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WELBA WTS-200 Installation And Operating Instructions Manual

Universal tank control
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Universal tank control
WTS-200
Installation and operating instructions
for plant engineering companies,
installers and service engineers
105871 - WTS-200
31.05.2021
Firmware V0.7
Measuring - Controlling - Regulating
All from the same source
welba.de
Programmable via
configuration software
WELBA „KONSOFT"

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Summary of Contents for WELBA WTS-200

  • Page 1 Measuring - Controlling - Regulating All from the same source welba.de Universal tank control WTS-200 Firmware V0.7 Installation and operating instructions for plant engineering companies, installers and service engineers Programmable via configuration software WELBA „KONSOFT" 105871 - WTS-200 31.05.2021...

  • Page 2: Table Of Contents

    - Cleaning mode ........23 Page 2 105871 - WTS-200 31.05.2021...
  • Page 3 Disposal ..........68 Page 3 105871 - WTS-200 31.05.2021...

  • Page 4: Introduction

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

  • Page 5: Safety

    The universal tank control may not be exported to the USA without the manufacturer's express permission. The parameter settings of the WTS-200 as supplied do not corre- spond to the intended use. This can lead to undefined behaviour by individual components when the system is commissioned.

  • Page 6: Intended Use

    Safety Intended use Universal tank controllers WTS-200 are designed to control heating systems, condensing units, alarms, fans, etc. in milk cooling tanks. Any other use of the device is permitted only with prior written permission from the manufacturer. The controller is intended only for incorporating into machinery, display panels or switchboxes etc.

  • Page 7: Wiring, Screening, Earthing

    Caution: All cables to the digital inputs must be shielded and kept as short as possible. EMC. Important note concerning the external fuse ! We recommend protecting the control system with a slow-blow fuse of 160 Page 7 105871 - WTS-200 31.05.2021...

  • Page 8: Installation

    Unpacking and storage If the packaging is damaged or something is missing, do not fit the tempera- ture controller. In this case please contact Welba. If you keep the temperature controller for a period before using it, store it in a clean dry place at a temperure of between -20°C and +70°C.

  • Page 9: Fitting The Sensor

    (or if a sensor other than the one supplied is to be fitted), the "actual value correction" parameter must be adjusted accordingly. See the page 59. Page 9 105871 - WTS-200 31.05.2021...

  • Page 10: Electrical Connection

    , Contactors are to be fitted with an RC protective circuit. , The digital inputs may only be connected via potential free switch contacts. Page 10 105871 - WTS-200 31.05.2021...

  • Page 11: Connection Diagramm

    5 6 7 8 9 10 11 12 13 14 max. switching current relay: K1...K10 5A/230VAC1 K6 K7 K8 K9 K10 K2 K3 K4 K5 Digital inputs 25 24 23 22 21 20 19 18 17 16 Page 11 105871 - WTS-200 31.05.2021...

  • Page 12: Technical Data

    156 x 96 mm - insertion depht 45 mm Protection (housing front) IP 65 Environment specifications: - Operation temperature 0° .. +50°C - Storage temperature -20° .. +70°C - max. humidity 75% (no dew) Technische Änderungen vorbehalten. Page 12 105871 - WTS-200 31.05.2021...
  • Page 13 Measurement range -10 .. 70° C Cable lenght Standard 2 metres Sensors other than our standard type are available on request (different bush from or cable length). Some of the options are shown here. Page 13 105871 - WTS-200 31.05.2021...

  • Page 14: Function Overview

    Funcion overview The WTS-200 is a universal tank control unit combining a modern milk cooling regulator and a complete cleaning programme control system in one. The control unit has various operating modes: ! OFF mode (with continuous stirring function + QUICKWASH) The control unit is on stand-by.

  • Page 15: Internal Data Storage

    Internal data storage An integrated data storage permanently records the mode, the milk temperature, the compressor and stirrer status of the last one to two days. This data can be conveniently evaluated via the "Welba evaluation Software "Welba KONSOFT". Optional:...

  • Page 16: The Configuration Software Konsoft

    The configuration software KONSOFT For software description see separate instructions. The user-friendly configuration software “KONSOFT" for the WTS-200 can be used for configuration parameter setting visualisation storage updating Configuration All setting parameters can be entered and stored, with reference to levels, on your PC using a clearly designed template.

  • Page 17: Operating Levels

    E-parameters Code: A03 I/O test parameters o.-parameters Code: 0E5 Operation of the WTS-200 takes place at various levels: Working level: … for normal daily operation. ! OFF mode = control unit switched off. ! Start cooling mode. ! Start cleaning mode.

  • Page 18: Operation Of Working Level

    AGITATOR button in OFF mode = Continuous 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 58. Page 18 105871 - WTS-200 31.05.2021...
  • Page 19 Taste “PFEIL AB” (+ QUICKWASH) in programming mode = changing of setting values in OFF mode = press button for about 2 sec.: Start of the short rinsing programme (only, if set in parameter [r28], see page 46.) Page 19 105871 - WTS-200 31.05.2021...

  • Page 20: Meaning Of Leds

    LED “WASH END” continuous cleaning is completed LED "COOLING MODE" Mode blinking Cooling start delay is activ continuous "Cooling mode" is activ Mode LED "CLEANING MODE" continuous "Cleaning mode" is activ blinking “Quickwash” is active. Page 20 105871 - WTS-200 31.05.2021...

  • Page 21: Operating Modes

    A start signal (from the robot or an external button) must be present for at least 5 seconds. Stop: - Depending on setting in parameter [P38] - or at any time via the OFF-button. For setting see parameter [P36..P38]. Page 21 105871 - WTS-200 31.05.2021...

  • Page 22: Cooling Mode

    A short intermediate stirring period [duration = ] is triggered. ! Press 'AGITATOR' in cooling mode for around 5 seconds: A long intermediate stirring period [duration = ] is triggered. See also the section: 'Intermediate stirring options' on page 58. Page 22 105871 - WTS-200 31.05.2021...

  • Page 23: Cleaning Mode

    Start cleaning mode via digital input - (e.g. with external button) See above for cleaning procedure. Special functions for cleaning , START-options for the cleaning process see page 33 , Single step function during the cleaning process see page 34 Page 23 105871 - WTS-200 31.05.2021...

  • Page 24: Cleaning Programme Description

    Exception: , 'ALC' (alkaline) or 'ACI' (acidic) is displayed during detergent dosing Mode during the heating phase, a '-H-' is displayed alternating with the current temperature - depending on the setting in parameter [r97]. Page 24 105871 - WTS-200 31.05.2021...
  • Page 25 The „rinsing time“ is determined in parameter [n15] (same name). + Drain water (Programme step: n16) Agitator and cleaning pump switch off - drain valve opens. The time of the „drain water“ is defined in parameter [n16]. Page 25 105871 - WTS-200 31.05.2021...
  • Page 26 The „rinsing time“ is determined in parameter [n25] (same name). + Drain water (Programme step: n26) Agitator and cleaning pump switch off - drain valve opens. The time of the „drain water“ is defined in parameter [n26]. Page 26 105871 - WTS-200 31.05.2021...
  • Page 27 Agitator and pump continue to run, drain valve opens already. Time „rinsing“ => Parameter [n35] + Drain water (Programme step: n36) Agitator and cleaning pump switch off - drain valve opens. The time of the „drain water“ => Parameter [n36] Page 27 105871 - WTS-200 31.05.2021...
  • Page 28 The „rinsing time“ is determined in parameter [n45] (same name). + Drain water (Programme step: n46) Agitator and cleaning pump switch off - drain valve opens. The time of the „drain water“ is defined in parameter [n26]. Page 28 105871 - WTS-200 31.05.2021...
  • Page 29 Agitator and pump continue to run, drain valve opens already. Time „rinsing“ => Parameter [n55] + Drain water (Programme step: n56) Agitator and cleaning pump switch off - drain valve opens. The time of the „drain water“ => Parameter [n56] Page 29 105871 - WTS-200 31.05.2021...
  • Page 30 The „rinsing time“ is determined in parameter [n65] (same name). + Drain water (Programme step: n66) Agitator and cleaning pump switch off - drain valve opens. The time of the „drain water“ is defined in parameter [n66]. Page 30 105871 - WTS-200 31.05.2021...

  • Page 31: Cleaning With Alkaline Or Acidic Detergent

    D1 or D2. Setting in parameter [r20]. Cleaning stage 3 Cleaning stage 4 Cleaning stage 5 Cleaning stage 6 Main rinse Intermed. rinse Main rinse After rinse Page 31 105871 - WTS-200 31.05.2021...

  • Page 32: Cleaning Cycle Completed

    Information The drain time [n70] can be stopped by pressing the OFF-button. See also page 56. To reset the fault messages: - Hold down the UP ARROW (RESET) button for about 4 seconds. Page 32 105871 - WTS-200 31.05.2021...

  • Page 33: Power Failure During The Cleaning Process

    " keep button CLEANING pressed until the desired start-rinsing cy- cle (SP1 to SP6) is displayed. " When the button is released, the cleaning starts with the selected rinsing cycle and keeps on running until the cycle is finished. Page 33 105871 - WTS-200 31.05.2021...

  • Page 34: Single Step Function During Cleaning

    LED 'CLEANING END' does not flash. Cleaning can be interrupted at any time by pressing the OFF-button. A drain phase is automatically initiated - which cannot be interrupted. The display shows "ABL" alternating with the temperature. Page 34 105871 - WTS-200 31.05.2021...

  • Page 35: Adjustment Of Parameters In General

    Saving the changed parameters and switching back to the Attention: Any changes will not working level: be accepted! (possible from any parameter) ! Press UP and DOWN buttons simultaneously for approx. 5 seconds. The device switches to the OFF mode. Page 35 105871 - WTS-200 31.05.2021...

  • Page 36: Operation Of 'Cooling Parameters 1' Level

    C24 Duration of 'intermediate stirring LONG' (default 10 minutes) Period in minutes during which the agitator operates if the AGITATOR button is pressed for approx. 3 seconds during a cooling pause. Range 1 to 999 minutes. Page 36 105871 - WTS-200 31.05.2021...
  • Page 37 A correction can be applied to the value measured by the sensor. Then applies it cumulatively throughout the entire measurement range. See page 59. Range -10 to 10K Softwareversion C98 Installed software version The software version installed is shown to help service techni- cians. Page 37 105871 - WTS-200 31.05.2021...

  • Page 38: Operation Of 'Cooling Parameters 2' Level

    0 = Intermediate stirring not possible 1 = 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 Page 38 105871 - WTS-200 31.05.2021...
  • Page 39 2 = · no premature stop possible · no Autostart of the cleaning after successful decanting 3 = · no premature stop possible · Autostart of the cleaning (after successful decanting) Page 39 105871 - WTS-200 31.05.2021...
  • Page 40 P64* “OFF”-time cooling start (default 20 min) Setting range 5 .. 60 min. P65* number cooling starts (default 5) Setting range 1 .. 50 * not activated with [P61 selection 0 and 1] Page 40 105871 - WTS-200 31.05.2021...
  • Page 41 * Settings 3 and 4: When the compressor is switched on, feedback is expected at the digital input of the controller after 60 seconds at the latest. If this feedback is not received, fault "F53" is triggered. Page 41 105871 - WTS-200 31.05.2021...
  • Page 42 - If T2 is active, the LED for T2 flashes and shows that switch- back to T2 will happen automatically. P81 Duration until switch-back to T1 (default 120 min.) Enter the switch-back time to the target temperature T1 Range 1 .. 999 min. Page 42 105871 - WTS-200 31.05.2021...
  • Page 43 P89 Monitoring time from the start of cooling (default 300 min) 0 = no time limit 1..600 = minutes after starting the cooling, the low pressure monitoring switches itself off until the next cooling activation. Range 0 .. 600 min. Page 43 105871 - WTS-200 31.05.2021...

  • Page 44: Operation Of 'Cleaning Parameters 1' Level

    Circulation with water refill 0 - 999 sec. 0 sec. n44 Circulation time 0 - 999 sec. 30 sec. n45 Washout time 0 - 999 sec. 0 sec. n46 Drain time 0 - 999 sec. 60 sec. Page 44 105871 - WTS-200 31.05.2021...
  • Page 45 Dosing time P-ACID in the after-rinse 0 - 999 sec. 0 sec. added in the after rinse on request. Temperature settings Range default Heating temperature main rinse 1 0 - 80° 45° Heating temperature main rinse 0 - 80° 45° Page 45 105871 - WTS-200 31.05.2021...

  • Page 46: Operation Of 'Cleaning Parameters 2' Level

    4 2 = 1 x pre-rinse 2 seconds. 3 = 1 x after-rinse 4 = je 1 x pre-rinse 1 + after-rinse 5 = je 1 x pre-rinse 2 + after-rinse Page 46 105871 - WTS-200 31.05.2021...
  • Page 47 1 = Cold water 2 = Hot water 3 = Mixed water Select drain valve Select drain valve for cleaning cycle 1 (pre-rinse 1) default 1 1 = Drain valve 1 2 = Drain valve 2 Page 47 105871 - WTS-200 31.05.2021...
  • Page 48 ING button, the cycle can now be advanced step by step. * for the installer only Display during rinsing default 0 Display of temperature Display of programme step 2 = Display changes between step and temperature Page 48 105871 - WTS-200 31.05.2021...

  • Page 49: Operation Of 'Hardware Configuratioon' Level

    8 = cold water 9 = compressor 10 = agitator 11 = alarm relay (see also [A45]) 12 = P-ACID 13 = Transfer valve 14 = multifunction time relay 15 = drain valve 2 Page 49 105871 - WTS-200 31.05.2021...
  • Page 50 A45 Relay configuration “Alarm“ default 0 0 = closing contact, alarm if closed 1 = closing contact, alarm if open (non-volatile) 2 = opening contact, alarm if closed (non-volatile) 3 = opening contact, alarm if opened Page 50 105871 - WTS-200 31.05.2021...
  • Page 51 A95 Baud setting default 3 1 = 9600 2 = 19200 3 = 38400 A96 Device adress Range 1.. 4 default 1 Language setting A98 Language setting default 0 0 = german 1 = english Page 51 105871 - WTS-200 31.05.2021...

  • Page 52: Operation Of 'Service Parameter' Level

    -1 .. 99 = deactivated 0…99 = first part of the PIN (eg. PIN = 1234) E51 SIM-PIN for ESGSM-001 (optional) 0 .. 99 0…99 = second part of the PIN (eg. PIN = 1234) Page 52 105871 - WTS-200 31.05.2021...

  • Page 53: Operation Of 'I / O Test Parameter' Level

    Test level input o.41 Level 1 The SET button can be used to check the switching status of the level input. No values can be entered here. input not connected input connected Page 53 105871 - WTS-200 31.05.2021...

  • Page 54: Fault Messages

    T1 T2 °C Mode Note: With an optional Welba alarm and remote maintenance modem, all fault messages can also be sent as SMS or EMAIL to predefined addresses. Fault messages: , Any occurring faults appear flashing on the display. , At the same time, the faults are reported to an optionally connected alarm...
  • Page 55 - Press the UP ARROW (RESET) button: the alarm relay is reset - Hold down the OFF button for 4 seconds: The fault message in the display is reset - Restart the cleaning process * optionally * optional Page 55 105871 - WTS-200 31.05.2021...
  • Page 56 [r37]. Possible cause of fault: - Heater faulty To reset the fault message: - Press the UP ARROW (RESET) key: the fault is reset. * optionally Page 56 105871 - WTS-200 31.05.2021...
  • Page 57 F97 Software fault Please contact the manufacturer EEP Memory fault See page 60. dEF Automatic factory reset after update The controller was reset to factory settings after a software update. See page 60. * optionally Page 57 105871 - WTS-200 31.05.2021...

  • Page 58: Other Information

    Other information Function “Intermediate stirring” The universal tank control WTS-200 has a function allowing the agitator Mode to be switched on manually in coolin mode. This can be done is different ways. Regardless of the chosen option the corresponding LED always indi- cates when the agitator is operating.

  • Page 59: Setting The Actual Value Correction

    The level control is factory-set to 'medium' water quality. Depending on the hardness of the local water supply sensitivity can be adjusted parameter [r30] as follows: 0 .. +10 more sensitivity 0 .. -10 lower sensitivity Page 59 105871 - WTS-200 31.05.2021...

  • Page 60: Procedure Following Power Failure

    Press button SET to confirm the factory reset. Set and store original parameterization for the tank. NOTE: If "EEP" appears again on the display after the factory reset and after another OFF and ON-switching, the control is irreparably defective. Page 60 105871 - WTS-200 31.05.2021...

  • Page 61: Emergency Cooling In The Event Of A Sensor Fault

    Via [P89] can be set whether the low pressure monitoring is to be permanent or temporally limited. The advantage of permanent monitoring is that even the loss of cooling agent is detected! Page 61 105871 - WTS-200 31.05.2021...

  • Page 62: Different Variants For Cooling Start Delay

    A new manual activation of the cooling start delay can be triggered only by a long pressing of the button "COOLING". To cover all the different system configurations possible, the WTS-200 offers a range of variants for cooling start delay.

  • Page 63: Integrated Multifunction-Time Relay

    When the trigger signal is given, an impulse of length T2 is released at the relay-output (however, only as long as the trigger signal is present). If the trigger signal drops out within the time T2 the relay also drops again. Trigger signal Relay output Page 63 105871 - WTS-200 31.05.2021...
  • Page 64 Selection 8: Delayed impulse,SWITCHED-OFF-triggered (Event-triggered -> cannot be interrupted!) A delay time T1 starts after the trigger signal has ceased. Then the relay-output is switched on for the time T2. Trigger signal Relay output Page 64 105871 - WTS-200 31.05.2021...

  • Page 65: Enter The Sim Pin For The Esgsm-001

    ESGSM-001! If the status-LED of the ESGSM-001 flashes "2x in RED", a 4-digit SIM- PIN must be entered. NOTE: If a "-1" is set and saved in [E50], the PIN entry via the WTS-200 is deactivated. Proceed as follows: Enter the first two digits of the PIN in parameter [E50].

  • Page 66: 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 Page 66 105871 - WTS-200 31.05.2021...
  • Page 67 (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 protective contact does not reopen. Page 67 105871 - WTS-200 31.05.2021...

  • Page 68: Disposal

    Local and current legislation must be observed. Publisher: WELBA GmbH Tel. +49 (0)2638 / 9320-0 Electronic Control Engineering Fax. +49 (0)2638 / 9320-20 E-mail: info@welba.de Gewerbepark Siebenmorgen 6 D-53547 Breitscheid Web: www.welba.de Page 68 105871 - WTS-200 31.05.2021...

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