Page 1 Universal tank control All from the same source WTS-300 Installation and operating instructions for plant engineering companies, installers and service engineers Firmware V4.3 Programmable via configuration software WELBA „KONSOFT" WTS-300 G1 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 1...
Page 2: Table Of Contents
Displacement cleaning with feed container and dosing pumps ........37 Cleaning programme diagram (Maximum configuration) ............38 Explanation and programming of the cleaning process .............. 40 6.3.1 Factory setting ........................40 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 2...
Page 3 Function test "Do-Not-Load LED" and "external alarm light" ........... 121 Procedure following power failure ....................122 Power pack or operation via external power supply ..............123 Agitator monitoring module (optionally) ..................124 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 3...
Page 4 12.3 SMS, alarm + remote maintenance module ESGSM ..............151 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 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 4...
Page 5: Information About This Operating Instructions
1.1 Information about this operating instructions These operating instructions are intended for the use by plant engineers, installers or service technicians of the WTS-300 universal tank control. This manual contains all necessary suggestions, Information, recommendations and advice for the safe and proper installation and commissioning of the tank control.
Page 6: 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 improving the prop- erties of use and further developments.
Page 7: Device Description
Despite all care, we point out that the use of the free PC-Software NOTICE is at your own risk. WELBA does not accept any liability for damages or loss of data result- ing from the installation or use of the Software.
Page 8: Item Supplied
-10 .. 70° C Cable length 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. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 8...
Page 9: Technical Data Of Control Unit
- Operation temperature 0° .. +50°C - Storage temperature -20° .. +70°C - max. humidity 75% (no dew) 75% (no dew) Technical data subject to change. * via I/O expansion module ESIO-001 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 9...
Page 10: Safety
In preparing the operating instructions for the end user, especially the chapter on “Safety”, account must be taken of local regulations. The parameter settings of the WTS-300 as supplied do not correspond to the intended use. This can lead to undefined behaviour by individual components when the system is commissioned.
Page 11 The device 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! 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 11...
Page 12: Intended Use
Please read carefully before installation and before any work on or with the regulator! Universal tank controllers WTS-300 are designed to control heating systems, con- densing units, alarms, fans, etc. in milk cooling tanks as well as to monitor milk qual- ity.
Page 13: 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 The transformer, which is installed in the WTS-300, has a two-chamber safety NOTICE winding, which is only short-circuit-proof due to the built-in thermal protection.
Page 14: Installation
 Insert the housing from the front through the switchboard cut-out.  Attach the holding frame in the rear position as shown by the picture.  Fasten the housing by using the screws provided. all drillings ø 4 mm 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 14...
Page 15: Fitting The Sensor
(not even within the switchbox). Temperature range sensor cable -10°C .. +70°C The WTS-300 has been designed for connection to various types of sensor (see technical data). It can function properly only if one of those sensor types is installed and the parameters are correctly set.
Page 16: Electrical Connection
 Switch on the controller and set the parameters (possibly using the optional WELBA-KONSOFT configuration software).  Plug the pre-cabled plug-in terminals of the components into the controller.  Close the switchbox. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 16...
Page 17: Wiring
Contactors are to be fitted with an RC protective circuit. Connection of the digital inputs: Only the output signal of the control provided at terminal 38 must be connected to the digital inputs (via potential-free switching contacts)! 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 17...
Page 18: Connection Diagram (Delivery Configuration)
GND * = capacitively decoupled from GND If the tank housing is to be used as one of the two level poles, this pole must be con- nected to GND*. Connection pressure sensor 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 18...
Page 19: Wiring The Digital Inputs
Digital inputs 4.6 Connection robot If the WTS-300 and the robot have a separate power supply, the robot can still be stopped (by corresponding connection) in the event of power failure. Robot requires an active signal to stop (high-active) ...
Page 20: Operation
5. Operation 5. Operation 5.1 Function overview The WTS-300 is a universal tank control unit which combines all the basic functions in one device: - milk cooling control - comprehensive cleaning control - an extended robot interface - an extended tank monitor All basic functions can be selected and operated from the working level.
Page 21: Continuous Stirring Mode
(heater, pump, detergent injection) can be set separately. The automatic switchover from acidic to alkaline detergent is also adjustable. The WTS-300 controls the different processes and times fully automatically. Following a power failure the control unit will restart in the mode it was in be- fore.
Page 22 5. Operation 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 22...
Page 23: 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 24: Guideline For The Initial Installation / Parameterization
IF TANK MONITORS SHALL BE USED: Step 8 A-parameter, h-parameter, adapt H-parameter according to condi- tions. Assign occurrences to the various alarms in the F-parameters (alarm Step 9 horn, LED-display, SMS-message, etc.) 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 24...
Page 25 If only 4 blinking horizontal bars are displayed after the application of the mains volt- age, the time has to be reset. See section 5.4 For data evaluation, the Software Konsoft uses the entered date of the WTS-300. If NOTICE...
Page 26: Setting The Date And Time
 Use the arrow keys to set the correct day.  Then set the hour and minute displays in the same way.  When finished press the SET button.  Setting is completed, and the actual time is displayed. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 26...
Page 27: Operation In Levels
Here an individual behaviour can be assigned for each fault. Configuration - (A parameter) Determination / Parameterisation of the hardware configuration I/O test parameters - (o parameter) Is intended for commissioning the control system. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 27...
Page 28: Operation Of Working Level
The working level is used for operation and control in everyday operation: OFF mode = switch off the control (Stand-by) Start cooling mode Start continuous stirring Start cleaning mode Robot operation Milk removal via the butterfly valve Observe tank monitor 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 28...
Page 29: Button Functions
5 seconds = „ROBOT STOP“ button (if parameterized) Starts or stops both the robot and the cooling mode as well. „PNEUMATIC OUTLET VALVE“ button (if parameterized) Opens / closes the pneumatic outlet valve. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 29...
Page 30: Meaning Of The Led's
The control is in error mode and must be acknowledged with the "OFF" button. LED “END OF CLEANING / TANK EMPTY” permanent Cleaning successfully finished - tank is ready for further filling. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 30...
Page 31 - milk can be loaded.. LED (blue) "Data” Flashing Tank monitor data are stored on the USB stick. 5 sec. permanent, then off Saving finished, stick can be removed. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 31...
Page 32: Operation Modes
There are various cooling start delay options. See section 9.15.2 After the start of the cooling mode The COOLING mode LED is lit Roboter Stop The robot is enabled (LED off). Valve open The butterfly valve is closed (LED off). 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 32...
Page 33 If parameter [c25] is set higher than '0', when the button is pressed the agitator runs for the set number of minutes.  Press “OFF” button: Switches off continuous stirring mode prematurely. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 33...
Page 34  Hold down the ROBOT STOP button for approx. 3 seconds: robot opera- Robot Stop tion is either enabled or stopped (Toggle function) Valve open The current switching status is indicated by LED. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 34...
Page 35  LED shows red: DO NOT LOAD MILK! The fault is indicated in the display. RESET A detailed description of the tank monitor function may be found in section 7.1 of these operating instructions. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 35...
Page 36: Cleaning
Metering pump valve valve for alcaline for acid detergent detergent Agitator Pump Drain valve Cleaning method for milk cooling tanks, where alkaline and acidic detergents are supplied by separate dosing pumps. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 36...
Page 37: Displacement Cleaning With Feed Container, Dosing Pumps In Circulation Pipe
Feed container Pump Level 1 Drain valve Cleaning method for milk cooling tanks, where water and detergent are dosed level- controlled in a feed container, before pumped out for tank cleaning. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 37...
Page 38: Cleaning Programme Diagram (Maximum Configuration)
Only available when activated in parameters Switch-on delay for heater Post-heating temperature during main circulation Cleaning pump venting (if set in parameter [r80]) Switch-on delay drain valve [r26] 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 38...
Page 39 ‚green' (see section 6.1.3 and 6.1.4) n-parameter, only required for water intake by level Adjustment of dosing times for detergents (see section 6.3.6) Heat-up time (variable - until the set temperature is reached) 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 39...
Page 40: Explanation And Programming Of The Cleaning Process
6.3 Explanation and programming of the cleaning process 6.3.1 Factory setting In the factory setting, the WTS-300 is set as follows: Only 1 main rinse cycle per cleaning cycle 3 cleaning cycles are carried out with alkaline detergent, before 1x acidic clean-...
Page 41: Different Methods Of Water Intake
- all after-rinses cold water valve warm water valve The WTS-300 offers various methods of water intake to suit the different types of system. The setting for this is made in the first parameters of each rinsing cycle. See section 6.4 TIME (factory setting) Here the water intake is opened TEMPIRAL ONLY.
Page 42: Cleaning With Alkaline Or Acidic Detergents
See also section 6.2 - Cleaning flow chart. Detergent is added by beaker NOTICE When adding detergent by a beaker, see section 11.1 – Possibility 2. * only required for cleaning methods with pre-hopper 'green'. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 42...
Page 43: Parameterization Of The Cleaning Stages
 Drain valve opens for the pre-set time [n03]. The drain valve is assigned to the respective cleaning stage via the parameters [r60 to r68]. Parameter [r24 / r25] determines whether the drain valve is normally open or nor- mally closed. Applies to all cleaning stages. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 43...
Page 44 An additional time can be defined in parameter [n15], in which the drain valve parameterized on „0“ opens (agitator and cleaning pump continue to run)  Agitator and pump switch off.  Outlet valve opens for the pre-set time [n16]. See also [n15]. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 44...
Page 45 An additional time can be defined in parameter [n25], in which the drain valve opens (agitator and cleaning pump continue to run)  Agitator and pump switch off.  Drain valve opens for the pre-set time [n26]. See also [n25]. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 45...
Page 46  Agitator and pump start to run. Water circulates in the tank. n33 have to be parameterized on „0“ Another option is to select an 'additional water intake time' using [n33]. * (D1 or D2 in cleaning programme diagram) 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 46...
Page 47  An additional time can be defined in parameter [n35], in which the drain valve opens (agitator and cleaning pump continue to run)  Agitator and pump switch off.  Drain valve opens for the pre-set time [n36]. See also [n35]. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 47...
Page 48 An additional time can be defined in parameter [n45], in which the drain valve opens (agitator and cleaning pump continue to run)  Agitator and pump switch off.  Drain valve opens for the pre-set time [n46]. See also [n45]. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 48...
Page 49 See section 7.5.3 - F44 If a switch-on delay [r36] has been parameterized for heating, heating starts only after this time has elapsed. (This is to ensure that water is in the heater.) 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 49...
Page 50  An additional time can be defined in parameter [n55], in which the drain valve opens (agitator and cleaning pump continue to run)  Agitator and pump switch off.  Drain valve opens for the pre-set time [n56]. See also [n55]. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 50...
Page 51 An additional time can be defined in parameter [n65], in which the drain valve opens (agitator and cleaning pump continue to run)  Agitator and pump switch off.  Drain valve opens for the pre-set time [n66]. See also [n65]. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 51...
Page 52 See section 7.5.3 - F44 If a switch-on delay [r36] has been parameterized for heating, heating starts only after this time has elapsed. (This is to ensure that water is in the heater.) 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 52...
Page 53  An additional time can be defined in parameter [n75], in which the drain valve opens (agitator and cleaning pump continue to run)  Agitator and pump switch off.  Drain valve opens for the pre-set time [n76]. See also [n75]. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 53...
Page 54 An additional time can be defined in parameter [n85], in which the drain valve opens (agitator and cleaning pump continue to run)  Agitator and pump switch off.  Drain valve opens for the pre-set time [n86]. See also [n85].]. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 54...
Page 55 [r60 to r69].  Parameter [r24 / r25] determines whether the drain valve is normally open or nor- mally closed. Applies to all cleaning stages. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 55...
Page 56: Abort Of The Cleaning
NOTICE: The drain time [n100] can be stopped by pressing the OFF button. See also section 7.5.3 Reset / acknowledge the fault messages:  Press the RESET button for approx. 4 seconds. RESET 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 56...
Page 57: Power Failure During Cleaning
Fault 'F30' appears in the display until it is acknowledged. Depending on the parameterisation [P60], the cleaning changes to "OFF mode" or to "cooling mode" 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 57...
Page 58: Dosing Of Detergent And / Or Water Intake By Flow Metering
L122 <=> acidic detergent L123 <=> disinfectant L124 <=> cold water L125 <=> warm water If the pulse numbers are unknown, they must be determined - as described in section 6.6.4. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 58...
Page 59: Dosing Of The Quantity-Controlled Detergent And Disinfectant
Individual timeout for each programme steps (adds up from the corresponding n- parameter [n01, n02, n12, n13...] + [L107]) after timeout the cleaning is continued * Control stops at the end of cleaning. Robot remains stopped 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 59...
Page 60: Testing / Determining The Number Of Pulses Of The Flow Sensors Per Litre
TIP: If you do not have a 1-litre measuring container available, you can also use a bucket with a defined filling quantity, for example. The number of pulses displayed must be converted to pulses per litre. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 60...
Page 61: Tank Monitor And General Fault Handling
"A" parameters (see section 8.11) must be assigned to a relay or the SMS function must be activated. The tank monitor of the WTS-300 has the following alarm types: Critical tank monitor alarms (red LED + fault code in the display) min.
Page 62 If several alarms are present, the reset button must be pressed several times. See section 7.3 (Turns off when cleaning cycle runs for at least 10 minutes ...) Is displayed as a blinking display code only. System alarm 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 62...
Page 63: Tank Monitor: Milk Removal Yes Or No
Green = on = off  The driver goes to the WTS-300 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 64 Green = off critical alarm = on  The driver goes to the WTS-300 and checks the tank monitor. The red LED is lit or flashing, an error code blinks in the display and, depending on the circumstances, a horn may sound.
Page 65 + informative alarm Red = on  The driver goes to the WTS-300 and checks the tank monitor. Green and red LEDs are flashing, an error code blinks in the display and, de- pending on the circumstances, a horn may sound ...
Page 66: Tank Monitor: Handling Multiple Faults
If no button is pressed for 3 seconds, the display switches back to the time. It is only when the cleaning cycle is active for at least 10 minutes that the tank monitor resets all critical alarms. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 66...
Page 67: Listing Fault Codes And Their Description
Minimum acting time = [H31] Agitator fault in cooling mode (milk not stirred) Alarm functions only if optional “Welba agitator monitor” is installed and parameters set [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 68: Informative Tank Monitor Alarms (Green)
Alarm is triggered, if a new cleaning does not take place within the time [h33] Time / date not set The alarm is triggered if the date and time are lost. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 68...
Page 69 The alarm is triggered as soon as the temperatures differ by value [h38]. Battery voltage too low The alarm is triggered if the battery charge is no longer sufficient. Check batteries – exchange or charge them, if necessary. See also section 9.7. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 69...
Page 70: System Alarms - Cleaning
- the red LED “FAULT” then flashes, with error code F42 During washing the thermal contact of the washing pump has triggered (if parameter set in [r12]. Possible cause of fault: - Cleaning pump overheated. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 70...
Page 71 - Water circuit damaged / interrupted Excess temperature monitor for heater - washing completed - fault is shown on the display During washing the heater's dry-running protection has triggered (if set in [r39]). 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 71...
Page 72: System Alarms - Cooling
Sensor short circuit as F56, but fault code F57 is displayed. Sensor range exceeded Sensor reports upward or downward exceeding of measuring range as F56, but fault code F58 is displayed. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 72...
Page 73: System Alarms - External Sensors
Depending on the parameterization of the parameter [A85], the cleaning is aborted in the event of a phase error. 7.5.7 Test alarm Test alarm (see section 9.5) 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 73...
Page 74: Setting Of Parameters
8. Setting of parameters 8. Setting of parameters 8.1 Change and save parameter values The WTS-300 is configured in 11 different parameter levels. To change parameters in one of the lower levels, enter the corresponding 'level code' CODE Working level...
Page 75 Return without saving the values:  Press the OFF button – or  If no button is pressed for 60 seconds: The controller automatically returns to the OFF mode. All changes are lost. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 75...
Page 76: Level "General Cooling Parameters" (C Parameters)
0 .. 999 min. in mode ‚continuous stirring‘ Setting of maximum continuous stirring period. 0: indefinite stirring (to end, the OFF button must be pressed) 1..999: max. stirring period in minutes 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 76...
Page 77 A correction can be applied to the value meas- ured by the sensor. Then applies it cumulatively throughout the entire measurement range. Software version Installed software version The software version installed is shown to help service technicians. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 77...
Page 78: Level "Extended Cooling Parameters" (P Parameters)
5.6.3 0: deactivated 1: short / long 2: toggling by button Automatic start to continuous stirring 0 .. 1 when cooling mode ends see section 10.1.1 0: deactivated 1: activated 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 78...
Page 79 1..72: x-hours after start of last cleaning an automatic stirring is activated Limitation of running time. 0,1..10,0 h Pre-stirring stops after the set time if there is no milk collection with a subsequent cleaning. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 79...
Page 80 Function 34 must be as- 1: can only be opened when robot stopped signed to one of the digital 2: activated, requires an additional RobotStop inputs [A21..A33]. feedback via digital input 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 80...
Page 81 - no Autostart of the cleaning after successful decanting - no premature stop possible - Autostart of the cleaning (after successful decanting) * Parameter [A21..A33] must be parameterized to 22 (decanting function start button). 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 81...
Page 82 Achievement of litres [P43] entered, triggers alarm. 4: Detection at level input 2 triggers alarm. Maximum filling quantity in litre 0 .. 500 input in hectolitres (=100 l) 0...500 (is equivalent to 0 to 50.000 litres) 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 82...
Page 83 [P58]. Running time for post-cooling 0,5 .. 15,0 min. The specified cooling time is indicated together with the time accumulated up to that point. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 83...
Page 84 “cooling” 4: as 2, however, the compressor lock can be stopped up to the next cooling start with button “cooling” INFORMATION: Assign function 19 to one of the digital inputs [A21..A33]! 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 84...
Page 85 Min. fill.-quantity to switch the 2nd cooling level on 1..5000 ltr. 2000 Min. fill.-quantity to switch the 3nd cooling level on 1..5000 ltr. 4000 Mutual switch-on delay of the compressor stages 2..25 sec. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 85...
Page 86 [P80] = 2 or 3 Time 1 for automatic switchover to T2 00:00 .. 23:59 4:00 see also [P80] Time 2 for automatic switchover to T2 00:00 .. 23:59 16:00 see also [P80] 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 86...
Page 87 0: deactivated 1*: high-active, signal at input triggers alarm 2*: low-active, no signal at the input triggers an alarm NOTE: Observe function assignment [A21 - A28]! * Note function assignment [A21..A33]! 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 87...
Page 88: Level "General Cleaning Parameters" (N Parameters)
0 .. 999 sec. Additional water intake time + circulation 0 .. 999 sec. Main circulation time 0 .. 999 sec. Rinse out time 0 .. 999 sec. Drain time 0 .. 999 sec. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 88...
Page 89 Additional water intake time + circulation 0 .. 999 sec. n84 Main circulation time 0 .. 999 sec. n85 Rinse out time 0 .. 999 sec. n86 Drain time 0 .. 999 sec. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 89...
Page 90 [n54] (hidden if r35 = 0 / 1) n111 Post-heating temp. during circulation in cleaning 0 .. 99,9 °C 40,0 stage disinfection [n74] (hidden if r35 = 0 / 1 / 2) 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 90...
Page 91 8. Setting of parameters 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 91...
Page 92: Level "Extended Cleaning Parameters 1" (R Parameters)
1..10: x times alkaline, before one time acid 0..120 sec. r22 Premature switching off of the rinsing pump when adding detergent via beaker in dosing step D1/D2 (see section 11.1) 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 92...
Page 93 (cleaning stage 9) button CLEANING 5: 2x pre-rinse 1 (cleaning stage 1) 6: 2x pre-rinse 2 (cleaning stage 2) 7: 2x after-rinse (cleaning stage 8) 8: 2x rinse-out (cleaning stage 9) 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 93...
Page 94 1.. 8 sec.: Switch off the heater after x seconds without pressure Over temperature protection heater (Fault F49) To protect the heater (open in the event of a fault) 0: No protective contact 1: Protective contact active 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 94...
Page 95 1 .. 2 the function A 15 (drain valve) must additionally 1: Drain valve 1 2: Drain valve 2 be assigned to one of the relays in the A parame- ters. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 95...
Page 96 1..6: activated, seconds without pressure. r87 Avoidance of rinsing shadows on the agitator 0..1 blade 0: deactivated 1: in the circulation phase (n14, n24, n34...n84) the agitator stops every 25 seconds for 5 sec. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 96...
Page 97 2: Display changes between step and temperature r98 Display of the maximum cleaning temperature 0 .. 1 achieved in OFF after cleaning 0: deactivated 1: alternating with the time * only for the installer 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 97...
Page 98: Level "Extended Cleaning Parameters 2" (L Parameters)
Amount of water in step n93 Detergent / disinfectant quantity setting 0…10,00 l L101 Amount of detergent alkaline 0,30 0…10,00 l L102 Amount of detergent acid 0,30 0…10,00 l L103 Amount of disinfectant 0,30 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 98...
Page 99 Impulse counter “acidic“ 1…9999 L121 2000 Impulse counter “alkaline“ 1…9999 L122 2000 Impulse counter “disinfectant“ 1…9999 L123 2000 Impulse counter “cold water“ 1…9999 L124 2000 Impulse counter “warm water“ 1…9999 L125 2000 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 99...
Page 100: Level "Service Parameters" (E Parameters)
[E16] but on IO expansion module I1*. E18 Display of the analogue input 4..20 mA 0,0..20,0 mA as [E16] but on IO expansion module I2*. * If the respective input is deactivated, "- -" is displayed 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 100...
Page 101 E65 … last cycle time of compressor 1 0 .. 99,9h E66 … last cycle time of compressor 2 0 .. 99,9h E67 … last cycle time of compressor 3 0 .. 99,9h 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 101...
Page 102: Level "General Tank Monitor Parameters" (H Parameters)
5: Flow switch. Feedback via the flow switch is expected when the respective pump is activated. h38 Max. temperature difference monitoring sensor during 1,0 .. 5,0 cooling mode * 0: deactivated 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 102...
Page 103 A 4-digit password (not 0000) has to be entered in parameter [h98]. For the activation of the password protection the password in parameter [h99] has to be repeated exactly. After the level code is re-entered the password query takes place. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 103...
Page 104: Level "Extended Tank Monitor Parameters" (H Parameters)
0 .. 999 min. 450 no stirring of milk * H41 Timeout "No agitator" * 0 .. 999 min. H42 Min. run time agitator [zu H41] 0 .. 500 sec. * 0 = deactivated 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 104...
Page 105 (not 0000) must be entered in parameter [H98]. In order to activate the password protection, the password in parameter [H99] must be re- peated exactly. If the level code is entered again, the password is requested after- wards. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 105...
Page 106: Level "Alarm - Event Assignment" (F Parameters)
    ̶ ̶      Critical tank monitor alarms (red LED) ̶ ̶ ̶     ̶ ̶      105204 – WTS-300-E - V4.1 - 20.01.2022 Page 106...
Page 107 1 .. 13 … external fault 1 .. 13 ... Malfunction analog input 4..20 mA 1 .. 13 ... Phase error F99 ... Test alarms (see section 9.5) 1 .. 13 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 107...
Page 108: Level "Configuration" (A Parameters)
This configuration is very important and should be the first step when setting the parameters for a system. The WTS-300 supports a large number of different system configurations (with or without robot operation), milk tanks with more than one compressor, different outlet valves etc.).
Page 109 0 .. 26 assignment relay K4 – I/O module (optionally) 0 .. 26 assignment relay K5 – I/O module (optionally) 0 .. 26 assignment relay K6 – I/O module (optionally) 0 .. 26 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 109...
Page 110 3 – I/O module (optionally) 0 .. 42 assignment digital input 4 – I/O module (optionally) 0 .. 42 assignment digital input 5 – I/O module (optionally) 0 .. 37 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 110...
Page 111 3: opening contact, alarm if opened A47 Configuration „red warning light“ 0..1 Parameter [A1..A20] => 19 0: is reset during the cleaning (same as red LED) 1: is reset with pressure 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 111...
Page 112 * Prioritisation of analogue inputs (parameter [A54 => A56 => A57]). Example: If low pressure monitoring was parameterised in parameter [A54], the same setting in parameters [A56 + A57] would be ignored. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 112...
Page 113 9: * two agitators Agitator monitoring without a separate module If agitator monitoring is made via switch contact of the WTS-300 10: * one agitator 11:* two agitators Agitator monitoring module ESVAW-003-A with one agitator switch-on-relay that is integrated in the module...
Page 114 2: Additional compressor protection. In case of an error the compressor is switched off 3: Additional cleaning pump protection. In case of an error the cleaning is interrupted 4: Additional compressor protection and cleaning pump protection. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 114...
Page 115 1 .. 8 Language setting Range Def. A98 Language setting for Konsoft monitor 0 .. 2 0: german 1: english 2: french Factory reset Range Def. A99 Factory reset 0 .. 999 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 115...
Page 116: Level "I/O Test Parameters" (O. Parameters)
0 .. 1 stored. Test Relay 6 – ext. I/O module (optionally) o.20* 0 .. 1 * is only displayed if ext. I / O extension module is activated and parameterized. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 116...
Page 117 Agitator 1 in watt o.72* Agitator 2 in watt o.73* Agitator 3 in watt o.74* Agitator 4 in watt * is only displayed if the agitator monitoring module is activated and parameterized 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 117...
Page 118 Pulse counter 4 “Cold water” o.85* Pulse counter 5 “Warm water” * is only displayed if flow sensors are activated and configured Display of the Software version adaptor o.98 Display of the Software version adaptor 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 118...
Page 119: Other Information - General
- the COOLING button is pressed while the valve is open. - the WASHING button is pressed while the valve is closed. Valve open If the butterfly valve is closed in washing mode, the cycle is interrupted, provided [r10=2] is configured. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 119...
Page 120: Sensor Correction Procedure
3: - but the temperature is shown on the display in OFF-mode. If FÜ2 develops a fault (break or short-circuit), fault code [F38] will also be displayed after 5 minutes. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 120...
Page 121: Test Functions
"external alarm light". Method:  Hold the "Reset button" for approx. 4 seconds: For approx. 10 seconds, the red "Do-Not-Load LED" is switched on and the relay "external alarm light" is energized. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 121...
Page 122: Procedure Following Power Failure
 Set and store original parameterization for the tank. NOTE: If "F.EEP" appears again on the display after the factory reset and after another NOTICE OFF and ON-switching, the control is irreparably defective. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 122...
Page 123: Power Pack Or Operation Via External Power Supply
Operation via external power supply In the event of extreme voltage fluctuations in the power supply (or if no 230V power supply is available), the WTS-300 can also be operated via an external 12 V power External 12V power supply supply.
Page 124: Agitator Monitoring Module (Optionally)
The module has to be configurated in parameter [A71]. For the correct installation please pay attention to the supplied documentation of the respective module. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 124...
Page 125: I/O Expansion Module Esio
 Activation I/O extension module => Parameters [A74] 9.10 USB module ESUSB The USB module ESUSB-001 is used to read out stored data from Welba controllers that can be read out with the Welba KONSOFT configuration software (e.g. WTS- 300 or TW-31/-32).
Page 126: Integrated Multifunction-Time Relay
9. Other information – General 9.11 Integrated multifunction-time relay The WTS-300 has an integrated time relay function by which external components can be switched. There is no need of an additional time relay. Setting as follows:  Select time relay function via parameter [A86] (selection 1..8).
Page 127 Selection 8: (Event-controlled -> cannot be stopped!) After the omission of trigger signal, a delay time T1 starts. The relay output is switched on for time T2. Trigger signal Relay output 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 127...
Page 128: Safety Chain For 'Remote Start' Functions
 Assign function '36' (release remote start) to one of the digital inputs [A21..A33]. Push button remote start CLEANING Safety switch and / or manhole Push button remote start COOLING and / or Safety switch Push button remote start STIRRING rinsing tank 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 128...
Page 129: Rs485 Interface
9. Other information – General 9.13 RS485 interface The WTS-300 has two RS485 interfaces as connection options for: RS485 PC  A PC with the Welba Konsoft for parameterizing, updating and reading the data  Remote maintenance module ESGSM for a remote configuration and sending SMS-error messages ...
Page 130: 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 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 130...
Page 131 (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. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 131...
Page 132 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. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 132...
Page 133: Robot Control
9. Other information – General 9.15 Robot control The WTS-300 offers two possibilities of controlling a connected robot: - via the button “Robot Stop” - via the signal “Cleaning active” For both functions, the appropriate parameter settings must be done beforehand..
Page 134: Cleaning Release By Robot
The WTS-300 can be configured in such a way that washing is not started directly by pushing the button, but in addition a robot release signal is needed.
Page 135: Compressor Switch-On Delay / Pre-Agitating
Cancel compressor lock:  Press the OFF button,  Start cooling mode immediately (without cooling start delay) by double-clicking the “COOLING” button. The compressor lock is deactivated once (until the next cooling start). 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 135...
Page 136: Other Information - Cooling
When using a robot, it is possible to start the cooling mode automatically after a successful cleaning. If cleaning is not successful, the control remains in cleaning mode and manual acknowledgement is necessary. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 136...
Page 137: 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-300 offers a range of variants for cooling start delay.
Page 138 If the compressor is switched off, it cannot start again until at least the quantity of milk set in parameter [P53] has been added. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 138...
Page 139: Emergency Cooling / Sensor Fault
In this case, once the electrode is reached, an alarm is given and the outlet valve is opened. All relevant settings are found in [P40]. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 139...
Page 140: Connection /Parameterization External Analogue Pressure Sensor
Either a pressure sensor for the filling level or the cooling agent can be connected to the analogue input of the WTS-300. See graphic. When using the pressure sensor „filling level“, it has to be set as follows: Installation case "A"...
Page 141: Tanks And Silos With Multiple Cooling Stages (Cooling Step Control)
10. Other information - Cooling 10.6 Tanks and silos with multiple cooling stages (cooling step control) The WTS-300 supports silos with up to three cooling stages. 5 different methods are possible to control the second and third cooling steps. Applicable for all methods: In the parameters [A1..A20] the connected cooling levels and compressors have to...
Page 142: Tank Overflow Protection
 Enter the maximum filling quantity of the silo-tank in hectolitres ((= 100 litres) in parameter [P43]  Set level switch as described in section 10.5 Fault display: When the upper filling level is achieved fault [F51] “tank overflow protection” is triggered. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 142...
Page 143: Anti-Freezing Protection By Means Of Low Pressure Monitoring
10. Other information - Cooling 10.8 Anti-freezing protection by means of low pressure monitoring With the WTS-300 "freeze protection" can be set up via the low pressure monitoring of the compressor. This prevents small quantities of milk from freezing in the tank or silo.
Page 144: Thermal Protection - / Fault Monitoring Compressor [P72]
Fault monitoring is only possible if a digital input [A21..A33] with function 5 is as- signed for each compressor. The first assigned digital input monitors compressor 1, the second one compressor 2 and the third one compressor 3. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 144...
Page 145: Fault Messages Low Pressure (F80)
Via parameter [P91], the signal of an external high-pressure switch can be generated as fault message. Function assignment digital input [A21..A33] => 21 (fault high-pressure) Parameter [P91] - Setting 1 + 2 independent of the low-pressure monitoring 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 145...
Page 146: Other Information - Cleaning
[r72]..at a certain time enter them in parameter [r73]. A parameterized elapsed time of the break or the countdown-timer is displayed al- ternately with “STOP”. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 146...
Page 147: Heating Control
Rinse out Intermediate rinse 1 Heater The WTS-300 distinguishes between two heating phases: - Heating-up phase - programme step "H“ - Further heating phase - during the main circulation (n34 or n54 and n74). During the heating-up phase, the water is heated to the temperature set (the display shows the temperature measured by sensor 1 instead of the programme stage).
Page 148: Level Control Setting
11.7 Relay function 'set level 2 to relay' If this function '23' is assigned to a relay [A1..A20], the relay is always energized when water is detected at the level 2 input. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 148...
Page 149: Function Of Pressure Switch - Effect On Pump And Heater
During automatic venting with pressure switch evaluation, parameters [r11] and [r38] do not come into play. NOTICE The digital input in parameter [A25] (5=Pressure switch water "Default setting") is used directly for evaluation. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 149...
Page 150: Service Functions For Testing The Cleaning Cycle
Cleaning can be stopped at any time by pressing the OFF button. A drain phase is automatically carried out - this cannot be stopped. In the display, "ABL" appears alternating with the temperature. 105204 – WTS-300-E - V4.1 - 20.01.2022 Page 150...
Page 151: Other Information - Tank Monitor
The activation delay of the tank monitor is required to test the operation modes dur- ing the commissioning without activating false alarms. The delay is activated when the WTS-300 is switched on. All time-dependent alarms are temporarily deactivated Only after the set time [H90] has elapsed the tank monitor is set to the basic condition and activated.

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