Table of Contents
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Installation and operating instructions
for plant engineering companies
WELBA GmbH
Electronic Control Engineering
Gewerbepark Siebenmorgen 6
D-53547 Breitscheid
Universal Milking Control
WMS-100
WMS-100 G1
WELBA
Phone:
+49 (0)2638 / 9320-0
Fax:
+49 (0)2638 / 9320-20
E-mail:
info@welba.de
Net:
www.welba.de
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Table of Contents
Summary of Contents for WELBA WMS-100 Series
- Page 1 WELBA Universal Milking Control WMS-100 Installation and operating instructions for plant engineering companies WMS-100 G1 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...
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Page 2: Table Of Contents
Contents Appliance description ........3 Intended use . -
Page 3: Appliance Description
Appliance description The control unit type WMS-100 is designed to operate the automatic washing systems of all common types of milking plant. The device controls all the main plant components via a cleaning pro- gramme that offers maximum programming flexibility and is easy to ope- rate. -
Page 4: Intended Use
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. The universal milking control type WMS-100 is used to control vacuum pumps, solenoid valves, heaters and dosing pumps in milking plants. Any other use of the device is permitted only with prior written permis- sion from the manufacturer. -
Page 5: Installation
Installation It is 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 "... - Page 6 Installation 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 and heater. ! Do not feed digital inputs with external voltage! Use potential-free switches.
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Page 7: Disposal
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. -
Page 8: Technical Data Of Regulator
Technical Data Operating voltage 230V AC +/-10%, 50 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... -
Page 9: Working Level Description
Working level description Working level for normal daily operation Code 471 Code 454 Code 382 Code 567 Cleaning parameter Cleaning parameter User-defined Service parameters running times Configuration cleaning functions (t-parameters) (P-parameters) (E-parameters) (b-parameters) Operation of the WMS-100 takes place at various levels: Working level: …... -
Page 10: Washing Programme Description
Washing programme description Page 10 WMS-100 104193 V2.7 - 14.10.2019... - Page 11 Washing programme description Washing stage Washing stages and program steps A washing cycle consists of up to six different washing stages. Each washing stage consists of up to 8 time adjustable steps Fixed and settable relay functions: In the milking plant control system nine functions are assigned to fixed relays (see previous page).
- Page 12 Washing programme description The following descriptions of the washing stages cover all the functions which can be controlled by the WMS-100 – regardless of whether the function is actually present in your milking plant. Functions assigned to fixed relays + Function “cold water valve” (relay K1) + Function “warm water valve”...
- Page 13 Washing programme description , Parameter [E23] is used to determine whether a heating system is present and when it is activated. , Parameter [E24] is used to set the maximum heating time. If the set temperature is not reached during this time, the cleaning process proceeds to the end and an error report is made.
- Page 14 Washing programme description Washing stage 1: PRE-RINSE 1 Parameter [E31] = 0 ‘Wash stage 1’ deactivated Parameter [E31] = 1..5 Run 'wash stage 1’ n times + Take in water: The cleaning parameter [E71]determines which water valves are to be operated. It is also determined whether water intake is to be controlled by 'level' [P10 = 0] or by 'time' [P10 >...
- Page 15 Washing programme description Functions which can be assigned to the three free relays. Parameters [E9 to E11] are used to determine which of the following functions are assigned to the three relays K9, K10 and K11. + Drain valve 2 Parameters [E81 to E86] can be used to determine, separately for each washing stage, whether drain valve 1, drain valve 2 or both together are opened.
- Page 16 Washing programme description Washing stage 3: MAIN WASH 1 + Take in water: The cleaning parameter [E73] determines which water valves are to be operated. It is also determined whether water intake is to be controlled by 'level' [P30 = 0] or by 'time' [P30 > 0]. If 'level' is selected and the level is not reached after the set time [E27] has elapsed, the cleaning process is stopped.
- Page 17 Washing programme description Washing stage 5: MAIN WASH 2 Parameter [E35] = 0 ‘Wash stage 5' deactivated Parameter [E35] = 1 Run 'wash stage + Take in water: The cleaning parameter [E75] determines which water valves are to be operated. It is also determined whether water intake is to be controlled by 'level' [P50 = 0] or by 'time' [P50 >...
- Page 18 Washing programme description °C If the washing programme has run without fault the control unit automati- cally switches to 'OFF mode'. ‘OFF' is displayed. The LED 'END OF CLEANING' remains lit until the OFF button is pressed. Any other mode can now be selected. Page 18 WMS-100 104193 V2.7 - 14.10.2019...
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Page 19: Operation Of Working Levels
Operation of working level Working level for normal daily operation Code 471 Code 454 Code 382 Code 567 Cleaning parameter Cleaning parameter User-defined Service parameters running times Configuration cleaning functions (t-parameters) (P-parameters) (E-parameters) (b-parameters) The working level is for normal daily operation. °C Button functions To change to a different... -
Page 20: Meaning Of Led
Operation of working level °C Meaning of LEDs LED “MILKING” “milking mode” is activ LED “CLEANING” „cleaning mode“ is activ “Drop full” LED alkaline detergent selected “Drop empty” LED acidic detergent selected LED “FAULT” blinking The control unit is in fault mode, which must be cancelled. -
Page 21: Overview Of Operating Possibilities
Operation of working level °C Overview of operating possibilities 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. Only detergent LED 'acidic' or 'alkaline' lights up. The following operating modes can only be selected from the OFF mode. -
Page 22: Start Options For Cleaning
Operation of working level if present: °C Washing can be started only if the safety switch for the tank outlet is open. Only relevant if parameter [E26] is set to 1 START options for cleaning The detergent LED shows which detergent will be used for the next washing cycle. -
Page 23: Adjustment Of Parameters In General
Adjustment of parameters in general Working level for normal daily operation Code 471 Code 454 Code 382 Code 567 Cleaning parameter Cleaning parameter User-defined Service parameters running times Configuration cleaning functions (t-parameters) (P-parameters) (E-parameters) (b-parameters) In order to change parameters in one of the lower levels enter the appropriate ‚level letter‘... - Page 24 Adjustment of parameters in general Display parameter value: ! Use the / buttons to select the desired parameter. ! Press the 'SET' button: the parameter value is displayed. Change parameter value: ! Use the / buttons to select the desired parameter. ! Hold down the 'SET' button and use the button to select the desired value.
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Page 25: Operation Of The 'Cleaning Parameters, Running Times' Level
Operation of the 'cleaning parameters, running times' level Working level for normal daily operation Code 471 Code 454 Code 382 Code 567 Cleaning parameter Cleaning parameter User-defined Service parameters running times Configuration cleaning functions (t-parameters) (P-parameters) (E-parameters) (b-parameters) P-Parameters Switch to level “cleaning parameters / running times” ! See page 23. - Page 26 Operation of the 'cleaning parameters, running times' level P45 Final pumping (milk pump) 0 - 900 sec. 60 sec. P46 Final suction time 0 - 900 sec. 30 sec. P47 Pause 0 - 999 min. 0 min. Running times for washing stage 5 (main wash 2) P50 water intake time Setting range Factory setting...
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Page 27: Operation Of The 'Cleaning Parameters, Configuration' Level
Operation of the 'cleaning parameters, configuration’ level Working level for normal daily operation Code 471 Code 454 Code 382 Code 567 Cleaning parameter Cleaning parameter User-defined Service parameters running times Configuration cleaning functions (t-parameters) (P-parameters) (E-parameters) (b-parameters) E-Parameters Switch to level “cleaning parameters / configuration”” ! See page 23. - Page 28 Operation of the 'cleaning parameters, configuration’ level E26 Safety switch present 0 .. 6 0 = deactivated 1 = Cleaning only‚ “high-active“ (signal must be present in order to clean) 2 = Cleaning only ‚ “low-active“ (signal must not be present in order to clean) 3 = Milking only‚...
- Page 29 Operation of the 'cleaning parameters, configuration’ level E45 Dry-running protection via digital input 0 .. 2 0 = deactivated 1 = high-active 2 = low-active E46 Additional water intake function via digital input 0 .. 4 0 = deactivated 1 = high-active 2 = low-active 3 = high-active + heater off 4 = low-active + heater off...
- Page 30 Operation of the 'cleaning parameters, configuration’ level Drain valve selection Setting range Factory setting 1 = Drain valve 1 2 = Drain valve 2 3 = Drain valve 1+2 E81 Drain valve select. wash. stage 1 (pre-rinse 1) 1 .. 3 E82 Drain valve select.
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Page 31: Operation Of The Level "User-Defined Cleaning Functions
Operation of the level “User-defined cleaning functions” Working level for normal daily operation Code 471 Code 454 Code 382 Code 567 Cleaning parameter Cleaning parameter User-defined Service parameters running times Configuration cleaning functions (t-parameters) (P-parameters) (E-parameters) (b.-parameters) b-Parameters Switch to level “User-defined cleaning functions” ! See page 23. -
Page 32: Operation Of The Level "Service Parameters
Operation of the level “Service parameters” Working level for normal daily operation Code 471 Code 454 Code 382 Code 567 Cleaning parameter Cleaning parameter User-defined Service parameters running times Configuration cleaning functions (t-parameters) (P-parameters) (E-parameters) (b-parameters) t-Parameters Switch to level “Service parameters” ! See page 23. - Page 33 Operation of the level “Serice parameters” + For installation 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 [E94]. If cleaning has once been started from the selected washing stage, it will subsequently again start from the same stage.
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Page 34: Sensor Correction Procedure
Setting the actual value correction A correction 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. -
Page 35: Fault Indication On The Display
Fault indication on the display Faults in the regulator are indicated by a flashing display as follows: LED - Display Faults Pipe not in cleaning position Pipe not in milking position Water temperature not reached Broken sensor: The sensor or sensor cable is faulty and must be replaced or repaired. -
Page 36: General Measures When Using Electronic Control Systems
General measures when using electronic control systems 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. - Page 37 General measures when using electronic control systems If specific interference sources cannot be avoided they should at least be kept at a 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.
- Page 38 General measures when using electronic control systems 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.
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Page 39: Electro Circuit Diagram Wts-100-2 G1
Electro circuit diagram WMS-100 G1 Freely selectable Freely selectable output function in output function in parameter E9 parameter E10 L N 1 WMS-100 14 15 18 19 20 21 22 23 24 25 26 27 F1 F2 L1 L2 L3 N PE PE PE PE N N N N 24 25 26 27 0,16A... -
Page 40: Glossary
Glossary Detergent dosage options [E43] Parameter [E43] is used to set when detergent is to be injected [E43] = 0 a fter water intake [E43] = 1 after heating [E43] = 2 “beaker dosage“ If “beaker dosage“ is activated, injection stages “D” are omitted, and detergent is injected at the same time as water intake in stages [P30] and [P50]. - Page 41 Glossary Description of digital inputs and their functions External start and stop for milking (digital input 1) A button connected to digital input 1 can be used, from OFF mode, to start and then stop the milking process. Milking/cleaning safety switch (digital input 2) [E26] Parameter [E26] can be used to activate a safety switch (on the second digital input).