ... battery voltage 0,0V ... 12,0V - - Display the current battery voltage

(Only if optional power pack is installed)

8. Setting of parameters

8.7 Level “General tank monitor parameters” (h parameters)

Working level

for normal daily operation

General cooling parameters code: C212

Extended cooling parameters code: D345

General cleaning parameters code: B454

Extended cleaning parameters code: C567

h parameters

Code: 4711

Switch to level “General tank monitor parameters” See section 8.1.

Service parameters code: EA03

General tank monitor parameters code: 4711

Extended tank monitor parameters code: F94A

Alarm configuration code: FFF F

Configuration code: A384

I/O test parameters code: 10E5

Fault messages tank monitor during cooling mode Fault Range Default

h20 Target temperature 1st milking F20 0 .. 30,0 °C 5,0 (Starting from this point the monitoring of the

over / under temperature begins [h25] + [h29])

h21 Max. time to reach target temperature [h20] 0 = deactivated 0 .. 999 min. 120 h23 Max. overtemperature for a time (from cooling start) F23 0 .. 30,0 °C 10,0 h24 Max. time of overtemperature (from cooling start) 0 = deactivated 0 .. 999 min. 120 h25 Max. overtemperature with direct alarm triggering F25 0 .. 99,9 °C 25,0

(from 1st milking) h27 Min. undertemperature for a time (from cooling start) F27 0 .. 30,0 °C 2,0 h28 Max. time of undertemperature (from cooling start) 0 = deactivated 0 .. 999 min. 120 h29 Min. undertemperature with direct alarm triggering F29 0 .. 30,0 °C 0,5

(from 1st milking) Start the counter from cooling start h31 Max. cooling interruption 0 = deactivated F31 0 .. 999 min. 60 h32 Max. time in off mode after cleaning 0 = deactivated F32 0 .. 5000 min. 60 h33 Min. cleaning cycle F33 0 .. 250 h 78

0 = deactivated h35 Detergent monitoring alkaline by float switch F35 0 .. 2 0

0 = deactivated,

1 = high aktiv

2 = low aktiv h36 Detergent monitoring acid by float switch F36 0 .. 2 0

0 = deactivated

1 = high aktiv

2 = low aktiv

h38 Max. temperature difference monitoring sensor F38 1,0 .. 5,0 2,0

during cooling mode

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8. Setting of parameters

Setting milk times to monitor „cooling activated” Range Default

This function triggers an alarm if cooling has not been activated at the entered milk times. This is to prevent to forget the activation of the cooling in case of the first milking after the cleaning.

h41 milk time 1 00:00..23:59 --:-h42 milk time 2 00:00..23:59 --:-h43 milk time 3 00:00..23:59 --:--

Settings tank monitor LOG files Range Default

h90 Selection period (in days) of the recording data (Konsoft) 1 .. 365 90

h91 Logging intervals cleaning mode in minutes 1 .. 10 1

h92 Logging intervals OFF and cooling mode in minutes 1 .. 30 15

h93 Customer number part 1 (the first 4 digits...) 0 .. 9999 0

h94 Customer number part 2 (...the last 4 digits) 0 .. 9999 0

h96 Tank number part 1 0 .. 9999 0

h97 Tank number part 2 0 .. 9999 0

Parameter level-locking

h98 Password protection 0 .. FFFF 0 h99 Password protection 0 .. FFFF 0

Explanations to the password protection:

In addition to the level code the level “General tank monitor parameter” can be

protected by another password. A 4-digit password (not 0000) has to be entered in parameter [h98]. For the activation of the password protection the password in parameter [h99] has to be repeated exactly.

After the level code is re-entered the password query takes place.

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8. Setting of parameters

8.8 Level “Extended tank monitor parameters” (H parameters)

Working level

for normal daily operation

General cooling parameters code: C212

Extended cooling parameters code: D345

General cleaning parameters code: B454

Extended cleaning parameters code: C567

Service parameters code: EA03

H parameters

Code: F94A

Switch to level “Extended tank monitor parameters” See section 8.1.

General tank monitor parameters code: 4711

Extended tank monitor parameters code: F94A

Alarm configuration code: FFF F

Configuration code: A384

I/O test parameters code: 10E5

Don‘t add milk - temperature conditions Fault Range Default

H10 Milk temperature too high for too long F1 0 .. 50,0 °C 13,0 H11 Time limit for [H10] 0 = deactivated 0 .. 999 min. 600

H12 Milk temperature too high for too long F2 0 .. 50,0 °C 16,0 H13 Time limit for [H12] 0 = deactivated 0 .. 999 min. 360

H14 Milk temperature too high for too long F3 0 .. 50,0 °C 28,0 H15 Time limit for [H14] 0 = deactivated 0 .. 999 min. 300

Power failure times

H19 Temperature limit for fault F6 0 = temperature-independent F6 0 .. 50 °C 6,0

H20 Max. power failure time in cooling mode 0 = deactivated F6 0 .. 999 min. 60

Cleaning temperature monitoring

H30 Minimum cleaning temperature 0 = deactivated F11 0 .. 50,0 °C 40,0

H31 For min. time 0 = deactivated F12 0 .. 999 min. 2

Agitator monitoring

H40 Agitator fault in cooling mode - no stirring of milk 0 = deac. F15 0 .. 999 min. 450 H41 Timeout "No agitator" 0 = deactivated F16 0 .. 999 min. 60 H42 Min. run time agitator [to H41] F16 0 .. 500 sec. 60

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8. Setting of parameters

Tank monitor activation

H90 Activation delay (see section 9.19) 0 .. 300 min. 180 0 = deactivated

Parameter level lock

H98 Password protection 0 .. FFFF 0 H99 Password protection 0 .. FFFF 0

Information on password protection: The level "extended tank monitor parameters" can additionally be protected with

another password. For this purpose, a 4-digit password (not 0000) must be entered in parameter [H98]. In order to activate the password protection, the password in parameter [H99] must be repeated exactly.

If the level code is entered again, the password is requested afterwards.

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8. Setting of parameters

8.9 “Alarm - Event assignment” (F parameters)Level

Switch to level “Alarm configuration” See section 8.1.

F parameters

Code: FFFF

Working level

for normal daily operation

General cooling parameters code: C212

Extended cooling parameters code: D345

General cleaning parameters code: B454

Extended cleaning parameters code: C567

Service parameters code: EA03

General tank monitor parameters code: 4711

Extended tank monitor parameters code: F94A

Alarm configuration code: FFF F

Configuration code: A384

I/O test parameters code: 10E5

In this level, each fault message F1 to F61 is assigned the effect of this alarm. See the table below.

Alarm effect

display code (flashes)

Setting

„green“ LED

„red“ LED

stores in ‚Konsoft‘

alarm relay in general

alarm relay tank monitor

sms

WTS-300 system alarms (only display)

1: 2: 3: 4: 5: 6:

Informativ tank monitor alarms (green LED)

7: 8:

9: 10: 11:

Critical tank monitor alarms (red LED)

12: 13:

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Critical

tank monitor alarm

(always red LED)

Depending on the setting,

it is an informative or a

critical tank monitor alarm

(green or red LED)

8. Setting of parameters

Setting Default

Fault configuration... F1 ... milk temperature too high for too long high 1 12 .. 13 13 F2 ... milk temperature too high for too long high 2 12 .. 13 13 F3 ... milk temperature too high for too long high 3 12 .. 13 13

F6 ... power failure alarm 12 .. 13 13

F11 ... minimum cleaning temperature not reached 7 .. 13 11 F12 ... minimum cleaning time at temp. not reached 7 .. 13 11

F15 ... agitator fault in cooling mode 7 .. 13 11 F16 ... timeout "No agitator action" 7 .. 13 11

F20 ... cooling time exceeded for first milking 7 .. 13 11

F22 ... Cooling not switched on 7 .. 13 11 F23 ... milk temperature too high for too long 7 .. 13 11

F25 ... over-temperature directly 7 .. 13 11 F27 ... milk temperature too long too low 7 .. 13 11

F29 ... under-temperature directly 7 .. 13 11 F30 ... power failure (direct) 7 .. 13 11 F31 ... max. time without cleaning (after end cool. mode) 7 .. 13 11

F32 ... max. time without cooling (after cleaning mode) 7 .. 13 11 F33 ... min. cleaning interval 7 .. 13 11 F34 ... time / date not set 7 .. 13 11 F35 ... Detergent dispenser empty ‚alkaline' 7 .. 13 11 F36 ... Detergent dispenser empty ‚acid' 7 .. 13 11 F38 ... temperature difference exceeded 7 .. 13 11 monitoring sensor F39 ... battery voltage too low 7 .. 13 11

Depending on the setting

it is an informative or a

critical tank monitor alarm

or a system alarm

(Green or red LED

or display only)

F40 ... safety switch butterfly valve 1 .. 13 6 F41 ... pressure switch cleaning pipe 1 .. 13 6

F42 ... thermocontact cleaning pump 1 .. 13 6 F43 ... manual interruption of cleaning 1 .. 13 6

F44 ... timeout water intake by level 1 .. 13 6 F45 ... water in the tank after draining 1 .. 13 6

F48 ... timeout heating time cleaning 1 .. 13 6 F49 ... over-temperature monitor heater 1 .. 13 6

F51 ... Tank-overflow protection 1 .. 13 6 F52 ... water in tank cooling mode 1 .. 13 6

F53 ... thermal protection compressor 1 .. 13 6 F54 ... agitator-condition monitoring direct 1 .. 13 6 F55 ... Timeout quantity-dependent cooling start 1 .. 13 6

F56 ... broken sensor 1 .. 13 6 F57 ... sensor short circuit 1 .. 13 6 F58 ... sensor range exceeded 1 .. 13 6

F60 Communication external sensors 1 .. 13 6 F61 Communication GSM-Modul 1 .. 13 4

F99 ... Test alarms (see section 9.18) 1 .. 13 11

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8. Setting of parameters

8.10 Level “Configuration” (A parameters)

A parameters

Code: A384

Switch to level “Configuration” See section 8.1.

Working level

for normal daily operation

General cooling parameters code: C212

Extended cooling parameters code: D345

General cleaning parameters code: B454

Extended cleaning parameters code: C567

Service parameters code: EA03

General tank monitor parameters code: 4711

Extended tank monitor parameters code: F94A

Alarm configuration code: FFF F

Configuration code: A384

I/O test parameters code: 10E5

This configuration is very important and should be the first step when setting the parameters for a system.

The WTS-300 supports a large number of different system configurations (with or without robot operation), milk tanks with more than one compressor, different outlet valves etc.). In total, the control unit supports more output functions than there are relays and digital inputs on the printed circuit board.

Normally, however, not all functions are used at the same time. When starting configuration please give careful consideration to how you want to allocate all the various components to the relays and digital inputs.

Allocation of output relays:

In [A1 to A12] the functions needed are assigned to the output relays.

Allocation of digital inputs:

In [A21 to A28] input functions are assigned to the digital inputs.

Incorrectly set parameters can lead to serious malfunctions and damage to the milk-cooling tank.

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8. Setting of parameters

The relay functions for

assignment 1 and 14 are configured in parameters A45 and A46.

Tank monitoring alarm

Robot STOP

54321

6 10987 11 12 13 14 15NC16 17 18 19 20

Acid cleaning agents

L1 - Supply

Cleanig pump

Heater

Drain valve

Alkaline cleaning agents

Washer valve

Warm water valve

L1 - Supply

Cold water valve

K10

Compressor

Agitator

K11

K12

Assignment of output functions to relays K1 to K14

0: deactivated

1: alarm tank monitor * 2: robot stop 3: detergent „acid“ 4: heater 5: cleaning pump 6: drain valve 1 7: pneumatic butterfly valve 8: detergent „alkaline“ 9: warm water 10: cold water 11: compressor 1 / 1. cooling level 12: agitator 13: cleaning active 14: alarm in general *

15: drain valve 2

16: hot water valve 17: disinfection 18: compressor 2 / 2. cooling level 19: red warning light

20: compressor 3 / 3. cooling level

Range Default

A1 assignment relay K1 0 .. 20 1 A2 assignment relay K2 0 .. 20 2 A3 assignment relay K3 0 .. 20 3 A4 assignment relay K4 0 .. 20 4 A5 assignment relay K5 0 .. 20 5 A6 assignment relay K6 0 .. 20 6 A7 assignment relay K7 0 .. 20 7 A8 assignment relay K8 0 .. 20 8 A9 assignment relay K9 0 .. 20 9 A10 assignment relay K10 0 .. 20 10 A11 assignment relay K11 0 .. 20 11 A12 assignment relay K12 0 .. 20 12

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8. Setting of parameters

8.10 Level “Configuration” (A parameters)

Assignment of output functions to digital inputs 1 to 8

0: deactivated

1: safety switch (manual butterfly valve) 2: remote start cooling 3: dry protection heating 4: thermal protection pump 5: water pressure switch 6: thermal protection compressor 7: cleaning release robot 8: milk pump impulse 1 9: milk pump impulse 2

10: milk pump impulse 3 11: Inductive stirring unit sensor / switch 1 12: Inductive stirring unit sensor / switch 2 13: Float switch ‚alkaline’ 14: Float switch ‚acidic’

15: Start from rinse stop 16: Level sensor 1 (release 2nd cooling level) 17: Level sensor 2 (release 3rd cooling level) 18: Level sensor 3 (tank full) 19: Compressor lock /release

A21

A22

A23

A24

A25

A26

3938 4140 4342 44 4645

A27

Range Default

A21 assignment digital input 1 0 .. 19 1 A22 assignment digital input 2 0 .. 19 2

A28

A23 assignment digital input 3 0 .. 19 3 A24 assignment digital input 4 0 .. 19 4 A25 assignment digital input 5 0 .. 19 5 A26 assignment digital input 6 0 .. 19 6 A27 assignment digital input 7 0 .. 19 7 A28 assignment digital input 8 0 .. 19 8

Output signal configuration robot Default

A40 Robot operation / control pneum. butterfly valve 0 0: without robot and without pneumatic butterfly valve

1: only with robot

2: only butterfly valve control (pneumatic)

3: robots and pneum. butterfly valve control active

A41 Robot stop signal configuration (see section 4.6) 0 0: closing contact, robot stopped when closed

1: closing contact, robot stopped when open

2: opening contact, robot stopped when closed

3: opening contact, robot stopped when open

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8.10 Level “Configuration” (A parameters)

8. Setting of parameters

The settings to in A45 A4 7 are only active if the corresponding output function is assigned to a relay in the parameters A1 to A12: A45 = 14 A46 = 1 A47 = 19

Alarm relay configuration Default

A45 Relay configuration “alarm in general“ 0

(see output function 14 previous page)

0: closing contact, alarm if closed

1: closing contact, alarm if open (non-volatile) 2: opening contact, alarm if closed (non-volatile) 3: opening contact, alarm if opened

A46 Configuration “alarm tank monitor“ 0

(see output function 1 previous page)

0: closing contact, alarm if closed

1: closing contact, alarm if open (non-volatile) 2: opening contact, alarm if closed (non-volatile) 3: opening contact, alarm if opened

A47 Configuration „red warning light“ 0

0: is reset during the cleaning (same as red LED)

1: is reset with pressure

Configuration temperature sensor Range Default

A50 activation of second sensor 0 .. 2 0

0: deactivated

1: Safety temperature sensor

2: Heating temperature sensor

A51 Sensor type (Sensor 1 / sensor 2) 0 .. 3 0

0: KTY81/210

1: PT100 three-wire 2: PT1000 3: KTY81/110

Configuration analogue input Range Default

A54 Function analogue input 0 .. 2 0

0: deactivated

1: Determination of litres via filling pressure

(see section 9.23)

2: Low pressure monitoring

(see section 9.26)

Scaling determination of litres via pressure sensor Range Default

(Measuring range of the pressure sensors 0 up to 1000 mBar)

A60 Litre per cm filling height 0…100,0 ltr. 50,0

A61 Offset in litre 0…1000 ltr. 500

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8. Setting of parameters

Configuration external modules Range Default

A71 Configuration stirring unit monitoring 0 .. 15 0

look also section 9.22

0: deactivated 5: Clear bands (after deleting of the bands, the

number of agitators must be readjusted)

Agitator monitoring module ESVAW-001-A Switching on of the agitator by a WTS-300 relay

1: one agitator 2: two agitators 3: without function 4: without function

Agitator monitoring module ESVAW-002-A with two agitator switch-on-relays that are integrated in the module

6: one agitator 7: two agitators (if not used with [A14] other functions are selectable)

Agitator monitoring module ESVAW-003-A with one agitator switch-on-relay that is integrated in the module

12: One agitator 3-phases 400 V 13: Two agitators 3-phases 400V (over second module. Note addressing) 14: One agitator 2-phases 400V 15: Two agitators 2- phases 400V (over second module. Note addressing)

Agitator monitoring module ESVAW-004-A (same as ESVAW-001-A)

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Agitator monitoring without a separate module

If agitator monitoring is made via inductive agitator

sensor (max. 2 channels) 8: one agitator 9: two agitators

If agitator monitoring is made via switch contact

of the WTS-300 10: one agitator 11: two agitators

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8. Setting of parameters

8.10 Level “Configuration” (A parameters)8.10 Level “Configuration” (A parameters)

A72 activation detergent monitoring 0 .. 1 0 by conductometry

0: deactivated

1: activated

A73 activation GSM alarm module monitoring 0 .. 1 0 0: deactivated

1: activated

A75 activation power pack 0 .. 1 0 see section 9.21 0: deactivated

1: activated

Automatic change of daylight saving time Range Default

A78 Automatic change of daylight saving time 0 .. 3 2 0: deactivated

1: Western European time zone (change at 1:00) 2: Central European time zone (change at 2:00) 3: Eastern European time zone (change at 3:00)

Test parameter for the agitator rating Range Default

A80 Rating limit agitator -1 .. 1 0

-1: more sensitive 0: normal

1: less sensitive

Activate phase monitoring relay ESVAW-003 Range Default

A85 Activate phase monitoring relay ESVAW-003 0 .. 1 1 0: deactivated

1: activated

PC-Interface configuration Range Default

A95 Baud setting 1 .. 4 4 1: 9600

2: 19200 3: 38400 4: 76800

A96 Device address 1 .. 8 1

Language setting Range Default

A98 Language setting for Konsoft monitor 0 .. 1 0 0: german

1: english

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Factory reset Range Default

A99 Factory reset 0 .. 999 000

8. Setting of parameters

8.11 “I / O test parameters” (o. parameters)Level

Switch to level “I / O test parameters” See section 8.1.

o parameters

Code: 10E5

Working level

for normal daily operation

General cooling parameters code: C212

Extended cooling parameters code: D345

General cleaning parameters code: B454

Extended cleaning parameters code: C567

Service parameters code: EA03

General tank monitor parameters code: 4711

Extended tank monitor parameters code: F94A

Alarm configuration code: FFF F

Configuration code: A384

I/O test parameters code: 10E5

Meaning of the parameters

All inputs and outputs of the individual components can be tested in this parameter level. For this purpose the corresponding relays are set to 'I' or '0'.

NB: However, the two relays for the supply of acid and alkaline detergents are locked against each other since never acid and alkaline detergents may never enter the tank together!

This operating level is NOT reset automatically!

Test relay outputs Range Default Switched-on relays remain switched on until they are

reset manually.

o.1 Test relay 1 0 .. 1 0 o.2 Test relay 2 0 .. 1 0 o.3 Test relay 3 0 .. 1 0 o.4 Test relay 4 0 .. 1 0 o.5 Test relay 5 0 .. 1 0 o.6 Test relay 6 0 .. 1 0 o.7 Test relay 7 0 .. 1 0 o.8 Test relay 8 0 .. 1 0 o.9 Test relay 9 0 .. 1 0 o.10 Test relay 10 0 .. 1 0 o.11 Test relay 11 0 .. 1 0 o.12 Test relay 12 0 .. 1 0

0: Off

1: On

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8. Setting of parameters

Test digital inputs

All inputs [o.21 to o.28] can be selected via the arrow keys and tested as follows:

! Select the desired parameters with the arrow keys. ! Press the SET key briefly: '0' or '1' appears in the display (depending on the current

switching state of the respective component).

! Change switch state (e.g. safety switch).

The display toggles between '0' and '1'.

! Press the SET key again: The display shows the current parameter name again.

Range Default

o.21 Test digital input 1 0 .. 1 - - - o.22 Test digital input 2 0 .. 1 - - - o.23 Test digital input 3 0 .. 1 - - - o.24 Test digital input 4 0 .. 1 - - - o.25 Test digital input 5 0 .. 1 - - - o.26 Test digital input 6 0 .. 1 - - - o.27 Test digital input 7 0 .. 1 - - - o.28 Test digital input 8 0 .. 1 - - -

0: switched

1: unswitched

Test level inputs Range Default

o.41 Level 1 -10 .. 10 0 o.42 Level 2 -10 .. 10 0

-10: less sensitive 0: normal

+10: more sensitive

Adjust sensitivity: green LED "OK" lights up if o.41 / o.42 detects level

Display agitator capacity

o.70 test of relay on optional ESVAW 002 or 003 o.71 agitator 1 in watt o.72 agitator 2 in watt

Display of the Software version adaptor

o.98 Display of the Software version adaptor

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9. Other Information

9.1 Butterfly valve (manual or pneumatic)

manual

In the case of a manual butterfly valve, the position of the lever (open / closed) can be monitored via an optional safety switch. See also section 9.2

pneumatic

In the case of a pneumatic butterfly valve, this must be set in parameter [A40]. The corresponding function must then be assigned to a relay in one of parameters [A1 to A12]. Only then can the valve be opened or closed manually via the “Butterfly valve” button.

Convenience function (only with pneumatic butterfly valve) Significance: if the COOLING button is pressed in OFF mode, the pneumatic butterfly

valve is automatically closed.

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9.2 Safety switch for manual butterfly valve

The safety switch monitors the correct position of the lever on the tank outlet. The function of the safety switch is configured in parameter [r10]. Parameter [r10] is not available if a pneumatic butterfly valve is configured in [A40]

Fault indication

Robot Stop

Valve open

The “butterfly valve” LED flashes if, in OFF mode:

- the COOLING button is pressed while the valve is open.

- the WASHING button is pressed while the valve is closed. If the butterfly valve is closed in washing mode, the cycle is interrupted, provided

[r10=2] is configured.

9. Other Information

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9. Other Information

9.3 Robot control

The WTS-300 offers two possibilities of controlling a connected robot:

- via the button “Robot Stop”

- via the signal “Cleaning active”

For both functions, the appropriate parameter settings must be done beforehand.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Signal “Robot-Stop” (Robot stop via button)

If the cleaning button is pressed before the robot is stopped, the ROBOT LED flashes rapidly.

Robot

STOP

Robot Stop

Valve open

In [A40] robot operation must be configured and assigned to an output relay [default = A2 = 2].

Also pay attention to the setting in [A41], so that in the event of a power failure the robot is correctly controlled. See section 4.6

In OFF mode

, Press “ROBOT STOP” button: The robot is started or stopped again (toggle

function). The LED indicates the present status.

, If the robot is active (LED “Robot Stop” off) washing will not start. If the washing

button is pressed, the LED will flash.

, If cooling mode is activated while the robot is switched off, the robot will start

automatically.

In cooling mode

, switching to OFF mode, the robot remains active.

, If the button “Robot Stop” is pressed for 3 seconds, the robot is stopped and cooling

mode ends.

In cleaning mode

, The button “Robot Stop” does not have a function.

, If a fault occurs during washing: the robot is stopped.

When washing is successfully completed:

, the robot is automatically released, and , the control unit switches to OFF mode

(cooling must then be started manually or by the robot)

, if “Automatic start to cooling” is set: cooling mode is activated automatically.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Signal “cleaning active” (robot button has no function)

is given only during washing or in the event of a fault (washing stopped), if the control unit has not yet switched back to OFF mode.

Parameter setting: setting “13" must be assigned to one of the relays [A1 to A12]. When washing is successfully completed the robot can start cooling via a digital input

(must be set in [A22]).

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9. Other Information

9.3.1 Cleaning release by robot

r27 Cleaning release via digital input

0: deactivated 1: activated

Explanation

Setting the parameter [r27] to 'active' is only useful for robot operation. If the cleaning button is pressed after the tank has been emptied by the truck driver, it

may be that the robot is not ready for the cleaning process, depending on the configuration of the connected robot.

The WTS-300 can be configured in such a way that washing is not started directly by pushing the button, but in addition a robot release signal is needed.

Procedure

If the cleaning release in parameter [r27] is set to 'active' and the CLEANING button is pressed,

°C

Mode

- the display shows 'CLEn'

- the “washing“ mode LED flashes As soon as the robot is released, the cleaning process is started - the mode LED re-

mains lit permanently and the programme step for the cleaning process appears in the display

Note: The function can be deactivated by pressing the OFF key during the waiting period until the cleaning release 'CLEn' is activated.

Parameter setting - IMPORTANT

In order for the cleaning release to take place, the robot release signal must be assigned to one of the digital inputs. It is preferable to use terminal 45, since this is already configured at the factory via parameter [A27].

Parameter assignment

A21

A22

A23

A24

A25

A26

A27

A28

Connect digital inputs

3938 4140 4342 44 4645

with potential-free contacts!

Digital inputs

Robot

Contact closed -> release Contact open -> no release

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9. Other Information

9.4 Different variants for cooling start delay

Cooling start delay is set using parameters [P61 - P67].

The control can be programmed to delay the start of the compressor after the cooling mode has been triggered, to prevent a slight freezing of milk in the tank. This delay takes place only in case of first milking after the cleaning.

A new manual activation of the cooling start delay can be triggered only by a long pressing of the button “COOLING”.

To cover all the different system configurations possible, the WTS-300 offers a range of variants for cooling start delay.

0. no cooling start delay Cooling starts immediately

Cooling immediately temperature-regulated

1. simple cooling start delay

Cooling starts after a set time.

definied time temperature-regulated

2. periodic cooling phases

Cooling starts in the form of periodic cooling phases at set intervals before

then switching over to temperature regulation.

defined phases

temperature-regulated

3. periodic cooling phases after switch-on delay Cooling starts after a set time, in the form of pre-set periodic cooling phases at

set intervals before then switching over to temperature regulation.

defined tim

defined phases

temperature-regulated

4. according to number of milk pump impulses Cooling starts after the set number of milk pump impulses.

Milk pump impulses

temperature-regulated

5. periodic cooling phases after a number of milk pump impulses

Cooling starts after the set number of milk pump impulses in the form of pre-set periodic cooling phases at set intervals before then switching over to temperature regulation.

Milk pump impulses

6. Milk-volume-dependent cooling start delay from start cooling [P50 - P 55]

Compressor starts according to the parameterized milk quantity in the tank for the calculated running time, before switching to temperature control.

parameterized

milk quantity

7. Milk-volume-dependent cooling start delay from start cleaning [P50 - P 55]

Compressor starts according to the parameterized milk quantity in the tank for

the calculated running time, before switching to temperature control.

parameterized

milk quantity

defined phases temperature-regulated

calculated compressor

running- and break time

calculated compressor

running- and break time

temperature-regulated

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9. Other Information

Information on cooling start versions 6 and 7

calculated

running time

see [P53]

calculated

running time

see [P53]

calculated

running time

see [P53]

[P54]

Compressor

OFF OFF

first start

compressor

[P51] 50 Liter

restart

compressor

[P53] 20 liter

ONOFF

restart

compressor

[P53] 20 liter

OFF

cooling mode

Cooling mode*Cleaning*

* Settings in [P61] 6: START Cooling mode 7: START Cleaning mode

> [P55] minutes = alarm

Switch over to regular

Both settings "6" and "7" are used for volume-dependent switching on of the compressor in order to prevent the milk from freezing during robot operation when the cooling mode starts. Depending on the quantity of milk *, the compressor is switched on either sooner or later and then longer or shorter.

* The control calculates the current milk quantity in the tank from the entered ca-

pacity of the feed pump [P50] and the measured duty cycle of the feed pump.

Measured milk quantity = P50 x measured running time milk feed pump **

** The running time of the milk feed pump(s) is determined via digital inputs. I.e. the

digital inputs in the parameters [A21 - A28] need the assignment of the settings 8, 9 or 10 (depending on the number of milk pumps). For several milk pumps, the total pump running capacity is added -> and from this it is the total quantity of milk.

Depending on setting „6“ or „7“ the calculation of the milk quantity starts already

- Setting „6" = only with the beginning of the cooling mode

- Setting „7“ = or in the cleaning mode

Setting "7" is selected if during the cleaning of the main tank milk has already been milked into a buffer tank and this milk is pumped into the main tank after the end of cleaning to start the cooling mode. This amount of milk is added to the amount of milk from the start of cooling mode.

The running time of the compressor is calculated from the formula:

Running time compressor =

measured quantity of milk

P53

x P52

If milk is transported from the feed pump into the tank while the compressor is running, the running time of the compressor will be extended accordingly.

If the compressor is switched off, it cannot start again until at least the quantity of milk set in parameter [P53] has been added.

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9. Other Information

9.5 Compressor switch-on delay / pre-agitating

(Only useful when using a robot) If the milk cooling tank is filled by a robot, filling from below takes place via the tank

outlet. For some tank types, the temperature sensor is positioned very close to the tank outlet. For this reason, an increase in the milk temperature is measured during filling, although the actual milk temperature has not yet risen (due to a heat bubble at the outlet by the type of filling). This leads unnecessarily to the frequent switching on of the compressor and thus to an increased wear of the cooling system.

The parameter P6 can be used to parameterize a 'pre-agitating time' in which the agitator starts before the compressor is switched on. This is intended to ensure that the warm milk at the outlet is mixed with the remaining cold milk in the tank and the compressor is switched on only after the pre-agitating time has elapsed if the total milk quantity is above the target temperature.

9.6 Emergency cooling / Sensor fault

In the event of a faulty temperature sensor, a fault code is displayed:

, F56 fault configuration broken sensor , F57 fault configuration sensor short circuit , F58 fault configuration sensor range exceeded

Emergency programme

! A timer can be set in parameter [P4]. ! On pressing the COOL button, the compressor and agitator will run continuously

until the time set on the timer expires.

The timer can be switched off manually at any time using the OFF button.

9.7 Sensor correction procedure

Sensor correction means: A correction is applied to the value measured by the sensor. This is then cumulatively

effective over the whole measurement range. An adjustment to the sensor correction is then necessary only:

! in conjunction with first installation, ! if the sensor cable length is altered, ! when replacing a faulty sensor.

In order to adjust the sensor correction, a reference thermometer is needed.

Proceed as follows:

! Switch off power supply ! Install / change sensor ! Use the reference thermometer to establish the milk temperature. ! Switch on control unit and set [c90] to the measured number of degrees.

! The control unit calculates the difference between the reference thermometer

reading and temperature sensor 1 and automatically sets this in parameter [c91].

! Parameter [c91] can be displayed and adjusted at any time. ! Hold down the up and down arrow buttons simultaneously:

The settings are stored.

Proceed with the setting for sensor 2 (if present) in the same way. In this case parame-

Page 98 Page 99

ters [c92 and c93] must be set.

9.8 Function second temperature sensor

The second temperature sensor (FÜ2) may have two different tasks or functions.

, To act as a monitoring sensor (redundancy) for the first sensor. An adjustable differ-

ence between the two measured values gives rise to an alarm.

, To regulate the heating temperature / holding temperature during washing.

The second sensor input must be activated by an appropriate parameter setting [A50].

The maximum temperature difference for the monitoring sensor in comparison to the regulating sensor (FÜ1) is set in [h38]. If the set temperature difference is exceeded for longer than 5 minutes, fault code [F38] is displayed.

If FÜ2 develops a fault (break or short-circuit), fault code [F38] will also be displayed after 5 minutes.

9.9 Level alarm during cooling (Fault code F52)

9. Other Information

Safety function:

The level input will be monitored during cooling. In the case of systems with robot operation, depending on the layout of the system,

the washing line may be connected permanently. If, for example, a water valve jams and the water level rises, water could be forced into the tank via the washing line. In this case, once the electrode is reached, an alarm is given and the outlet valve is opened.

All relevant settings are found in [P40].

9.10 Automatic / convenience functions

9.10.1 Automatic start to continuous agitating mode after exiting cooling mode

Setting in parameter [P23]. When the cooling operation is stopped by the milk truck driver, a continuous agitating

mode can be initiated automatically in order to achieve better mixing of the milk in the tank.

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9.10.2 Automatic start to cooling mode after successful cleaning

Setting in parameter [P60]. When using a robot, it is possible to start the cooling mode automatically after a

successful cleaning. If cleaning is not successful, the control remains in cleaning mode and manual

acknowledgement is necessary.

9. Other Information

9.11 Heating control

Heater

Clean. stage 0

Rinse out Pre-rinse 1 Pre-rinse 2 Main rinse 1 Intermediate rinse 1

n11

Cleaning stage 1

n12

n13

n14

n15

Cleaning stage 2 Cleaning stage 3 Cleaning stage 4

n16

n21

n22

n23

n24

n25

n26

n31

n32D1n33D2H

n34

n35

n36

n41

n42

n43

n44

A B

The WTS-300 distinguishes between two heating phases:

A - Heating-up phase - programme step "H“ B - Further heating phase - during the main circulation (n34 or n54 and n74).

During the heating-up phase, the water is heated to the temperature set (the display shows the temperature measured by sensor 1 instead of the programme stage). The next programme stage then follows. The heating-up time is, however, limited by an adjustable timeout. Once the time has expired the control unit switches to the next programme stage. The completion of washing is followed by a corresponding fault report.

During the following further heating phase, the circulating washing solution is maintained at the further heating temperature that has been set.

NB:

If a second sensor has been configured as a washing sensor, temperature regulation and the display switch over to the second sensor. See also the section “Function of second temperature sensor 8.8".

n45

n46

Heater start delay

Depending on the system layout, a start delay for the heater can be set. This applies only at the beginning of the heating-up phase (depending on whether this starts in programme stage “D2" or “H”).

This delay can be used to prevent the system switching on to the next programme stage too soon ...

, ... if pre-heated water- e.g. from a boiler - is cooled down by the cold walls of the

tank and needs to be reheated, or

, ... if, as a result of pre-set pump venting, the pressure switch triggers and the heater

is switched off (see also the sections “Pressure switch” and “Pump venting”).

9.12 Function of pressure switch – Effect on pump and heater

A pressure switch fitted to the washing circuit can protect the pump and heater from damage.

Protection of the cleaning pump

Parameter [r11] can be used to set the length of time during which there may be no pressure in the washing line before washing is stopped. This prevents the washing pump being damaged by running dry.

Protection of heater

Parameter [r38] can be used to set the length of time during which there may be no pressure in the washing line before the heater is switched off. Washing continues nevertheless.

This prevents heater burn-out.

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WELBA WTS-300, WTS-300 G1 Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual