db^ c~êã qÉÅÜåçäçÖáÉë
Compact controller for milk cooling tank - A4 -
Instruction Manual / Installation Instructions / Parts List (Translation of the original operating instructions) 3300-9001-520 12-2009
db^ c~êã qÉÅÜåçäçÖáÉë J qÜÉ êáÖÜí ÅÜçáÅÉK
Contents
7.5.1 7.5.2 7.5.3 7.5.4
1
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1
Information on the instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1.2
Manufacturer’s address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.3
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.4
Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1
Owner’s obligation of care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
2.2
Explanation of the safety symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
2.3
Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
2.4
Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1
Correct applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
3.2
Changes to the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
3.3
Design of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
3.4
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
3.5
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
4
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1
Special personnel qualification required for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.2
Safety instructions for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.3
Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.4
Includes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.5
Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.6
Information on disposing of packing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1
Special personnel qualification required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
5.2
Safety instructions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
5.3
Fitting the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
5.4
Information on disposing of installation material after installation is finished. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
6
Initial Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1
Special personnel qualification required for initial commissioning
........................................
15
6.2
Safety instructions for initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
6.3
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1
Special personnel qualification required for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
7.2
Safety instructions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
7.3
Workplaces for operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
7.4
Description of the operating elements
...............................................................
19
7.5
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Agitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 21 22 22 23
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Contents
7.5.1 7.5.2 7.5.3 7.5.4
1
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1
Information on the instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1.2
Manufacturer’s address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.3
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.4
Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1
Owner’s obligation of care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
2.2
Explanation of the safety symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
2.3
Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
2.4
Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1
Correct applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
3.2
Changes to the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
3.3
Design of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
3.4
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
3.5
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
4
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1
Special personnel qualification required for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.2
Safety instructions for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.3
Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.4
Includes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.5
Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.6
Information on disposing of packing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1
Special personnel qualification required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
5.2
Safety instructions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
5.3
Fitting the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
5.4
Information on disposing of installation material after installation is finished. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
6
Initial Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1
Special personnel qualification required for initial commissioning
........................................
15
6.2
Safety instructions for initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
6.3
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1
Special personnel qualification required for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
7.2
Safety instructions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
7.3
Workplaces for operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
7.4
Description of the operating elements
...............................................................
19
7.5
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Agitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 21 22 22 23
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8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.1
Special personnel qualification required for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
8.2
Safety instructions for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
8.3
Fault messages and troubleshooting help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
8.4
Troubleshooting possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
9
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.1
Special personnel qualification required for decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
9.2
Safety instructions for decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
10
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11.1
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
11.2
Quick -reference guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
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Preface
Information on the instructions
1
Preface
1.1
Information on the instructions
These instructions are supplied with the product. D
D D
D
It is designed modular and is only in relation to the mentioned product. For details of the components which are relevant to the product, please refer to the appropriate manuals. This applies especially for safety information! This applies especially for safety information! They should be kept close at hand and remain with the equipment even if the equipment is sold. This manual is not covered by an amendment service. The current version can be obtained through your technical dealer or directly from WestfaliaSurge.
We reserve theright to make changes due to technical developmentsin thedata and images given in this manual. Reproduction, translation or copying in any form, including extracts, requires written authorization from WestfaliaSurge. Abbreviations, units, specialist terms, special names or specialist terminology are explained in more detail in the ”Appendix”. Pictograms used
This pictogram indicates information that will help towards a better understanding of the working processes. This pictogram indicates a special tool required for installation. A correction bar in the margin indicates changes to the previous edition. This pictogram refers to another document or chapter. If a manual number is given, the middle 4 figures indicate the language, as follows: Language
Language
Language
-9000-9001-
German English (Great Britain)
-9013- Dutch -9015- English (America)
-9032-9034-
Serbian Slovakian
-9002-
French (France)
-9016- Polish
-9036-
Lithuanian
-9003-
Italian
-9021- Danish
-9038-
Portuguese (Brazil)
-9004-
Romanian
-9022- Hungarian
-9039-
French (Canada)
-9005-
Spanish
-9023- Czech
-9040-
Latvian
-9007-
Swedish
-9024- Finnish
-9041-
Estonian
-9008-
Norwegian
-9025- Croatian
-9043-
Spanish (North America)
-9009-
Russian
-9027- Bulgarian
-9010-
Greek
-9029- Slovene
Possibly not all above-mentioned languages are available.
3300-9001-520
Preface
Customer service
1.2
Manufacturer’s address WestfaliaSurge GmbH Siemensstraße 25-27 D-59199 Bönen Deutschland
Tel.: +49 (0) 2383 / 93-70 Fax: +49 (0) 2383 / 93-80 e-mail:
[email protected] www.westfaliasurge.com 1.3
Customer service
If necessary, please contact your nearest authorised technical dealer.
3300-9001-520
Preface
Declaration of Incorporation
1.4
Declaration of Incorporation Declaration of Incorporation in accordance with the Machinery Directive: 2006/42/EC - Appendix:II B D Manufacturer:
GEA WestfaliaSurge Japy SAS Route de Gray, B.P. 18 F-21850 Saint Apollinaire (France)
Product category:
Control unit for milk cooling tank
Name / Model:
A4
The named product is in conformity with the requirements of the following European directives: 2006/95/EC 2004/108/EC
Low voltage guideline Electromagnetic compatibility directive
Conformity with the requirements of these directives is testified by complete adherence to the following standards: D
Harmonized European standards EN ISO 13732 (2009-09)
Food processing machinery Bulk milk coolers on farms - Requirements for construction, performance, suitability for use, safety and hygiene.
EN 60204-1 (2007-06)
Electrical equipment of machines
Attention! We would point out that start-up is not permitted until it has been established that the machine/installation in which thisproduct is installed, meets the requirements of the guideline on which it is based.
Person responsible for compiling the relevant technical documents:
Bönen, 03.12.2009
Josef Schröer GEA WestfaliaSurge GmbH Siemensstraße 25-27 D-59199 Bönen (Germany) ℡ +49 (0) 2383 / 93-70 Reinhard Frenser (Head of Research and Development)
The undersigned is acting by virtue of power of attorney from the management of: GEA WestfaliaSurge Japy SAS, Route de Gray, B.P. 18, F-21850 Saint Apollinaire (France) Thisdeclarationcertifies compliance with the guidelines indicated, but doesnot establish any guarantee in the sense ofparagraphs 443, 444 BGB.
3300-9001-520
Safety
Owner’s obligation of care
2
Safety
2.1
Owner’s obligation of care
The product has been designed and constructed while taking account of a potential risk analysis and after careful selection of the harmonized standards and other technical specifications to be complied with. It therefore guarantees a maximum level of safety. This safety can only be achieved in practice on the farmhowever when all of the necessary measures have been taken. It is part of the owner’s obligation of care to plan these measures and check that they are carried out. In particular, the owner must ensure that D
D
D
D
D D
D
D
Everyone who works with or performs activities in connection with the product must carefully read the instructions (especially the safety instructions and warnings) and sign to confirm that they have understood them and will act in accordance with them! A full set of legible instructions is always kept by the product. Anyone who has to carry out work on the product can look at the instructions at any time. The instructions in the section entitled ”Basic safety instructions” are observed. The legal requirements are observed. Specific rules have been set up for its use, which also take account of the safety aspects. The product - Should only be used for its intended purpose. - Should only be used if it is in perfect operating condition and, in particular, the safety equipment should be regularly checked to make sure it is in perfect operating condition. The work to be carried out is performed by a sufficiently qualified person! In this respect, please also read the section on ”Personnel Qualification”.
D
D
D
D
D
D
3300-9001-520
These personnel will be regularly instructed in all relevant matters of safety at work and protection of the environment and be familiar with the manual, particularly the safety instructions it contains. Operating personnel who require training may only work on the product under the supervision of an experienced person. The successful completion of training is to be confirmed in writing. Safety signs, plates and decals, which are attached to the product, must be replaced immediately if they become illegible or lost! All safety or warning instructions applied are not removed and remain legible. The personal protective equipment required for personnel carrying out operation, maintenance and repairs is made available and used. Unauthorised persons (e.g. children) are not allowed in hazardous areas and do not have access to cleaning agents or disinfectants.
Safety
Basic safety instructions
2.2
Explanation of the safety symbols used
Safety symbols draw attention to the importance of the adjacent text. Safety symbols and signaling word Danger! The word ”Danger” together with a symbol signals a danger to people’s and/ or animals‘ lives and health. Attention! The word ”Attention” together with a symbol signals a danger for product, material or the environment. 2.3
Basic safety instructions Note! There are warnings about specific residual dangers in the corresponding chapters. Note! If the work requires special qualifications, these are described in the corresponding chapters! D
D
There are risks involved in the operation and maintenance of equipment for dairy farms. For your own safety, read and follow the operating manual carefully (especially the section entitled ”Safety information”)! The chapter on ”Technical data” gives the permissible working conditions (pressure ranges, temperature ranges, airflow quantities etc.) and these must be observed!
D
Do not open or dismantle devices (risk of injury)!
D
Do not remove any protective devices (risk of injury)!
D
D
When working with cleaning and disinfecting agents observe the notes on dangers and protective measures (risk of caustic burns)! When working with products from other manufacturers always observe the warnings from the safety data sheets and operating instructions from the product manufacturer!
D
Observe measures on protection against noise!
D
Do not stand underneath suspended loads.
D
D
Always keep the control cabinet, all electricity supply units, and electrical control units closed. Access is only permitted to authorized personnel with a key or special tool. Protect live and high-voltage components against moisture. Under no circumstances may water jets or high-pressure cleaners be directed at these!
3300-9001-520
Safety
Personnel qualification
2.4
Personnel qualification
All personnel who perform work on or with the product must carefully read and understand the instructions and act in accordance with them! D
D
3300-9001-520
Participation in corresponding product training is necessary. In principle, all work on electrical equipment and electrical connection work should only be performed by trained electricians.
Description
Changes to the product
3
Description
3.1
Correct applications
WestfaliaSurge products and equipment are designed exclusively for agricultural (mostly dairy) farms. The A4 compact controller is intended exclusively for controlling the cooling and agitation functions in milk cooling systems. Any applications that are not listed here are not part of the intended purpose and are therefore considered as improper use! The manufacturer/supplier is not liable for any resulting damage. The user alone bears the risk. Correct use also includes reading the instructions and observing the inspection and maintenance conditions. D
D
D
D
3.2
Original WestfaliaSurge parts and accessories are specially designed for WestfaliaSurge components. We would specifically like to point out that parts or accessories and installation instructions not provided by WestfaliaSurge are not checked or released by WestfaliaSurge. The installation or use of such products can have a negative effect on the specified characteristics of WestfaliaSurge products and can put people and animals at risk. The manufacturer cannot be held liable for injury to people and animals or damage to WestfaliaSurge products caused as a result of using non-original parts or accessories or by incorrect settings.
Changes to the product
For safety reasons, do not carry out any unauthorized changes! WestfaliaSurge must approve any planned changes in writing. Parts and special equipment which have been obtained elsewhere must be expressly authorized by WestfaliaSurge, in writing, for use in WestfaliaSurge components and installations.
3300-9001-520
Description
Technical Data
3.3
Design of the equipment
The control unit consists of: D
3.4
3.5
An electronic card (CPU) with inputs and outputs for the relays.
D
A temperature sensor (NTC).
D
Controlling milk temperature
D
Controlling a second pre-selected temperature
D
Digital temperature display
D
Agitation cycles
D
Cooling start delay
Functions
Technical Data Electrical data
Power supply
230V / -15% +10% / AC 50/60 Hz
Ambient temperature
-10° ... +60°C
Set-point adjustment
+2° ... +30°C
Differential gap
+0,7° ... +2,0°C
Temperature sensor
NTC (3k Ω / 25°C )
Temperature sensorÆs resistance values
3300-9001-520
T°C
Ÿ
T°C
Ÿ
3 4 5 6
8416 8006 7619 7252
7 8 9 10
6905 6576 6266 5971
Transport
Information on disposing of packing material
4
Transport
4.1
Special personnel qualification required for transport
Transport may only be performed by specially qualified personnel in accordance with the safety instructions. Also see the section on ”Personnel qualification”. 4.2
Safety instructions for transport
To prevent damage to property and/or life threatening injury to people during installation the following points must be observed: Also read the chapter on ”Safety”. Special transport hazards: D
4.3
4.4
There is a fire hazard due to the highly inflammable packing material - naked flames and smoking prohibited!
Dimensions and weight Packing unit (content)
dimensions (mm)
Weight (kg)
Wooden crate / cardboard box (automatic rinsing unit, valves, fasteners)
370x170x75
0,8
Includes
Check the goods supplied against the packing list enclosed for completeness and damage. 4.5
Storage conditions
When storing the goods supplied, the location must provide protection against:
4.6
D
Moisture
D
Frost
D
External damage (jolts, knocks, rodents, insects, . . . )
D
Direct sunlight
Information on disposing of packing material
After unpacking, the packing material is to be handled properly and disposed of carefully in accordance with the valid local regulations on waste disposal and utilisation.
3300-9001-520
Installation
Safety instructions for installation
5
Installation If necessary, please contact your nearest authorised technical dealer.
5.1
Special personnel qualification required for installation
Installation may only be carried out by specially qualified personnel in accordance with the safety instructions. Also see the section on ”Personnel qualification”. 5.2
Safety instructions for installation
To prevent damage to property and/or life threatening injury to people during installation the following points must be observed: D
Before installation, look for any damage caused during transport. Do not use damaged components! Also read the chapter on ”Safety”.
Special hazards during installation: D
D
Injury can be caused by the electrical current from live cable ends and components. If the bending radius is too small, it should be removed. Electrostatic processes can cause damage to electronic components. Attention! Only touch the edge of the printed circuit board and avoid static caused for example by clothing.
D
3300-9001-520
Before working on electrical installations or equipment (components, housings, etc.), they are to be disconnected from the mains. Any on/off or emergency stop switches are to be fitted with a lock to immobilise them in the open position and a warning sign is to be put up.
Installation
Fitting the control unit
5.3
Fitting the control unit Electrical connection Attention! All electrical installaton work must be carried out, as shown in the wiring diagrams enclosed, by an approved electrical installation firm in accordance with VDE requirements and the requirements of the local power supply companies.
Legend: A4 A4 electronic card KA1 Agitation relay KA2 Cooling relay KM1 Compressor switching contact M10 Agitator motor F1.1 Under-pressure switch (optional) F1.2 Over-pressure switch F1.4 Compressor motor protection (Klixon) Q1 Compressor motor protecting switch (optional) Y1 Solenoid valve, coolant S2 Safety switch, cooling tank cover R70 Temperature sensor 3300-9001-520
Initial Commissioning
Safety instructions for initial commissioning
5.4
Information on disposing of installation material after installation is finished.
Handle unused installation material properly and dispose in accordance with current valid local regulations on waste disposal and utilization.
6
Initial Commissioning
6.1
Special personnel qualification required for initial commissioning
Initial commissioning may only be performed by specially qualified personnel in accordance with the safety instructions. All settings that have to be made (e.g. on control units) should always be carried out by personnel with corresponding training/instruction from WestfaliaSurge. Also see the section on ”Personnel qualification”. 6.2
Safety instructions for initial commissioning
To prevent damage to property and/or life threatening injury to people during installation the following points must be observed: D
Before starting for the first time, check that all tools and other parts have been removed from the danger area. Also read the chapter on ”Safety”.
Special risks involved in initial commissioning: D
D
D
Incorrectly wired components.
connections
may
destroy
electrical/electronic
Defective connections can cause the product to start up unexpectedly or make uncontrolled movements. Electrostatic processes/interference may endanger electronic components and also lead to software faults and data loss. Back up data regularly therefore. Attention! Only touch the edge of the printed circuit board and avoid static caused for example by clothing.
3300-9001-520
Initial Commissioning
Settings
6.3
Settings Note! The settings are entered in programming mode!
For more information on this subject please see the section on: Operation / Operating / Programming mode
Code
Function
P00
Program version
P01
Configuration 1
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
Default (range)
Setting the set-point temperatures with the keypad Checking the supply voltage (d21) ”Relay KA1” Stirring while cooling ON Forced stopping of the compressor if the cooling time is exceeded No function No function No function Error code display TOTAL
Increments (unit)
1.1
0.1
135 (0 – 255)
1 Yes
No
1
1
0
1
2
2
0
2
4
4
0
4
0
8
0
0
0
16
0
0
0
32
0
0
0
64
0
0
128
128
0
128
135
135
0,0 (-3 - +3)
1 (°C)
Limit value, switch-off temperature Determine the setting range (lowest shut-off temperature) for the operator.
2,0 (0,0 – 10,0)
1 (°C)
P13
Limit-value, switch-on temperature Determine the setting range (higher switch-on temperature) for the operator.
30,0 (0,7 – 99,9)
1 (°C)
P14
Minimum temperature difference Determine the minimum temperature difference between the switch-on and the switch-off temperature.
0,7 (0,7 – 2)
0,1 (°C)
P15
Milk temperature too low (d19) Error code (d19) is displayed if the temperature is below the set value.
0,5 (-5 - +99,9)
0,1 (°C)
P16
Milk temperature too high (d20) Error code (d20) is displayed if the temperature is above the set value.
40,0 (-5 - +99,9)
0,1 (°C)
P18
Agitation on Operating time of agitator(s) during cyclic agitation and agitation after refrigeration has stopped.
2 (1 – 30)
1 (min)
P19
Agitation pause Rest time of agitator(s) during cyclic agitation.
13 (1 – 30)
1 (min)
P11
Temperature adjustment Adjust (calibrate) temperature
P12
User setting
3300-9001-520
Initial Commissioning
Settings
Increments (unit)
Code
Function
Default (range)
P20
Minimum voltage (d21) Cooling stops when the voltage has been below the limit value for more than 5 seconds (”d21” displayed). Cooling continues when normal voltage has been re-established for at least 30 seconds.
189 (164 - 210)
1 (V)
P21
Maximum voltage (d21) Cooling stops when the voltage has been above the limit value for more than 5 seconds (”d21” displayed). Cooling continues when normal voltage has been re-established for at least 30 seconds.
257 (244 – 281)
1 (V)
P24
Calibrate voltage Calibration of the voltage displayed in test mode.
-3 (-20 - +20)
1 (V)
P25
Start delay (min) Delayed start of the cooling function (1st milking). The switch-off temperature is displayed (flashing).
20 (0 – 255)
1 (min)
P27
Cooling restart pause Prevents the compressor form starting during the pause time.
5 (0 – 30)
1( min)
P30
Default refrigeration time (d13) Triggers display of fault code d13 if refrigeration lasts too long (factory set to 210 minutes).
210 (0 – 255)
1 (min)
P34
Cooling speed
8 (0 – 255)
1 (min/°C)
User setting
Rapid cooling points to a low level in the tank. The thermostat stops cooling at the restart point and prevents excessive cooling of the milk. Example: set-point temperature: 3.2 °C / 4°C. If temperature drops from 5 to 4 °C in less than 8 minutes, the thermostat switches off at 4 °C. This function is connected with the setting ”P27” (pause time). (P27) P42
2nd temperature range (°C û for thermostat 2) Selection of the 2nd set-point. Set a second switch-on and switch-off temperature with reference to thermostat 1. Example: P42 = 5 increases the switch-on and switch-off temperature by 5 °C.
0,0 (-9,9 - +30)
1 (°C)
P43
Switching time for 2nd temperature range Change from one set-point to the other (P42)after this delay.
0 (0 – 99)
1 (h)
3300-9001-520
Operation
Safety instructions for operation
7
Operation
7.1
Special personnel qualification required for operation
Operation may only be performed by specially qualified personnel in accordance with the safety instructions. The operator may only carry out work on the AutoRotor Global 90/70 Automation package if he has been trained, instructed and authorized to do so by the owner. Also see the section on ”Personnel qualification”.
7.2
Safety instructions for operation
To prevent damage to property and/or life threatening injury to people during installation the following points must be observed: D
Only fit or use the product for its intended purpose.
Before operating, make sure you are adequately familiar with the following: D
the operating and control elements
D
the equipment
D
Operating mode
Carry out the following checks before every start: D
D
Check and make sure that all operating media is suitable, present and connected. Check and make sure that only authorized personnel are in the work area of the machine and no other people will be endangered by the machine starting.
In normal operation: D
D
The product may only be started from the location specified.
No safety equipment may be removed or put out of operation during operation. 3300-9001-520
Operation
Description of the operating elements
7.3
Workplaces for operating personnel
Operation is directly in front of the product. 7.4
Description of the operating elements
The device is operated from the control panel on the front. Functions are shown on the display Operating panel
4
Keys and functions
1
Stop
2
COOLING mode
3
Agitation
4 8.8.8.
3300-9001-520
Display LED display (3-figure and 7-segment display.
Main display
Operation
Description of the operating elements
Menu structure Standby
Option
. . .
Thermostat 1 Stop
Thermostat 2 Stop
3.0
8.0
3s
3s
P25
(ºC)
24.3
3s
(3.0
Thermostat 1 Stop
-
(3.0
+ KA2
3s
(4.0
Thermostat 1 ON
-
(4.0
+
. KA1
3s
p00
1.1
3s
p01
-
135
135
+ 3s
p43
2
-
2
+
tst
sup
241
rel
r0
KA1 (On)
r1
KA2 (On)
flashes
slowly
dsp
(V)
8.8.8.
quickly
3300-9001-520
Operation
Operating
7.5
Operating
The ”A4” control unit has 3 operating modes. D
Standby
D
COOLING mode
D
Agitation
Switching between the modes is only possible in Standby (Display: stand-by, the system is on but is not giving any commands.
….).
In
Functions are selected by pressing the keys for at least 0.5 seconds. Key operation:
7.5.1
D
short
> 0,5 s
D
long
>3s
Standby
. . .
All actuators (functions) are off. Functions in standby mode D
D
D
D
Push-b utton
Press the ”cooling” button. (cooling start) If cooling starts with a time delay, the ôswitch-off temperatureö setting flashes on the display After the start delay, or when the Start button is pressed (>3 s), cooling begins and the milk temperature is displayed. Press the ”agitation” button. (agitation manual start) A moving dot on the display.
Display
3.0 0,5s
24.3 3s
.
0,5s
Pressing the button (> 3s) changes to programming mode. (call up setup mode)
. p00
3s
3300-9001-520
Operation
Operating
7.5.2
Cooling D
If cooling starts with a time delay, the ôswitch-off temperatureö setting flashes on the display. (>0,5s)
D
Start cooling by pressing the cooling button. (>3s)
3.0 flashes
24.3
Note! Rapid cooling points to a low level in the tank. The thermostat stops cooling at the restart point and prevents excessive cooling of the milk. Example: set-point temperature: 3.2 °C / 4°C. If temperature drops from5to4 °C in less than 8 minutes, the thermostat switches off at 4 °C. This function is connected with setting ”P27” (pause time).
Functions during the start delay
Push-b utton
Display
3.0
Temperature range selection (if P42 is set) D
8.0
Press agitation / settings button. (>3s)
Functions during cooling D
D
D
D
7.5.3
Press stop button. (>0,5s) (change to standby mode)
. . .
Press agitation / settings button. (>0,5s) The switch-off and restart temperature are displayed. Example : 3.0°C / 4.0°C.
0,5s
Press agitation / settings button. (>3s) Display flashes and can be changed by also pressing the stop or cooling button. The keypad can be locked to prevent the set-point values being changed (P01).
3s
3.0
The change is limited by a minimum value, a maximum value and a minimum difference of 0.7°C.
3.0
flashes
Agitation
Start agitation by pressing the ”agitation” button.
.
In the case of manual agitation, the dots move on the display.
Functions during agitation D
Press stop button. (change to standby mode)
Push-b utton
Display
. . .
3300-9001-520
Operation
Operating
7.5.4
Programming mode
Programming mode is started from standby. Press button (>3s) to start programming mode.
P00
Settings displayed
Note! Programming mode is automatically abandoned if no buttons are pressed for 30 seconds while a Code 30 is being displayed. Key functions in programming mode
Leave programming mode
Push-button
=ESC
Select parameter
Change parameter value + 3s
Change parameter value 3s
Functions in programming mode
Push-b utton
Display parameter value D
D
D
Required setting selected.
1.1.
Setting displayed (code / value alternating)
p25
3300-9001-520
20
Required setting selected. Display flashes and can be changed by also pressing the stop or cooling button. The keypad can be locked to prevent the set-point values being changed (P01).
Exiting programming mode D
Display
p00
Change parameter value D
Press stop button.
20
flashes
3s
. . .
Troubleshooting
Safety instructions for troubleshooting
8
Troubleshooting If necessary, please contact your nearest authorised technical dealer.
8.1
Special personnel qualification required for troubleshooting
Troubleshooting may only be performed by specially qualified personnel in accordance with the safety instructions. Also see the section on ”Personnel qualification”. 8.2
Safety instructions for troubleshooting
To prevent damage to property and/or life threatening injury to people during installation the following points must be observed: D
D
D
First of all, prevent the product from being restarted accidentally. Before working on electrical installations or equipment, they must be disconnected from the mains. Make the product safe so that it cannot be started accidentally. Ensure that safe disconnection can be carried out by a second person at any time. Also read the chapter on ”Safety”.
Special dangers involved in troubleshooting: D
D
If energy sources are switched on unintentionally this may lead to serious damage to property and/or life-threatening injuries to people and animals. Electrostatic processes may damage electronic components. Attention! Only touch the edge of the printed circuit board and avoid static caused for example by clothing.
3300-9001-520
Troubleshooting
Troubleshooting possible faults
8.3
Fault messages and troubleshooting help
The default codes usually enable the origin of the default to be located and rectified. Malfunction
Possible cause
d13
Cooling exceeded
time Cooling time is longer than P30 (210min)
d19
Milk temperature The milk temperature too low measured is lower than P15 (0.5°C).
d20 Temperature
The milk temperature taken during measured is higher than cooling too high P16 (40°C). (sensor default)
8.4
d21
Power supply out The supply voltage has of limits been above P21 (257 V) or below P20 (189 V) for more than 5 seconds.
d22
Restore defaults
Disturbance to the electronic board affecting the programme sequence.
Remedy D
D
D
D
D
D
D
Check compressor.
Check temperature of the milk in the tank. Check the temperature sensor. Check temperature of the milk in the tank. Check the temperature sensor. Check voltage supply to the cooling installation.
Check the parameters.
Troubleshooting possible faults Malfunction
Possible cause
The electronic card is not No power supply. working. Switches not working. The compressor working.
is
Control unit connected.
incorrectly
not Relay KA2 is not switching or a contact is damaged.
The agitator is not working.
Relay KA1 is not switching or a contact is damaged. Relay KA1 is not switching or a contact is damaged. Defective safety switch on the cover. Compressor auxiliary contact KM1 not switching.
3300-9001-520
Remedy D
Check
D
Check
D
Check
D
Check
D
Check
Decommissioning
Safety instructions for decommissioning
9
Decommissioning
9.1
Special personnel qualification required for decommissioning
Decommissioning may only be performed by specially qualified personnel in accordance with the safety instructions. Also see the section on ”Personnel qualification”. 9.2
Safety instructions for decommissioning
To prevent damage to property and/or life threatening injury to people during installation the following points must be observed: D
Make sure that operating media are disposed of without harming the environment. Also read the chapter on ”Safety”.
3300-9001-520
Spare parts
10
Spare parts
40
3300-9001-520
70
30
20
50
60
Pos.
Part no.
Description
20
3300-0857-379
Tank control unit, compl. (screwed cable gland on back)
A4 WS +3,5 m - 1x230-50/60
20
3300-0605-926
Tank control unit, compl. (screwed cable gland on bottom)
A4 WS +3,5 m - 1x230-50/60
30
3300-0222-983
Keypad foil
A4 - WestfaliaSurge
40 50
3300-0857-290 3300-0857-365
Electronic controller Temperature sensor
A4-230-50/60 A3/A4/Pylot/Expert-L=2m
50
3300-0221-740
Temperature sensor
A3/A4/Pylot/Expert-L =3,5m
50
3300-0222-118
Temperature sensor
A3/A4/Pylot/Expert-L=7m
60
3300-0611-229
Bracket
A4-CV/CVS
70
3300-0592-294
Balancing resistor
A3/A4/Pylot/Expert
Appendix
Abbreviations
11
Appendix
11.1
Abbreviations Term
Meaning
Ø
Phase
Units
° °C
Degrees (angles) Degrees Celsius/ Centigrade
s
Second
min
Minute
” (in)
Inch (= 25.4 mm)
mm
Millimeters
cm
Centimeters
m
Meter
mm2
Square millimeter
mm3
Cubic millimeter
g
Gram
kg
Kilograms
kPa
Kilopascal
kW
Kilowatt
A
Amp (current)
V
Volt (voltage)
Ω
Ohm (resistance)
3300-9001-520
Appendix
Quick-reference guide
11.2
Quick-reference guide Push-b utton
Display
Standby D
Change to standby mode. Press stop button. (change to standby mode)
. . .
0,5s
Cooling D
D
D
Start cooling by pressing the cooling button. If cooling starts with a time delay, ôswitch-off temperatureö flashes on the display.
3.0
flashes
0,5s
3.0
Select temperature range (if P42 is set) Press agitation / settings button. Press the cooling button (> 3s), cooling starts directly. The milk temperature is displayed when cooling starts.
8.0 24.3 3s
Agitation
. D
Start agitation by pressing the ”agitation” button. 0,5s
Malfunction
Possible cause
d13
The cooling time is longer than P30 (210min)
d19
The milk temperature measured is below P15 (0.5 °C).
d20
The milk temperature measured is above P16 (40 °C).
d21
The supply voltage has been higher than P21 (257 V) or lower than P20 (189 V) for more than 5 seconds.
d22
3300-9001-520
.
Disturbance to the electronic board affecting the programme sequence.
