MS-5000 Installation and operating instructions for
Contents
1. 2 0000002 Page 19 Page 2 Function MS 5000 28 08 08 The MS 5000 is a complete control cabinet for milkcooling tanks The integrated microprocessor regulator with automatic afterstirring has separate relay contacts for the compressor contactor and the stirrer The measured milk temperature is shown constantly on the display when the cooling mode is switched on Two freely adjustable target temperatures may be selected by push buttons Should the milk temperature exceed the chosen target tempe rature 4 or 8 by the hysteresis value the compressor and stirrer are automatically switched on Once the target temperature is reached the compressor contactor switches off The stirrer continues for the pro grammed period During refrigeration pauses the stirrer automatically switches on again according to the programmed intervals to ensure an even temperature throughout the milk Independently of this short or long intermediate stirring can be selec ted by pressing a button Software can also be used to programme the MS 5000 for permanent stirring i e the agitator is switched on and off by pressing a button Cooling mode Press the 4 8 button the compressor and agitator operate automati cally In between cooling periods agitator and compressor LEDs off intermediate stirring can be activated Stirring mode If stirring mode is active temperature shown in display e Short intermediate stirring Briefly pr2. component Another point to note here is that only capacitors which meet VDE 0656 may be used They must be suited to the mains voltage and designed for very high switching voltages The diagram on the left shows inductance interference suppression using an RC filter An RC filter should not be fitted directly to the regulator s switching contact as shown on the left as an idle current will flow through the RC combination even when the switching contact is open This current may be enough to mean that a downstream contactor is not de energised and aclosed protective contact does not reopen Page 16 MS 5000 28 08 08 Semiconductor switches such as thyristors or triacs also produce interference voltages They occur as a result of non linear characteris tics and finite ignition voltages These components must be protected against excessive voltages for which mainly varistors RC combina tions or choke coils are used The use of zero voltage switches is also recommended The suggestions made represent only a few of the possible ways of protecting a microprocessor controlled regulator system from interfe rence The suggested measures have the advantage that they will increase the lifetime of the devices as lower induction voltages redu ced spark formation will also reduce contact burn Page 17
3. SET and SET A or simul button taneously V Target temperat gps or__ for T1 Ow 8 A Target temperat or for T2 O WM A Hysteresis for or target temp 1 C10 SET A Vj 07K A Hysteresis for C1 or__ target temp 2 OAM o7k A Duration of afterstirring OAM 120sec A Duration of C2 Or __ pause sr OAM 20mins Duration of short AJ a intermittent c50 SET F 2mi stirring 4 v ans Duration of long A or intermittent cS A Y 10mins Stirring a i Sensor AON O Nia correction Ra A Oa Button lock OW o To switch back to the working level MS 5000 28 08 08 Press for 5 seconds simultaneously Switches back automatically after 30 seconds The programming level is for setting the regulatory parameters Access to this level is more complex in order to avoid accidental resetting of the values by the end user Switching to programming level e Press button Arrow UP and Arrow DOWN simultaneously for approx 5 seconds The first parameter C1 appears in the display e Press button Arrow UP and Arrow DOWN until you reach the parameter you want to adjust Meaning of parameters Parameter C1 Target temperature for T1 Parameter C2 Target temperature for T2 The target temperature is the temperature at which the corre sponding relay contact is to be activated Parameter C10 Hysteresis for target temp 1 Parameter C11 Hysteresis for target temp 2 The hysteresis determines how
4. UP again and hold down until Pb appears in the display e When Pb appears hold down button Arrow UP and Operation overview for configuration level simultaneously press button Arrow DOWN for approx Switching to configuration level see description 3 seconds e The display then shows the first parameter P5 in the configuration level Display Altering Factory setting setting setting Press Press button button V and 4 SET simultanously e Meaning of parameters Sensor failure SET Aly 1 function K1 eb or Sensor failure PAI Param P5 Function K1 in event of sensor failure SET A Vv 1 function K2 L e OU Param P6 Function K2 in event of sensor failure Hysteresis All The switching status of the relay contacts mode for T1 z g y F 9 can be set for the event of a sensor failure Hysteresis gt oo im 4 O OFFin the eventof failure mode for T2 onv 1 ONin the eventof failure Limit for target el HH OAM o App Ee downy G j Parameter P10 Hyst mode for target temperature T1 ae B io e OOW io Parameter P11 Hyst mode for target temperature T2 Limit for target e9 a with reference to the compressor relay temp T2 downw fF OAM ov 0 symmetrical Limit for target 9 1 one sided one side symetrical me j Ai 7 Hysteresis Hysteresis temp T2 upw OOV the hysteresis determines the y ob Limit for Hyst 1 eat value by which the temperatur
5. e Make sure that cables cannot chafe MS 5000 28 08 08 Page 5 Housing dimensions and technical data ON ON ON m OOOO OC SZ PY AN O00 S T L E Ee Sensor dimensions and technical data E E E E J 40 mm Z i Meo F E MS 5000 26 03 09 Operating voltage see version 230V AC N PE 50 60 Hz 400V AC N PE 50 60 Hz Relay contacts 230V AC N PE 50 60 Hz with screw terminals or when fitted with switching contactor 400V AC N PE 50 60 Hz with switching contactor and motor protection switch 2 make contacts Max switching voltage 16AAC 1 Max switching current Display 250 V 13 mm LED Display 3 digits Display resolution Range 9 9 99 9 C 0 1 C other 1 0 C Control type two step controller Measurement range 50 150 C Hysteresis 0 1 to 99 9 K free adjustable standard adjusting 0 7 K Type of operation cooling Housing see sketch Protection IP 65 Connection Screw terminals Environment conditions storage temperatur operation temperatur max humidity Sensor element Bush material 20 to 70 C 0 to 50 C 75 no condensation Specifications subject to change without prior notice PTC sensor KTY 10 6 1 4301 V2A Bush length 40mm Bush diameter 6 0 mm 0 1 Cable material PVC standard Silicon special model Measurement range PVC cable Silicon c
6. much the milk temperature may deviate from the target temperature before the cooling com pressor is switched on See sketch Parameter C20 Duration of afterstirring Duration sec for which the stirrer runs after the compressor has switched off Parameter C21 Duration of pause Duration min until the stirrer is switched back on after being turned off Parameter C50 Duration of SHORT intermittent stirring Duration min of stirring after short pressing of the intermittent stirring button Parameter C51 Duration of LONG intermittent stirring Duration min of stirring after longer pressing of the intermit tent stirring button Parameter C91 Sensor correction The sensor reading can be provided with a corrector which works cumulatively over the entire measurement range See also the section on sensor installation Page 14 Parameter C99 Button lock Alteration of the target temperatures in the working level can be blocked by setting the button lock 0 lock off 1 lockon Page 10 Configuration level This level is for configuring the regulator s basic functions operation To prevent interference by the end user access Switching to configuration level e Press button Arrow UP and Arrow DOWN simultaneously for approx 5 seconds e The first parameter C1 appears in the display e Press button Arrow UP repeatedly until the last parameter C99 at working level is reached e Press button Arrow
7. sensor lines This distorts measured values and signals and can disrupt the entire regulatory process It is therefore recommended that all sensors and signal lines be placed separately from the control and mains voltage lines If possible a separate mains line should be provided to feed the regula tor system This helps reduce any interference penetrating the regulator via the mains supply line Voltage surges resulting from switching substantial loads will also then be less of a problem In the case of contactors solenoid valves and other inductive consu mers the induction voltage occurring during switching has to be redu ced by appropriate protection methods The choice of methods depends on whether the consumer runs on DC orAC voltage e DC voltage In the case of d c voltage systems the induction voltage occurring can for example be limited by using self induction diodes varistors or suppresser diodes The diagram on the left shows one possibility using a self induction diode e AC voltage In the case of a c voltage interference suppression as described above is not possible Instead an RC combination must be used An RC filter must be connected as directly as possible to the inductance in order to ensure a short line In addition the component ratings of the RC combination must be geared to the inductance Too low ratings lead to excessive voltage and too high ratings cause significant losses in the interference suppresser
8. the parameters have been set It should not be used before this has been done as this might result in damage to the plant or the milk The device is fitted with a resistance temperature sensor The output ports are designed as potential free relay ports The device must not be installed in potentially explosive atmospheres the EC requirements for electromagnetic compatibility EMC and the Low Voltage Directive LVD The safety components meet the VDE regulations CE The control cabinet for milk cooling tanks type MS 5000 fulfils Safet y These operating instructions contain important technical and safety information Please read them carefully before installation and before working on or with the regulator The control cabinet must be installed by an authorised specialist observing local safety regulations Access to the environment when connected must be restricted to specialised personnel The control cabinet contains live components and must not be opened up It must not be used if the housing or connection terminals are damaged No fluids must penetrate the housing The control cabinet may not be exported to the USA wit hout the manufacturer s express permission MS 5000 28 08 08 Page 4 Installation a Installation of housing To secure the housing proceed as follows e Drill holes as shown in the diagram insert rawlplugs if necessary e Unfasten the four plastic closure screws and rem
9. 102107 by WELBA 26 03 09 MS 5000 Complete Control Cabinet for Milkcooling Tanks Installation and operating instructions for plant engineering companies WELBA GmbH Phone 49 0 2638 9320 0 Electronic Control Engineering Fax 49 0 2638 9320 20 Gewerbepark Siebenmorgen 6 E mail info welba de D 53547 Breitscheid Net www welba de Contents MS 5000 28 08 08 Intended USE ia ia deb ivtawe ident bew he ee ehd ieee nee Page 4 MEIC ea ors kirra aa edna Ete a haere REE vee E Page 4 l stallatiom seie neei pinnone a Peeks eee Be ee Page 5 Housing dimensions and technical data Page 6 Sensor Dimensions and technical Data Page 6 OPETAUON ate 2 u alae yh aac ote depen eee ee he mise edd Page 7 Operation Overview 2 Page 7 Parameter settings in general 200005 e eee Page 8 Working level operation 6 0 0 66 ee eee ee eee Page 9 Programming level operation 6 556506 n eee eee Page 10 Configuration level operation 00000000e Page 11 Intermediate stirring options during cooling Page 13 Continuous stirring in OFF mode c c6she eee de ceed Page 13 Setting the actual value correction 4 Page 14 Fault indication on the display 0000 Page 14 General measures when using electronic control systems Page 15 Circuit diagramm MS 5000 XX 1 2000000 08 Page 18 Circuit diagramm MS 5000 XX 3
10. able Cable lenght Protection type 30 70 C 50 150 C standard 2 metres IP 65 Page 6 Operation Working level for every day operation Programming level for setting the regulator parameters Configuration level for setting the basic functions Operation overview Target temperature Target temperature MS 5000 28 08 08 T1 T2 4 4 Hysteresis for T1 Hysteresis for T2 The control cabinet MS 5000 is operated at three levels Working level for everyday operation by the end user When cooling mode is active the milk temperature as currently measured is permanently displayed The working level also contains the functions e startcooling mode e Intermitted stirring during cooling mode duration depending on pre setting See section Intermediate stirring options during cooling on Page 13 e Start permanent stirring e Switch of e Switch over target temperatures 4 8 when activ e Display and change of target temperatures 4 8 Note The changing of targetTemperatures is only possible when in programming level the parameter button lock C99 is setto 0 Programming level This is the level at which the regulatory parameters are set Setting is more complex and possible only using specific combinations of buttons so as to prevent accidental chan ges to settings Configuration level This is the level at which the basic fun
11. ctions of the regulator are set As subsequent interventions by the end user after the parameters have been set can result in dangerous chan ges to functions which might not be immediately obvious access to the configuration level is even more complex e The milk is cooled to the selected target temperature 4 or 8 The adjusted target temperature is displayed by LED 4 or 8 The stirrer runs constantly at this stage e Once the target temperature has been reached the compressor switches off e The stirrer switches off after the programmed afterstir ring time e During refrigeration pauses the stirrer switches on for the duration of the afterstirring time to ensure an even temperature throughout the milk This will be repeaded periodically e Should the milk temperature exceed the selected target temperature 4 or 8 by the hysteresis value the compressor and stirrer are automatically switched on again Page 7 Parameter settings in general MS 5000 28 08 08 To adjust a parameter proceed as follows e Select parameter e Hold button SET down during the adjustment operation e Use button Arrow UP or Arrow DOWN to set the required value NB Holding buttons longer changes the value more quickly e Release button SET To store the changed parameter in the memory first release the arrow button and then button SET Switching back to working level possible from any parameter e Press button Arr
12. e Target Target draad s QOY 01 ofthe medium may deviate from temp temp imi 2 the corresponding target tempe Limit for Hyst 1 or upwards s OAM 2 rature before the relay contact is Limit for Hyst 2 ES ae activated See diagram downwards OOY 1 if the contact in question is for lool Limit for Hyst 2 or cooling the hysteresis is always upwards In the case of f E7 eam 2 heating contacts it is below the target temperature cooling upwards g Min action time oo or or heating contact is set at configuration level Compr K1 f Ov o In the symmetrical hysteresis mode the value selected is Min pause time A distributed on both sides of the target temperature Compr K1 Switching c or Param P20 Limit for target temperature T1 downwards T1 to T2 ED e OOV Param P21 Limit for target temperature T1 upwards Mode intermitt or Param P22 Limit for target temperature T2 downwards stirring s OOM 1 Param P23 Limit for target temperature T2 upwards ob PN l Temperature ae Setting of input limits for target temperatures at working and scale ZH OAY programming levels To switch back to the working level Range 10 99 C A V Press for 5 seconds simultaneously Switches back automatically after 30 seconds MS 5000 28 08 08 Page 11 Parameter P30 Limit for hysteresis T1 downwards Parameter P31 Limit for hysteresis T1 upwards Parameter P32 Limit for hysteresis T2 downwards Parameter P33 L
13. ess the Agitator button sho appears in the display and the agitator starts to operate e Long intermediate stirring Press and hold down the Agitator button for 5 seconds lon appears in the display and the agitator starts to operate e Continuous stirring only if set at parameter level Press the Agitator button On appears in the display The agitatoroperates continuously until the Agitator button is pressed again If OFF mode is active Display is dark e Continuous stirring while cooling is switched off Press the Agitator button A rotating bar is shown in the display and the agitator operates continuously until you press the button STOP Off mode The regulator can be switched off using the STOP button Display and LEDs dark Both the output relays for the agitator and compressor are deactivated CAUTION The regulator is live even when switched off 4 8 Switch between target temperatures when cooling mode is active only Page 3 Intended use These operating instructions contain important technical and safety information Please read carefully before instal lation and before any work on or with the regulator The control cabinet for milk cooling tanks type MS 5000 is used to control the stirrer motors and cooling compressors of milk cooling systems Any other use of the device is permissible only with the manu facturer s written consent The control cabinet is ready for use once
14. imit for hysteresis T2 upwards Setting of input limits for hysteresis at programming level Range 0 99K Parameter P70 Minimum action time for compressor K1 Setting of minimum action time for compressor relay contacts K1 in order to prevent repeated switching on and off Range 0 0 999 seconds Parameter P71 Minimum pause time for compressor K1 Setting of minimum pause time for compressor relay contacts K1 in order to prevent repeated switching on and off Range 0 0 999 seconds Parameter P80 Switch from target temperatur T1 to T2 Setting of funktion switching target temperature 0 not possible 1 with button 2 donotuse Parameter P81 Function intermittend stirring Setting of funktion start manual intermittend stirring See section Intermediate stirring options during cooling page 14 0 not possible 1 Standard activate intermittend stirring short or long with button 2 donotuse 3 permanent stirring ON OFFPress button Agitator to start permanent stirring press button Agitator again to stop the stirrer Parameter P99 temperature scale 0 Celsius 1 not posible MS 5000 28 08 08 Page 12 Intermediate stirring options during cooling Continuous stirring in OFF mode MS 5000 28 08 08 The control cabinet MS 5000 has a function allowing the agitator to be switched on manually This can be done is different ways Regardless of the option chosen the correspondi
15. ng LED always indicates when the agitator is operating The function is set at configuration level using parameter P81 Parameter P81 is set to 1 Intermediate stirring SHORT or LONG can be switched on via the regulator s foil keyboard In this case e Intermediate stirring SHORT Press agitator button for approx 1 sec until Sho appears in the display Release the button immediately otherwise Intermediate stirring LONG will be activated e Intermediate stirring LONG Press agitator button for approx 3 secs until Lon appears in the display The duration of SHORT or LONG stirring is fixed at settings level using parameters C50 and C51 Parameter P81 is setto 2 not used Parameter P81 is set to 3 On request the MS 5000 can be set for continuous stirring i e the agitator can be switched on and off by pressing a button When the agitator is switched on or off the display briefly indicates ON or OFF In OFF mode continuous stirring can be selected by pressing the agitator button and switched off again by pressing the STOP button During continuous stirring the agitator LED lights up and a rotating bar is shown in the display Page 13 Setting the actual Acorrection can be made to the value as measured by the sensor which value correction applies cumulatively over the entire measuring range This is necessary when the length of the sensor cable is changed or a faulty sensor i
16. ove the housing top e Screw the housing bottom into place e Position the electrical wiring and sensor connection in accordance with the following instructions e Place the housing top in position and fasten with screws b Fitting the sensor The sensor cable must not be chafed or kinked There must be no strong 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 Changing the sensor cable length E If it is necessary to shorten or lengthen the sensor cable on installation g p Om 3 or if a sensor other than the one supplied is to be fitted the actual Sa ee value correction parameter must be adjusted accordingly See the F d section Setting the actual value correction on page 14 Observe the permitted temperature range to which the sensor is suited Sensor cable temperature range C PVC 30 to 70 Silicon 50 to 150 c Elektrical connections The supply voltage may not be switched on until all com ponents including the sensor are connected Pay attention to the technical data As soon as power is connected to the thermostat the stirrer will run for the duration of the programmed afterstirring time C10 The cooling compressor switches on as a function of the milk temperature e Electrical connections must be as shown in the diagram below e Use cable bushes
17. ow UP and Arrow DOWN simultaneously for approx 5 seconds The current actual value appears in the display If at programming or configuration level no buttons are pressed for approx 1 minute the regulator switches back to working level automatically Page 8 Working level operation Operating overview for working level Switch from target temperature T1 to T2 SHORT interm stirring until Sho appears LONG interm stirring until Lon appears Target temperature T1 when LED 4 lit Target temperature T2 when LED 8 lit present ACTUAL VALUE displayed continuously The LED changes Ce from T1 to T2 or amp 8 from T2 to T1 A 1 Duration corresponds to sec programmed value C50 Duration corresponds to programmed value C51 Lob s sec Display Altering Factory setting setting setting Press Press SET and SET A or simul button taneously V ogu or oov Changing the target temperature is possible only when the button lock in the programming level C99 is set to 0 MS 5000 28 08 08 The working level is for day to day milk cooling operation When the cooling mode is active the display continuously shows the current milk temperature Function LED ao shows that target temperature setting for T1 is active LED IBEN shows that target temperature setting for T2 is active LED Agitator shows if agitator is switched on LED Compressor show
18. s been exceeded MS 5000 28 08 08 Page 14 General measures when using electronic control systems MS 5000 28 08 08 So that even complicated regulatory tasks can be presented to the user in a manner which is clear and simple and ensures high measurement accuracy today s electronic control systems make increasing use of microprocessors However the benefits of these systems are countered by the disadvantage that increased measurement accuracy is accom panied by sensitivity to interference In order to minimise the effect which interference may have on the regulator the user also must take account of a number of points when installing a new regulator Assistance here is provided by standard DIN VDE 0843 on the electro magnetic compatibility EMC of measurement control and regulatory devices in industrial process technology The following table shows for example the maximum interference levels to which according to the standard an appliance may be exposed Degree of Environment Test voltage Test voltage severity class Power supply Signal control line 1 well protected 0 5 kV 0 25 kV environment 2 protected 1 0 kV 0 5 kV environment 3 typical industrial 2 0 kV 1 0 kV environment 4 Industrial environ 4 0 kV 2 0 kV ment with very high interference level As the values given in the table are maximum values operational values should remain well below them However in practice this is possible onl
19. s if compressor relay is switched on Button Function 5 Button 4 8 in OFF mode starting of cooling Button 4 8 in cooling mode switch target temperature from T1 to T2 or from T2 to T1 if T2 is active Press the 4 8 button together with button SET in cooling mode to adjust the current target temperature downwards Press only SET button in cooling mode Target temperatur T1 or T2 displayed Press SET button in cooling mode together with button 5 or 7 adjust the current target temperature upwards or downwards Button Agitator in cooling mode press for appr 1 sec SHORT intermediate stirring press for appr 3 sec LONG intermediate stirringSee also the section describing the intermediate stirring options page 13 Button Agitator in OFF mode continuous stirring Press the Agitator button together with button SET in cooling mode to adjust the current target temperature upwards Button STOP thermostat is in stand by fuction Page 9 Programming level operation Target temperature Target temperature T1 T2 y Hysteresis A for T1 Y Hysteresis A for T2 Operating overview for programming level To change to programming level Press for 5 seconds simultaneously until parameter C1 appears Display Altering Factory setting setting setting Press Press
20. s replaced giving rise to an incorrect reading Caution when changing the sensor The regulator is adjusted to the selected sensor in the a factory When replacing a faulty sensor use only the same type In order to adjust the actual value correction a reference thermometer e g WELBATHM 2000 is needed Proceed as follows e Install sensor e Measure the temperature of the medium using the reference thermometer e Switch on the thermostat and set parameter C91 in the programming level to 0 e Switch back to working level and read the measured temperature on the display e Calculate the difference between the reference thermometer temperature and the display reading e Store the difference pay attention to plus or minus in the working level under parameter C91 Fault indication on the display Faults in the regulator are indicated by a flashing display as follows LED Display Fault F1 Sensor short circuit The sensor or sensor cable is faulty and must be replaced or repaired Parameter C91 Actual value correction must then be adjusted at programming level F2 Broken sensor The sensor or sensor cable is faulty and must be replaced or repaired Parameter C91 Actual value correction must then be adjusted at programming level F3 Memory fault Faulty regulator Remove the regulator and send it for repair FFF Measurement range exceeded The maximum measurement range of the sensor ha
21. y with difficulty as even a normal contactor without interference suppres sion produces interference pulses of up to 3 0 kV For this reason we recommend that the following principles be taken into account during installation Try to eliminate all sources of interference by carrying out interference suppression and minimising the interference level Radio interference suppression is required under VDE 0875 and confirmed by VDE 0874 In principle interference must be eliminated at source The nearer the interference suppresser is to the source of interference the greater its effect Interference spreads through wires or by electromagnetic radiation It is usually the former which interferes most seriously with regulation systems Possible interference sources to name but a few include e bouncing contacts when switching loads e switching off inductive loads contactors motors solenoid valves etc unsatisfactory routing of wires too small cross sections loose contacts rhythmically changing power stages power converters power breakers high frequency generators Page 15 U O Regulator contact Coil Diode U O Regulator contact AC Coil RC Filter O m i MS 5000 28 08 08 If specific interference sources cannot be avoided they should at least be kept ata distance from the regulator system Capacitive and inductive couplings can cause crosstalk between high voltage lines and parallel low voltage and
Download Pdf Manuals
Related Search