Operating Instructions
Contents
1. 31 Fault indication on the 32 General measures when using electronic control systems 33 Circuit diagram 5 100 2 61 36 WTS 100 2 20 06 11 Page 2 Appliance description WTS 100 2 20 06 11 The WTS 100 2 is a universal tank control unit combining a modern milk cooling regulator and a complete washing programme control system in one The control unit has various operating modes e OFF mode tank empty The control unit is on stand by The display shows OFF the LEDs are out and all output replays are deactivated The following operating modes can only be selected from the OFF mode It is not possible to switch directly from one of them to another CAUTION The control unit is live even when switched off e Cooling mode The current milk temperature as measured is permanently displayed It is possible to switch between two freely adjustable target temperatures by pressing a button If the milk temperature exceeds the selected target temperature T1 or T2 by the hysteresis value the compressor relay and agitator are automatically activated Once the target temperature is reached the compressor switches off while the agitator continues to operate for the pre set after stirring time During non cooling periods the agitator switches on at pre set intervals in order to ensure an even temperatu2. zuosros noez 9 eBeyo 2 y 32euuo2 5 mier JejeoH e lt E So gac F se pejoeuuoo ON Jone 59 H 5 OF 00 5 e 6 Az OLZ L8ALM 205098 sis HH z0 1 51a youms Mayes u EJ 2 OR ___ Z 6iq ueis youms Ages Qr Aq yeas jewerxg zb G 9 o josseidwog gt JosseJduio auey 0 uos saem o gt Q 5 Q N 2 O a O Jd yosuu0D 2 3 2 09 09 A ddns Jamod S xe Ss 401963002 99 1290 2 ircul gt a E 5 a 36 20 06 11 A G1 2 100 WTS
3. the LED v Washing END lights up The control unit is in fault mode which has to be cancelled Page 18 Washing programme description m Washing is stopped manually by using the OFF button Washing stops The outlet valve is opened for time n29 pressing the OFF button again ends the waiting time n29 The programme LED for this stage blinks The display alternates between OFF and the current temperature Aftertime n29 theoutlet valve closes thecontrol unit switches to OFF mode the LED v Washing END lights up m When poweris restored after an outage Theoutlet valve is opened for time n 16 Thecurrent temperature is displayed Aftertime 16 the outlet valve closes the control unit continues the washing programme from the start of the stage it was in when power was lost For installation and service purposes m Forinstallation and service purposes the control unit can be started at any desired washing stage The adjustment for this is done in the service parameter level r35 If the cleaning once was started from the selected rinse process it starts afterwards automatically again with the rinse process which is selected in the n parameter m All inputs and outputs for the individual tank components can be tested in the parameter level To this end the corresponding relays are set to l or 0 However the two relays for the addition of acidic and alkaline detergent are lock
4. 06 11 Page 5 Installation Itis essential not to install the device under the following conditions severe jolting or vibration permanent contact with water relative humidity of more than 90 sharply fluctuating temperatures condensation operation in an aggressive atmosphere ammonia or sulphur fumes risk of oxidation operation in the immediate vicinity of radio transmitters with high levels of spurious radiation Installation of housing For fixing the housing please follow the instructions e Place the seal carefully in the groove Ensure itis not twisted Cg e Insert the housing from the front through the switchboard cut out and fasten using the screws provided e Carry out the electrical wiring and sensor connection in accordance with the following description 166 156 95 Drilling diagram 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 Changing the sensor cable length 2 If it is necessary to shorten or lengthen the sensor cable on installation if a sensor other than the one supplied is to be fitted the actual i F 4 value correction parameter must be adjusted accordingly See the section Setting
5. Change parameter value e Use the A F buttons to select the desired parameter e Hold down the SET button and use the A or V button to select the desired value Hold down the arrow buttons to move more quickly In order to store the value release the A or V button first then the button Return to working level possible from any parameter e Press UP and DOWN buttons simultaneously for approx 5 seconds The current actual value is displayed If no buttons are pressed for 60 seconds the control automatically switches back to the working level Attention Any changes will not be accepted Page 20 Operation cooling 791 Working level for normal daily operation i Code 212 i Code 345 i Code 454 i Code 567 C t General cooling Extended cooling General washing Extended washing D a ra m e e rs parameters parameters parameters parameters Switch to General cooling parameters level e See page 20 Target temperature T1 Hysteresis for T1 Target temperature 2 Hysteresis for T2 WTS 100 2 20 06 11 Meaning of parameters c1 c2 c10 c11 targettemperature for T1 default 8 C target temperature for T2 default 4 C The target temperature is the temperature to which the milk is to be cooled down When the target temperature is reached the compressor switches off See diagram Range in each case 10 to 99 9 C Hysteresis for target temperature 1 default0 7 Hysteresis fo
6. set time n15 Washing stage 3 LED3 INTERMEDIATE RINSE Parameter n26 0 Wash 3 deactivated Parameter n26 1 10 Run Wash3 ntimes m Cold water is taken in by level or time as described in washing stage 1 If time controlled the time period is set by n11 m Agitator and pump startto run The water circulates for the pre set time n5 m Another option is to select an additonal water intake time using parameter n 12 m Agitator and pump switch off m Outlet valve opens for the pre set time n17 Page 16 Washing programme description WTS 100 2 20 06 11 Washing stage 4 LED4 MAIN WASH 2 Parameter 127 0 Wash 4 deactivated Parameter n27 1 10 Run Wash4 ntimes m Water taken Parameter r52 is used to determine whether cold hot or mixed water is taken in If water intake is regulated by time parameter n 18 applies m Agitator and pump startto run The water circulates in the tank m Another option is to select an additonal water intake time using parameter n19 m heater is fitted parameter r41 yes no it is switched on after period n 19 If when hot water enters the tank is still cold from the previous cooling operation the water can cool down quickly To prevent the heater switching off too soon the temperature is not measured until three minutes after the start of heating m Depending on the setting of the parameter n31 acidic detergent is injected at t
7. x 2 5 9 g D e c 5 c S z gt E 5 2 E C 5 E ER c o o gt 24 5 O lt T lt x lt no c c4 c c4 Q IE ___ ___ LA 1 EE E Q Sensitivity level Y N y The sensitivity level is factory set to average water quality nel 14 12 13lnclncl14 15 16 17 16 17 o SSF e NI gt m 8 N 5 5 Sensor Level L1 N 25 KTY 81 210 electrodes Operating voltage BB 230 V 50 60 Hz rn WTS 100 2 20 06 11 Page 8 Technical data tank control Operating voltage 230V AC N PE 50 60 Hz Relay contacts 10 make contacts max switching current 8 x each 10A AC1 250V AC 2 x each 16A AC1 250V AC max switching voltage 250V AC 50 60 Hz Display 13 mm LED Display 3 digits LED switching status displays 3 mm Display range 99 999 Number of Sensors 1 or2 Sensor type KTY 81 210 Sensor cable lenght 2 metres or as required Measurement range 5 70 Temperature resolution 0 1 C Control mode two step controller Hysteresis 0 1 K 99 9 K standard adjusting 0 7 K Water recognition via 2 electrodes optional Target temperature T1 standard adjusting 8 C Target temperature T2 standard adjusting 4 C Digital inputs 3 via optocoupler Conne
8. 103497 026 by WELBA 20 06 11 Universal tank control WTS 100 2 Installation and operating instructions for plant engineering companies WELBA GmbH Electronic Control Engineering Gewerbepark Siebenmorgen 6 D 53547 Breitscheid Phone 49 0 2638 9320 0 Fax 49 0 2638 9320 20 E mail info welba de Net www welba de Appliance description 3 Intended USB es eed head EROR eee 5 Safety aaa 5 Installation en eee Re dO REAR Oe 6 DISPOSAL e doo n oe wh s 7 Technical data 9 Sensor dimensions and technical data 9 Operating 5 issus RR RR Rem REOR 10 Operation of working levels s cose euo ERR a 11 Washing programme 15 Adjustment of parameters in 20 Operation of General cooling parameters level 21 Operation of Extended cooling parameters level 23 Operation of General washing parameters level 25 Operation of Extended washing parameters level 28 Intermediate stirring options in cooling mode 30 Continuous SUITING function 30 Sensor correction 31 Adjustment of level
9. ake time cold water washing stage 5 oder ber Niveau Range 0 999 seconds Factory setting 120 seconds n21 Additional water intake time cold water in washing stage 5 Range 0 999 seconds Factory setting seconds n23 Numberof wash 1 operations Range 0 10 Factory setting 0 n24 Number of wash 1 operations Range 0 10 Factory setting 1 n25 Number of wash 2 operations Range 0 10 Factory setting 1 WTS 100 2 20 06 11 Page 26 Operation of parameters level n26 n27 n28 n29 n30 n31 n40 n41 n50 WTS 100 2 20 06 11 Number of wash 3 operations Range 0 10 Factory setting 1 Number of wash 4 operations Range 0 10 Factory setting 1 Number of wash 5 operations Range 0 10 Factory setting 1 Water drainage time when washing is interrupted manually Range 0 999 sek Factory setting 150 sek Detergent injection sequence Active only if parameter 127 0 To set the number of alkaline washes after which an acidic wash will take place 0 alk alk alk acid 17 alk alk acid 2 alk acid Factory setting 0 Detergent injection time Choice of whether detergent is injected at the end of the water intake time n9 n19 or the subsequent water intake time n10 n18 The cleaning diagram on page 15 shows the factory setting O 0 detergent injection at the end ofthe subsequent water intake time n9 n19 1 detergent injection at the end of
10. al alteration General cooling parameters Parameters such as target values hysteresis etc are set here Extended cooling parameters For programming the control unit s individual tank specific cooling functions General washing parameters Parameters such as times are set here Extended washing parameters For programming the control unit s individual tank specific washing functions WTS 100 2 20 06 11 Page 10 Operation of working level To change to a different mode always press the OFF button first Active modes are closed down by pressing the OFF button Press COOLING twice to cancel the delayed start to cooling WTS 100 2 20 06 11 E T1 T2 Working level for normal daily operation i Code 212 i Code 345 i Code 454 Code 567 General cooling Extended cooling General washing Extended washing parameters parameters parameters parameters The working level is for normal daily milk cooling operation In cooling mode the current milk temperature as measured is permanently displayed Button functions OFF button e Switch regulator to STANDBY e Switch off continuous stirring e Acknowledge error e Switch to programming mode press button for 3 seconds SET button in working level without function COOLING button in OFF mode press twice in cooling mode Start cooling Bypass coolingstart delay Switch between target temperatures T1 T2 AGITATOR button in OFF mode Contin
11. ation of working level if present Washing can be started only if the safety switch for the tank outlet is open Only relevant if parameter n50 is setto 1 WTS 100 2 20 06 11 DIRECT START digital starting of cooling e Start cooling via digital input Direct start Asdescribed previously See page 3 Stirring in cooling mode INTERMEDIATE STIRRING e Briefly press AGITATOR in cooling mode Ashortintermediate stirring period duration c50 is triggered e Press AGITATOR in cooling mode for around 5 seconds Along intermediate stirring period duration c51 is triggered See also the section Intermediate stirring options on page 30 3 Continuous stirring mode if parameter c85 0 e Press AGITATOR button OFF mode Switches on continuous stirring rotating symbol in display e Press OFF button Switches off continuous stirring if parameter c85 gt 0 e Press AGITATOR button in OFF mode If parameter c85 is set to gt 0 once the button has been pressed the agitator runs forthe set number of minutes 4 Washing mode e Press WASHING button in OFF mode The washing programme runs automatically The current washing stage there are upto five is indicated by LED The agitator always operates at the same time as the washing pump Relay K10 is activated for the entire washing process Page 14 Washing programme description Washing programme diagram Washin
12. ays active 1 via keyboard standard switchover via foil keyboard P81 Intermediate stirring function default 1 Setting of intermediate stirring function See also section Intermediate stirring options on page 30 07 Intermediate stirring not possible 1 7 Standard setting Switch on intermediate stirring short or long using buttons 2 Continuous stirring ON OFF press the button once to switch the agitator on press again to switch it off WTS 100 2 20 06 11 Page 24 Operation of General washing parameters level Working level for normal daily operation i Code 212 i Code 345 i Code 454 i Code 567 t General cooling Extended cooling General washing Extended washing n pa ra m e e rs parameters parameters parameters parameters Switch to level General washing parameters e Seepage 20 WTS 100 2 20 06 11 Meaning of parameters n1 n2 n3 n4 n5 n6 n7 n8 n9 Additional water intake time in washing stage 0 1 Range 0 600 seconds Factory setting 20 seconds Intake time for alkaline detergent in washing stage 2 Range 0 600 seconds Factory setting Intake time for acidic detergent in washing stage 4 or 2 Range 0 600 seconds Factory setting Circulation time in washing stage 0 1 Range 0 300 seconds Factory setting seconds Circulation time in washing stage 3 Range 0 300 seconds Factory setting seconds C
13. ction Plug in screw connections for cables up to 2 5 mm Housing FEG 106 175 M front dimension 106 x 175 mm front panel cut out 156 x 96 mm insertion depht 45 mm Protection housing front IP 65 Environment specifications Operation temperature 0 50 C Storage temperature 20 7 max humidity 75 no dew Technical data subject to changes Sensor dimensions and technical data E E Sensor element KTY sensor ime 5 Bush material 1 4301 V2A APO mu Bush length 40 mm c 1 Bush diameter 6 0 mm 0 1 Cable material PVC SE mil 5 Measurement range 10 70 C Cable lenght Standard 2 metres mmt Protection type IP 65 Sensors other than our standard type are available on request p different bush from or cable length Some of the options are shown here WTS 100 2 20 06 11 Page 9 Operating levels Working level for normal daily operation Code 212 345 454 567 General cooling Extended cooling General washing Extended washing parameters parameters parameters parameters Operation of the WTS 100 2 takes place at various levels Working level for normal daily operation e OFF mode control unit switched off e Startcooling mode e Start continuous stirring mode e Start washing mode The subsidiary parameters are accessed by entering a code in order to avoid their accident
14. during cooling Adjustment of P parameter see page 21 ob The universal tank control WTS 100 2 has a function allowing the agitator to be switched on manually This can be done is different ways Regardless of the chosen option the corresponding LED always indicates when the agitator is operating The function is set at configuration level using parameter r8 1 Parameter r81 is setto 0 Intermediate stirring is not possible Parameter P81 is set to 1 standard 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 Parameter P81 is set to 2 Function Continuous stirring ON OFF By pressing the button the agitator is switched on and can be switched off by pressing the OFF button Continuous stirring function WTS 100 2 20 06 11 Continuous stirring is started by pressing the Agitator button in OFF mode if parameter c85 0 Pressing the OFF button stops continuous stirring if parameter c85 gt 1 999 The agitator stops automatically after the set time Arotating bar appears in the display during continuous st
15. e recommended that all sensors and signal lines be placed separately from the control and mains voltage lines If possible a separate main line should be provided to feed the regulator 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 consumers the induction voltage occurring during switching has to be reduced by appropriate protection methods The choice of methods depends on whether the consumer runs on DC or AC 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 component Another point to note here is that only capacitors which meet VDE 0656 may be used They must be suited to the mains vo
16. ed against each other acidic and alkaline detergents must never be in the tank atthe same time WTS 100 2 20 06 11 Page 19 Adjustment of parameters in general WTS 100 2 20 06 11 Working level for normal daily operation 212 i Code 345 i Code 454 i Code 567 General cooling Extended cooling General washing Extended washing parameters parameters parameters parameters Enter level codes In order to change parameters in one of the lower levels enter the appropriate level code General cooling parameters Code 212 Extended cooling parameters Code 345 General washing parameters Code 454 Extended washing parameters Code 567 Proceed as follows control unit must be in OFF mode e Press OFF button for 3 seconds 000 appears in the display the first 0 blinks Use the A F buttons to select the first digit of the required code Confirm the correct digit by pressing SET The digit is accepted and the second O blinks e Usethe A F buttons to set the second digit Confirm the correct digit by pressing SET The third O blinks e Usethe A F buttons to set the third digit Confirm the correct digit by pressing SET The first parameter ofthe selected level now appears If an incorrect code is entered the control unit switches back into OFF mode Display parameter value e Usethe A F buttons to select the desired parameter e Press the SET button the parameter value is displayed
17. g stage 0 Washing stage1 Washing stage2 Washing stage3 Washing stage4 Washing stage 5 K1 Agitator K9 Compressor Cold water Hu n19 K4 Warm water K7 Alk detergent K8 Acid detergent K6 Drain K5 Pump K2 Heater K10 Cleaning broken lines only applicable if activated through parameters The n designations represent the parameters which can be used to adjust the corresponding times See page 25 for adjustment of n parameters A washing cycle consists of up to six different washing stages The frequency of each stage during a cycle can be by the user See parameter n23 to n28 Washing stage 0 LED 1 PRE RINSE Parameter n23 0 Wash stage 0 deactivated Parameter n23 1 10 Run wash stage 0 n times Information regarding relay K10 m Wateris taken in Washing The washing parameter r49 is used to stipulate whether cold hot or The relay serves to cancel milking mixed water is to be taken in authorisation for milking robots that It is also stipulated for all stages r30 whether water is to be taken in are connected When washing starts regardless of the stage relay K10 is switched on by level or by time n8 If in the event of intake by level the level is not reached after a pre and remains activated until the end set the washing cycle is interrupted See fault description ortho washing programme m Agitator and pump startto run Dig relay also remains activated 1 The
18. he end ofthe washing programme The relay also remains activated if the control system switches to error mode Only when the error is acknowledged manually does the relay switch off WTS 100 2 20 06 11 Faults during washing General principle To acknowledge the fault report press the OFF button for 3 seconds OFF is displayed and the LED Washing END lights up Any other mode can now be selected Washing temperature not reached The washing programme continues to the end Atthe end ofthe washing programme aflashing fault report F04 is displayed the LED FAULT blinks the LED v Washing END lights up The control unit is in fault mode which has to be cancelled The digital input for the safety switch n50 1 for the tank outlet is triggered contact opens Washing stops The outlet valve is opened for time n 16 The programme LED for this stage blinks The display alternates between OFF and the current temperature Aftertime n 16 theoutlet valve closes aflashing fault report FO3 is displayed the LED FAULT blinks the LED v Washing END lights up The control unit is in fault mode which has to be cancelled Timefor water intake by level exceeded Washing stops The outlet valve is opened for time n 16 The programme LED for stage 5 blinks Aftertime n 16 theoutlet valve closes aflashing fault report F14 is displayed the LED FAULT blinks
19. he end of the water intake time n18 or the subsequent water intake time n19 for the period n3 m Once the heating temperature is reached n41 the heater switches off If the temperature is not reached within the pre set time r42 the control unit continues with the programme but a fault report is displayed at the end See fault description m Thewatercirculates for the pre set time n13 m Agitator and pump switch off m Outletvalve opensforthe pre settime n15 Washing stage 5 LED5 FINALRINSE Parameter n28 0 Wash 5 deactivated Parameter n28 1 10 Run Wash5 ntimes m Cold water is taken in by level or time as described in washing stage 1 If time controlled the time period is set by 120 m Agitator and pump startto run The water circulates for the pre set time n 14 m Another option is to select an additonal water intake time using parameter n21 m Agitator and pump switch off m Outletvalve opens for the pre set time n 16 If the washing programme has run without fault the control unit automatically switches to OFF mode OFF is displayed and the LED v END lights up Any other mode can now be selected Page 17 Washing programme description Information regarding relay K10 Washing The relay serves to cancel milking authorisation for milking robots that are connected When washing starts regardless of the stage relay K10 is switched on and remains activated until t
20. irculation time in washing stage 2 Range 0 600 seconds Factory setting 60 seconds Drain time outlet valve open in washing stage 0 1 Range 0 999 seconds Factory setting 60 seconds Water intake time in washing stage 0 1 or by level Range 0 600 seconds Factory setting seconds Additional water intake time in washing stage 2 Range 0 600 seconds Factory setting 20 seconds Page 25 Operation of General washing parameters level n10 Water intake time in washing stage 2 or by level Range 0 600 seconds Factory setting 40 seconds n11 Water intake time cold water in washing stage 3 or by level Range 0 600 seconds Factory setting 40 seconds n12 Additional water intake time for cold water in washing stage 3 Range 0 300 seconds Factory setting 20 seconds n13 Circulation time in washing stage 4 Range 0 600 seconds Factory setting 120 seconds n14 Circulation time in washing stage 5 Range 0 300 seconds Factory setting 60 seconds n15 Draintime in washing stage 2 4 Range 0 999 seconds Factory setting 90 seconds n16 Draintime in washing stage 5 Range 0 999 seconds Factory setting 120 seconds n17 Draintime in washing stage 3 Range 0 999 seconds Factory setting 90 seconds n18 Water intake time in washing stage 4 oder ber Niveau Range 0 999 seconds Factory setting 120 seconds n19 Additional water intake time in washing stage 4 Range 0 999 seconds Factory setting seconds n20 Water int
21. irring Page 30 Setting the actual value correction Adjustment of c parameter see page 27 Acorrection can be made to the value as measured by the sensor which applies cumulatively over the entire measuring range This is necessary when the length of the sensor cable is changed or a faulty sensor is replaced giving rise to an incorrect reading 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 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 Adjustment of level control WTS 100 2 20 06 11 The level control is factory set to medium water quality Depending on the hardness of the local water supply the sensitivity can be adjusted on a potentiometer as follows e Turn potentiometer 1 to the right to increase sensitivity e Turn potentiometer 1 to the left to reduce sensitivity Level is indicated by LED 2 Page 31 Fault indication on the display 158 Faults in regulator are indicated by flashing display as follow
22. ke is controlled by time parameter n 10 applies here Parameter r51 is used to stipulate whether cold hot or mixed water isto be taken in m Agitator and pump startto run The water circulates in the tank m Another option is to select an additonal water intake time using parameter n9 m heater is fitted parameter r40 yes no it is switched on after period n9 If when hot water enters the tank is still cold from the previous cooling operation the water can cool down quickly To prevent the heater switching off too soon the temperature is not measured until three minutes after the start of heating m Depending on the setting ofthe parameter n31 detergent is injected at the end of the water intake time n10 or the subsequent water intake time n9 as follows If Wash 4 is operational parameter n27 gt 0 only alkaline detergent is injected here for duration n2 If Wash 4 is deactivated parameter n27 0 alternately alkaline detergent is injected for duration n2 or acidic detergent is injected for duration n3 See also parameter n30 m Once the heating temperature is reached n40 the heater switches off If the temperature is not reached within the pre set time r42 the control unit continues with the programme but a fault report is displayed at the end See fault description m The water circulates for the pre set time n6 m Agitator and pump switch off m Outletvalve opens for the pre
23. ltage 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 34 General measures when using electronic control systems WTS 100 2 20 06 11 f Semiconductor switches such as thyristors or triacs also produce interference voltages They occur as a result of non linear characteristics and finite ignition voltages These components must be protected against excessive voltages for which mainly varistors RC combinations 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 microprocessor controlled regulator system from interference The suggested measures have the advantage that they will increase the lifetime of the devices as lower induction voltages reduced spark formation will also reduce contact burn Page 35
24. ng pressed and the compressor is starting The Compressor LED blinks during this period All subsequent cooling cycles start without a delay Range 0 to 999 minutes Maximum cooling time for first milking default 0 minutes The active target temperature must be reached within the set time otherwise a fault report F 15 appears in the display Set to 0 to deactivate this function Range 0 to 999 minutes Maximum continuous stirring period default 30 min Setting of maximum continuous stirring period 0 indefinite stirring to end the OFF button must be pressed 1 999 max stirring period in minutes Display actual temperature The present actual value measured by the sensor is shown Sensor correction A correction can be applied to the value measured by the sensor Then applies it cumulatively throughout the entire measurement range See page 31 Range 10 to 10K Installed software version The software version installed is shown to help service technicians Page 22 Operation of Extended cooling parameters level Working level for normal daily operation i Code 212 i Code 345 i Code 454 i Code 567 P t General cooling Extended cooling General washing Extended washing p a ra m e e rs parameters parameters parameters parameters Switch to level Extended cooling parameters e Seepage 20 WTS 100 2 20 06 11 Meaning of parameters P5 P6 Relay function K1 agitator in the event of sensor fa
25. 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 the 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 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 33 General measures when using electronic control systems e Regulator contact Coil Diode b Regulator contact AC Coil RC Filter WTS 100 2 20 06 11 If specific interference sources cannot be avoided they should at least be keptata distance from the regulator system Capacitive and inductive couplings can cause crosstalk between high voltage lines and parallel low voltage and sensor lines This distorts measured values and signals and can disrupt the entire regulatory process It is therefor
26. r target temperature 2 default0 7 K The hysteresis determines the amount by which the milk temperature is allowed to differ from target temperature T1 or T2 before the cooling compressor is switched on again See diagram Range in each case 0 1 to 10K Duration of after stirring default 120 seconds Period in seconds for which the agitator continues to operate after the compressor is switched off Range 0 to 999 seconds Pause duration default 20 minutes Period in minutes between agitator switching off and switching on again for the duration of the after stirring period selected Range 0 to 999 minutes Duration of intermediate stirring SHORT default 2 minutes Period in minutes during which the agitator operates if the UP arrow button is pressed for approx 1 second during a cooling pause Range 0 to 999 minutes Duration of intermediate stirring LONG default 10 minutes Period in minutes during which the agitator operates if the UP arrow button is pressed for approx 3 seconds during a cooling pause Range 0 to 999 minutes Page 21 Operation of cooling 791 c79 c80 c81 c85 c90 c91 c98 WTS 100 2 20 06 11 Changeover delayed start cooling switch for remote start default 0 0 without delayed start cooling 17 with delayed start cooling Delayed start to cooling for first milking default 0 minutes Delay in minutes between the Cooling button is bei
27. re throughout the milk Independently of this a short or long intermediate stirring period can be selected during cooling by pressing a button Operate by pressing button on foil keyboard If the delayed start is activated parameter c80 cooling starts for the first milking after a delay If the cooling button is pressed twice cooling starts immediately Operation via digital input The cooling starts immediately depending on the setting in parameter C79 or with a delayed start cooling e Continuous stirring mode The agitator can be switched on from the OFF mode by pressing a button and press OFF button to switch off C85 0 In parameter C85 it can be adjusted at what time the agitator will switch off This action can be discontinued at any time with the OFF button When C85 is set to 0 the agitator is running indefinitely but can be switched off with the OFF button at any time Page 3 Appliance description e Washing mode The washing timer controls water intake as either by time or level selected All running times heater pump detergent injection can be set separately Detergent switchover from acidic to alkaline can also be set The WTS 100 2 controls the various processes and times needed for a thorough wash fully automatically Following a power failure the control unit restarts in the mode in which it was operating before the outage WTS 100 2 20 06 11 Page 4 Intended use The
28. s LED Display Faults F03 Digital input for tank outlet safety switch triggered See page 18 F04 Heating duration too long If the target temperature for the water is not reached within the set time washing continues and a fault report F04 is displayed at the end The time is set in the Extended washing parameters level under r42 F05 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 See page 31 F06 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 See page 28 F12 Safety switch fault Safety switch not set to Cooling Washing F14 No water Fault occurs when the level is not reached during the set water intake time See page 18 F15 Cooling time exceeded The active target temperature must be reached within the set time otherwise a fault report F 15 is displayed See page 22 F99 Memory fault Faulty regulator Remove the regulator and send it for repair FFF Measurement range for sensor 1 exceeded The sensor fitted can only measure temperatures between 50 and 150 C WTS 100 2 20 06 11 Page 32 General measures when using electronic control systems WTS 100 2 20 06 11 So that even complicated regulatory
29. se operating instructions contain important technical and safety information Please read carefully before installation and before any work on or with the regulator The universal tank control type WTS 100 2 is used to control heating and cooling systerns alarm devices fans etc Any other use of the device is permitted only with prior written permission from the manufacturer The universal tank control is ready for use once the parameters have been set It should not be used before this has been done as this might resultin damage to the plant and the item to be cooled or heated The device is fitted with a resistance temperature sensor atmospheres The universal tank control type WTS 100 2 fulfils the EC requirements for electromagnetic compatibility EMC and the Low Voltage Directive LVD The safety components meet the VDE regulations CN c The device must not be installed in potentially explosive Safety The universal tank control must be installed by an authorised specialist observing local safety regulations Access to the environment when connected must be restricted to specialised personnel The universal tank control 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 universal tank control may not be exported to the USA without the manufacturer s express permission WTS 100 2 20
30. 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 accompanied 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 electromagnetic 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 Asthe values given in the table are maximum values operational values should remain well below them However in practice this is possible only with difficulty as even a normal contactor without interference suppression produces interference pulses of up to 3 0 kV For this reason we recommend that the following
31. tconnected 17 inputconnected r30 Water intake by level ortime default 0 0 Level 1 Time r31 Max water intake time for intake by level then stop default 10 min Range 0 60minutes 0 notmonitored r35 Startin washing stage X default 1 onlyfor technician The next wash will start with the selected washing stage Afterwards you start again with the rinse process which has been selected as starting rinse process in the n parameter Range 1 5 WTS 100 2 20 06 11 Page 28 Operation of Extended washing parameters level r40 r41 r42 r49 r50 r51 r52 r60 WTS 100 2 20 06 11 Heating in washing stage 2 default 1 0 NO 1 YES Heating in washing stage 2 default 0 0 NO 1 YES Max heating time default 60 minutes If the target temperature for the water is not reached within the set time washing continues and a fault report F04 is displayed at the end Range 15 999 min Water intake in washing stage 0 default 1 Water intake in washing stage 1 default 1 Water intake in washing stage 2 default 0 Water intake in washing stage 4 default 0 0 7 hot water only 1 cold water only 2 mixed water hot and cold outlet valve function default 0 Choice of whether the outlet valve used should be closed or open when de energised The control unit acts according to the setting 0 de energised closed normal function 1 de energised open Page 29 Intermediate stirring options
32. the actual value correction on page 31 mm WTS 100 2 20 06 11 Page 6 Installation Electrical connection 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 tank control and to the equipment The mains voltage should not be switched on until all components including the sensor are connected No appliances with current levels in excess of the maximum values indicated on the relays should be connected to the relay contacts Use contactors Downstream contactors must be fitted with an RC protection circuit see also page 33 You will find the circuit diagram for your tank control on the back of the housing above the connection terminals Disposal For the purposes of disposal the device is classified as waste electronic equipment within the meaning of European Directive 2002 96 EC WEEE and must not be included with household waste It must be B4 disposed of through the correct channels Local and current legislation must be observed WTS 100 2 20 06 11 Page 7 Installation Connection diagram e Electrical connections must be as shownin the diagram below e Usecable bushes e Make sure that cables cannot chafe e Observerelay current rating e Inall cases use contactors for pump compressor and heater e Do not feed digital inputs with external voltage Use potential free switches 5
33. the water intake time n10 n18 Factory setting 0 Heating temperature in washing stage 2 Range 0 70 C Factory setting 53 Heating temperature in washing stage 4 Range 0 70 C Factory setting 45 Safety switch present yes no default 1 0 NO 1 YES Page 27 Operation of Extended washing parameters level Working level for normal daily operation i Code 212 i Code 345 i Code 454 i Code 567 t General cooling Extended cooling General washing Extended washing r p a ra m e e rs parameters parameters parameters parameters Switch to level Extended washing parameters e Seepage 20 Meaning of parameters r1 Testrelay output 1 r2 Testrelay output 2 r3 Testrelay output 3 r4 Testrelay output 4 r5 Testrelay output 5 r6 Testrelay output 6 r7 Testrelay output 7 r8 Testrelay output8 r9 Testrelay output9 10 Testrelay output 10 Fortesting the relay contacts Onleaving this level all outputs are automatically returned to O 0 Relay switched off 17 Relayactive agitator heater cold water valve hot water valve washing pump outlet valve alkaline detergent pump acidic detergent pump compressor cleaning activ Nee eee r42 Test digital input safety switch r43 Test digital input level 714 Test digital input external cooling start The SET button can be used to check the switching status of the digital inputs No values can be entered here 0 inputno
34. to switch directly between them CAUTION The control unitis live even when switched off 2 Cooling mode MANUAL starting of cooling e Press COOLING button on foil keyboard in OFF mode LED T1 or T2 lights up for target temperature 1 or 2 If the target temperature set is briefly displayed then the current temperature of the medium is shown If the other target temperature is preferred press the COOLING button again the switchover option from T1 to T2 can be blocked via parameter P80 If Cooling start delay c80 is programmed cooling will not start immediately During the delay the compressor LED blinks Press the COOLING button twice in succession to start cooling without a delay The milk will now be cooled to the set target temperature The agitator motor runs continuously If the milk temperature is already lowerthan the target temperature only the agitator operates When the target temperature is reached the compressor switches off The agitator switches off at the end ofthe after stirring time C20 During cooling pauses the agitator switches on periodically in accordance with the pause time set c21 for the duration of the after stirring time c20 in order to ensure an even temperature throughout the milk If the milk temperature exceeds the selected target temperature by the set hysteresis value c10 or c11 the compressor and agitator automatically start again Page 13 Oper
35. ult default 2 Relay function K9 compressor in the event of sensor fault default 2 The switching status of the relay contacts K1 and K9 is adjustable for the event of a fault 0 1 in case of fault ON 2 no influence Lower limit for target temperature T1 default 2 C Upper limit for target temperature T1 default 20 C Lower limit for target temperature T2 default 2 C Upper limit for target temperature T2 default 20 C Setting via keyboard of limitations for target temperatures in working and adjustment level Range 10 to 99 C Lower limit for hysteresis T1 default 0 1 Upper limit for hysteresis T1 default 2 Lower limit for hysteresis T2 default 0 1 Upper limit for hysteresis T2 default 2 Setting via keyboard of limitations for hysteresis in the adjustment level Range 0 to 99K Minimum cooling time for compressor K1 default O min Setting of minimum running time for compressor to prevent output relay K1 switching on and off too frequently Range 0 0 to 999 min Minimum pause time for compressor K1 default 0 min Setting of minimum pause time for compressor to prevent output relay K1 switching on and off too frequently Range 0 0 to 999 min Page 23 Operation of Extended cooling parameters level P80 Switchover from T1 to T2 default 1 Setting of Switch targettemperature function 0 not possible target temperature T1 alw
36. uous stirring in cooling mode press 1 sec Intermediate stirring SHORT in cooling mode press 3 sec Intermediate stirring LONG See also section Intermediate stirring options on page 30 WASHING button in OFF mode Start washing Page 11 Operation of working level Meaning of LEDs Clo 6 LED AGITATOR in cooling mode Agitator is switched on In continuous stirring mode Continuous stirring ist aktiv in conjunction with rotating symbol in display LED COMPRESSOR continuous Compressor contactor is switched on blinking Start delay is activated T1 LED T1 Target temperature T1 active 2 LED T2 Target temperature T2 active 0 LED FAULT blinking The control unit is in fault mode which must be cancelled LED WASH END continuous Washing is completed lt LEDs WASHING STAGE in washing mode Washing stage 1 5 is active 00000 WTS 100 2 20 06 11 12 Operation of working level if present T1 T2 Washing can be started only if the safety switch for the tank outlet is open Only relevant if parameter 50 is set to 1 WTS 100 2 20 06 11 4 A 1 OFF mode tank empty The control unit is on stand by The display shows OFF the LEDs are out All output relays are deactivated The following operating modes can only be selected from OFF mode anditis not possible
37. water circulates for the pre set time n4 the control system switches to error P 8 ae mode Only when the error is Another option is to select an additonal water intake time using acknowledged manually does the parameter n1 Agitator and pump switch off Outlet valve opens for the pre set time n7 Parameter r60 is used to determine whether the drain valve is normally open or closed Applies for all washing stages Washing stage 1 LED 1 PRE RINSE Parameter n24 0 Wash stage 1 deactivated Parameter n24 1 10 wash stage 1 n times m Water is taken in by level or time as described in washing stage 1 The washing parameter r50 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 settime the washing cycle is interrupted See fault description WTS 100 2 20 06 11 Page 15 Washing programme description WTS 100 2 20 06 11 m Agitator and pump start to run The water circulates for the pre set time n4 Another option is to select an additonal water intake time using parameter n1 m Agitator and pump switch off m Outlet valve opens for the pre settime n7 Washing stage 2 LED2 MAIN WASH 1 Parameter n25 0 Wash stage 2 deactivated Parameter n25 1 10 Run wash stage 2 n times m Water is taken in by level or time as described in washing stage 1 If water inta
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