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WELBA TW-32 Installation And Operating Instructions Manual

Tank monitor
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Tank monitor
TW-32
for two separate milk tanks
Installation and operating instructions
for plant engineering companies,
installers and service engineers
Firmware V1.7
105488 – TW-32-E - V1.7 - 01.03.2021
1. Introduction
Measuring - Controlling - Regulating
All from the same source
Programmable via
configuration software
WELBA „KONSOFT"
P6age 1

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Summary of Contents for WELBA TW-32

  • Page 1 All from the same source TW-32 for two separate milk tanks Installation and operating instructions for plant engineering companies, installers and service engineers Firmware V1.7 Programmable via configuration software WELBA „KONSOFT" 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 1...

  • Page 2: Table Of Contents

    5.3 Setting the date and time ....................... 26 5.4 Operation in levels ......................... 27 5.5 Operating and display elements ....................28 5.5.1 Button functions ........................ 28 5.5.2 Description of LEDs ......................29 105488 – TW-32-E - V1.2 - 01.03.2021 Page 2...
  • Page 3 8.12 General measures when using electronic control systems ............68 Publisher: Welba GmbH Fon: +49 (0)2638 / 9320-0 Electronic Control Engineering Fax: +49 (0)2638 / 9320-20 Gewerbepark Siebenmorgen 6 info@welba.de D-53547 Breitscheid www.welba.de 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 3...

  • Page 4: 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 TW-32 tank monitor. This manual contains all necessary suggestions, information, recommendations and advice for the safe and proper in- stallation and commissioning of the tank monitor.

  • Page 5: Limitation Of Liability

    Use of unapproved spare parts (e.g. batteries) 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 con- tract are applicable. We reserve the right to make technical changes in the context of im- proving the properties of use and further developments 1.3 Warning notices in these operating instructions...

  • Page 6: Device Description

    Power failure With the integrated power pack the temperatures are monitored and stored even in the case of a power failure. Thus the TW-32 can continue its work during a power failure and activate an alarm. Data storage/-evaluation The determined data of the last 300 days (max.) temperatures, alarms, operating...

  • Page 7: Type Designation

    Despite all care, we point out that the use of the free PC-Software is at your own risk. NOTICE WELBA does not accept any liability for damages or loss of data resulting from the installation or use of the Software.

  • Page 8: Technical Data Of Control Unit

    Overvoltage category III, pollution degree I Environment specifications: - Operation temperature 0° .. +50°C - Storage temperature -20° .. +70°C - max. humidity 75% (no dew) 75% (no dew) Technical data subject to change. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 8...

  • Page 9: Sensor Dimensions And Technical Data

    -10 .. 70° C Cabel lenght standard 2 metres A Sensors other than our standard type are available on request (dif- ferent bush form or cable length). Some of the options are shown here. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 9...

  • Page 10: Safety

    It is essential to investigate and remedy the cause of the alarm in order to avoid harmful effects on the milk!!!!!! Even without an alarm message, the operator of the equipment has to ensure the transportability of the milk!!!! 105488 – TW-32-E - V1.2 - 01.03.2021 Page 10...
  • Page 11 Since the tank guard may not be opened by laypeople, the replacement DANGER! of the batteries may only be carried out by a qualified electrician DO NOT USE BATTERIES !!! EXPLOSIVE !!!!! 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 11...

  • Page 12: Intended Use

    Please read carefully before installation and before any work on or with the tank monitor. The tank monitor TW-32 is used to monitor agitator motors, compressors and clean- ing components in milk cooling tanks in the agricultural environment for the purpose of ensuring the milk quality.

  • Page 13: Safety During Installation

     Connect mains supply.  Lock the switch box and switch on the mains voltage.  Switch on and parameterize the control as described in section “Operation”. (Possibly with the optionally available configuration Software WELBA-KON- SOFT). 2.5 Wiring, screening, earthing When selecting wiring materials and installing and connecting the temperature con- troller to the electricity supply account must be taken of DIN VDE 0100 “Erection of...

  • Page 14: Electrical Safety

    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 TW-32 has a two-chamber safety winding, is only conditionally short-circuit-proof due to the built-in thermal pro- NOTICE tection.

  • Page 15: Notes On Wiring

    Make the connection according to the wiring diagram on the next page.  Use cable bushes  Make sure that cables do not chafe!  Observe relay current rating!  Do not wire digital inputs with external voltage!  Use potential-free switches. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 15...

  • Page 16: Installation

    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 temperature of between -20°C and +70°C. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 16...

  • Page 17: Fitting The Sensor

    (not even within the switchbox). Temperature range sensor cable -10°C .. +70°C. The TW-32 has been designed for connection to various types of sensor (see tech- nical data). It can function properly only if one of those sensor types is installed and the parameters are correctly set.

  • Page 18: Electrical Connection

    The tank monitor is only ready for use after the appropriate setting of ATTENTION the parameters. Commissioning without the corresponding parameter setting is not permitted. The guideline for the correct setting of the parameters can be found in section 7.1. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 18...

  • Page 19: Design Of The Control

    4. Electrical connection 4.2 Design of the control The TW-32 consists of a switch box with integrated control unit 3. All necessary components for the operation are included in the switch box: 1. SMS-module (optional) 2. Agitator monitoring module (different versions) 3.

  • Page 20: Automatische Betriebsmoduserkennung

    Example of connecting external signalers The correct connection of the external signal transmitters and sensors is described in section 4.5. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 20...

  • Page 21: Error Detection (Example)

    Detergent “empty” alkaline Example Error F35 -> Error is displayed, if the float switch reports “Container empty”. A listing of the predefined errors and their causes can be found in section 6.5. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 21...

  • Page 22: Connection Of External Signal Transmitters And Sensors

    After the connection of the external signal transmitters and sensors: Test the correct wiring. To test the correct wiring the functions of the corresponding inputs can be tested in parameters “o.21” to “o.42”. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 22...
  • Page 23 1. 1 Tank ice water cooling milk feed milk pump robot signal Ice water plate heat milk feed milk pump robot signal pump robot pumpe exchanger pump robot „start cooling“ „start cooling“ 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 23...

  • Page 24: Operation

    KONSOFT files. This allows us to deliver a pre-pro- grammed tank monitors in case of a spare part delivery. When exchanging the tank monitor at the end customer's site only the actual value correction has to be re-entered. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 24...

  • Page 25: The Configuration Software Konsoft

    NOTICE 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.

  • Page 26: Setting The Date And Time

    Information: Switching to summer- / winter time NOTICE An automatic switching to summer-/winter time can be parameterized in parameter [A78]. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 26...

  • Page 27: Operation In Levels

    The working level is used for control in everyday operation. The TW-32 is parameterized in 7 different parameter levels. The subordinate parameter levels are only entered after entering a code in or- der to avoid inadvertent adjustment of the parameters.

  • Page 28: Operating And Display Elements

    I/O test parameter remains dark. 5.5.1 Button functions In case of a trouble-free working process the TW-32 does not require any handling with the following exception: in case of setting the clock (see section 5.3) in case of reading and confirming error codes (see section 6.4).

  • Page 29: Description Of Leds

    – has already been confirmed permanent Data transfer LED (blue) "Data” blinking USB-stick inserted: Data are transferred permanent flashing USB-stick inserted: and goes off after 5 sec. Data transfer successfully completed No USB-stick inserted 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 29...

  • Page 30: Operation And Fault Handling

    During cleaning: cleaning pump etc. - times for water intake and outlet - heating times, etc. A list of all system-alarms and their corresponding configuration can be found in section 7.5 105488 – TW-32-E - V1.2 - 01.03.2021 Page 30...
  • Page 31 In case of several alarms, the RESET button has to be pressed several times. See section 6.3 (Turns off when cleaning cycle runs for at least 10 minutes) is displayed only as a blinking display code System alarms 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 31...

  • Page 32: Milk Removal Yes Or No

    = off  The driver goes to the TW-32 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.
  • Page 33  After emptying the tank the cleaning process has to be started. Only when the cleaning cycle has been active for at least 10 minutes, the tank monitor automatically resets all critical alarms. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 33...
  • Page 34  After emptying the tank the cleaning process has to be started. Only when the cleaning cycle has been active for at least 10 minutes, the tank monitor resets automatically all critical alarms. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 34...

  • Page 35: Handling Multiple Faults

    If no button is pressed for 3 seconds the display switches back to standard display. NOTICE Only when the cleaning cycle has been active for at least 10 minutes, the tank monitor resets automatically all critical alarms. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 35...

  • Page 36: Listing Fault Memory And Description

    Alarm is activated if the cleaning stops earlier than the time [H32] that has been set. Agitator fault in cooling mode (milk not stirred) Alarm functions only if optional “Welba agitator monitor” is installed and parameters set [A70/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].

  • Page 37: Informative Tankwächteralarme (Grün)

    Alarm is activated if after exceeding a temperature set by the TW-32 a new cooling or cleaning mode is not detected within the time [h31].
  • Page 38 Alarm is activated only during the cleaning if the float switch detects “de- tergent acidic empty”. Battery voltage too low The alarm is triggered if the battery charge is no longer sufficient. See also section 8.10 105488 – TW-32-E - V1.2 - 01.03.2021 Page 38...

  • Page 39: System Alarms

    F59 is dis- played. 6.5.4 System alarms external sensors Erroneous communication with agitator monitoring module and phase error (only for ESVAW-003). See parameter [A85]. Erroneous communication with GSM-module See parameter [A73]. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 39...
  • Page 40 6. Operation and fault handling 105488 – TW-32-E - V1.2 - 01.03.2021 Page 40...

  • Page 41: Setting Of Parameters

    Step 5 ters (alarm horn, LED-display, EMAIL or SMS-messages etc.) Store the parameterization of the TW-32 with the KONSOFT. In this case, you can reload the correct parameterization to the new device in the case of a spare parts delivery. Only the actual value correction has to be entered newly.

  • Page 42: Change And Save Parameter Values

    7. Setting of parameters 7.2 Change and save parameter values The TW-32 is configured in 7 different parameter levels. To change parameters in one of the lower levels, enter the corresponding 'level code'. CODE Working level h = General tank monitor parameter...
  • Page 43 Return without saving the values:  If the OFF key is pressed - or  If no button is pressed for 60 seconds: The controller automatically returns to the operation mode. All changes are lost. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 43...

  • Page 44: (H Parameters)

    Extension of time cleaning cycle after [h5] 1..30 min. Setting of time for the extension of the cleaning cycle if during time [h5] a new “open cold water valve” or an agi- tator start is detected. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 44...
  • Page 45 0..30,0 °C h28 Time limit for [h27] 0..999 min 120 0: deactivated 1…999: Time limit in minutes h29 Alarm in case of exceeding the temperature 0..30,0 °C with direct alarm activation 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 45...
  • Page 46 1 = wiring “high active” 2 = wiring “low active” h36 Monitoring of detergent “acidic” 0 .. 2 by float switch 0 = deactivated 1 = wiring “high active” 2 = wiring “low active” 105488 – TW-32-E - V1.2 - 01.03.2021 Page 46...
  • Page 47 Customer number part 1 0 .. 9999 h94 Customer number part 2 0 .. 9999 h96 Tank number part 1 0 .. 9999 h97 Tank number part 2 0 .. 9999 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 47...

  • Page 48: Level "General Tank Monitor Parameters

    H21 Minimum cooling temperature 0..50,0 °C Enter “target-cooling temperature” in °C H22 Maximum time until cooling temperature has been 0..999 min. achieved [H21] deactivated 1..999: time limit until target-cooling temperature has been achieved 105488 – TW-32-E - V1.2 - 01.03.2021 Page 48...
  • Page 49 For the activation of the password protection the following steps are necessary in parameters [H98 and H99] - enter the identical password - quit the H-parameter level The password request is made when re-entering the level-code “F94A”. ATTENTION: Please write down the password!! 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 49...

  • Page 50: Level "Alarm - Event Assignment

        ̶ ̶      Critical tank monitor alarms (red LED) ̶ ̶ ̶     ̶ ̶      105488 – TW-32-E - V1.2 - 01.03.2021 Page 50...
  • Page 51 ... sensor range exceeded 1 .. 13 (Green or red LED ... signal error mode detection 1 .. 13 or display only) Communication external sensors 1 .. 13 Communication GSM-Modul 1 .. 13 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 51...

  • Page 52: Level "Hardware Configuration

    In [A1 to A3] the necessary functions to the output relays K1 to K3 are assigned. Assignment of the digital inputs: In [A21 to A32] the input functions to the digital inputs DE1 to DE12 are assigned. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 52...
  • Page 53 DE9 Connect potential-free 0 .. 16 assignment digital input DE10 contacts to terminal 38 0 .. 16 assignment digital input DE11 0 .. 16 assignment digital input DE12 0 .. 16 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 53...
  • Page 54 One 2-phase 400V agitator at ESVAW-003-A (adress: tank 1=0 | tank 2=2) Two 2-phase 400V agitator at two ESVAW-003-A (adress: tank 1 = 0 + 1 | tank 2 = 2 + 3) 105488 – TW-32-E - V1.2 - 01.03.2021 Page 54...
  • Page 55 2: English (presentation with decimal points in the csv.file of the USB port) Factory reset Range Def. A99 Factory reset 0 .. 999 Reset all values to factory setting. ATTENTION: All settings are lost. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 55...

  • Page 56: Level "Sensor Adjustment

    A correction can be applied to the value measured by the sensor 2. It is then applied cumulatively throughout the entire measurement range. Software version C98 Installed software version The software version installed is shown to help service technicians. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 56...

  • Page 57: Level "Service Parameters

    0…99,9 °C E26 ... the last cleaning temperature reached - - - Displays the maximum temperature during the last cleaning cycle. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 57...

  • Page 58: Level "I / O Test Parameters

    Switched on relays remain switched on until they are reset manually. o.1 Test relay 1 0 .. 1 o.2 Test relay 2 0 .. 1 o.3 Test relay 3 0 .. 1 0: On 1: Off 105488 – TW-32-E - V1.2 - 01.03.2021 Page 58...
  • Page 59 Tank 2 - agitator 2 in watt o.74 - - - - - - Others o.98 Software version supply board Display of the software version of the power supply. Uses for communication with the service technician. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 59...

  • Page 60: Other Informations

    The additional safety function “first milk comes into the tank” can be set and param- eterized. Independent on parameter [h1] the cooling mode detection can also be detected with “first milk comes into the tank” [h2]. (Makes no sense in case of robot operation). 105488 – TW-32-E - V1.2 - 01.03.2021 Page 60...

  • Page 61: Detection Of Mode "Cleaning" - Parameter [H4]

    Same as setting 1, but with extension of time for detection agitator [h5+h6] Same procedure as setting 1, however, the signal of the agitator is additionally used as trigger signal to start the timer [h6]. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 61...

  • Page 62: Definition Of Term "Milk Temperature Too High For Too Long

    A time is set in which the milk must have reached a pre-set temperature - after the start of the cooling. If the temperature has not been reached within this time, the alarm will be activated. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 62...

  • Page 63: Activation Delay Tank Monitor [H90]

     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 pa- rameters [c92 and c93] must be set. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 63...

  • Page 64: Setting Of The Level Control

    Setting in the I/O test parameters:  Feed water with the consisting tank cleaning control until level has been achieved (optical control of the electrode)  Select parameter [o.41] - in TW-32 in level “I/O test parameter” (see section 7.9) more sensitive Setting level 1.

  • Page 65: Function Power Pack + Regular Exchange

    DO NOT USE BATTERIES !!! EXPLOSIVE !!!!! Installation: WELBA  Connect the power pack to terminals 21 + 22 (observe polarity) Power pack  activate power pack in parameter [A75]: 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 65...

  • Page 66: Monitoring Of Detergent Dispenser

    Das ESVAW-004-A The ESVAW-004-A monitoring module is designed for monitoring up to 4 agitator motors. In conjunction with the TW-32 only the motors A and B are supported motors C and D are optional usable. For proper installation and LED behaviour, refer to the enclosed documenta- tion of the respective module.

  • Page 67: Cancellation Of The Recorded Temperatures In The Diagram

     Set value 5 -> store  Select parameter [H71] again  Set the original value (depending on configuration) -> store The tank monitor requires about 4 days for the assimilation of the new motor data. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 67...

  • Page 68: General Measures When Using Electronic Control Systems

     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 105488 – TW-32-E - V1.2 - 01.03.2021 Page 68...
  • Page 69 (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 a closed protec- tive contact does not reopen. 105488 – TW-32-E - V1.7 - 01.03.2021 P6age 69...
  • Page 70 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. 105488 – TW-32-E - V1.2 - 01.03.2021 Page 70...

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