Fabdec DARI-KOOL GALA-KOOL Pro User manual

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2020A
Part No: GPRO-MAN-V2.5-EN
Installation and Operation Manual
GALA-KOOL Pro Universal Tank Control
Standard version 2.5
REV F

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Contents
1 Introduction
1.1 Page 4Function overview
2 Safety
2.1 Electrical safety 6 Page
2.2 Intended use 7 Page
2.3 Wiring, screening, earthing Page 7
3 Electrical connection
3.1 Connection diagram 8 Page
4 Technical data
4.1 Technical data of control unit 9 Page
4.2 Fitting the sensor 9 Page
5 Operation
5.1 Setting the date and time 10 Page
5.2 Operation in levels 11 Page
5. 2.1 Button functions 12 Page
5.2.2 Meaning of the LED’s 13 Page
5. 2.3 Operation modes 14 Page
5. Operation of working level2.4 16 Page
6 Cleaning
6.1 Cleaning methods (cooling tank-configurations) Page 18
6.1.1 Circulation cleaning with a beaker Page 18
6.1.2 Circulation cleaning with two dosing pumps Page 18
6.1.3 Displacement cleaning with feed container, dosing pumps
Page in circulation line 19
6.1.4 Displacement cleaning with feed container dosing pumps and Page 19
6.2 Page 20Cleaning programme diagram
6.3 Page Explanation and programming of the cleaning process 22
6. Page 4 28 Service functions for testing the cleaning cycle
7. Tank monitor and general fault handling
7 Page .1 Description of tank monitor operation 30
7 Page .2 Tank monitor: Milk removal YES or NO 32
7 Page .3 Tank monitor: Handling multiple faults 35
7 Page .4 Tank monitor: Display fault memory 35
7 Listing fault codes and their description Page .5 36
.5.1 Critical tank monitor alarms (red)7 Page 36
.5.2 Informative tank monitor alarms (green)7 Page 37
.5.3 System alarms cleaning7 Page 38
.5.4 System alarms cooling7 Page 40
7. Page 5.5 System alarms external sensors 41
7.5.6 Test alarm Page 41
8. Setting of parameters
8 Page .1 Change and save parameter values 42
8 Level c-parameter Page .2 „General cooling parameters“ 44
8 Level P-parameter Page .3 „Extended cooling parameters“ 46
8 Level n-parameter Page .4 „General cleaning parameters“ 51
8 Level „ r-parameter Page .5 Extended cleaning parameters“ 54
8 Level E-parameter Page .6 „Service parameters“ 59
8 Level h-parameter Page .7 „General tank monitor parameters“ 60
8 Level H-parameter Page .8 „Extended tank monitor parameters“ 62
8 Level -> Event assignment F-parameter Page .9 „Alarm “ 64
8 Level A-parameter Page .10 „ “Configuration 66
8 Level o-parameter Page .11 „I-/O- test parameters“ 72

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Contents
9. Other information
9 Page .1 Butterfly valve (manual or pneumatic) 74
.2 Safety switch for manual butterfly valve9 Page 75
9 Page .3 Robot control 76
9 Page .3.1 Cleaning release by robot 77
9 Page .4 Different variants for cooling start delay 78
.5 Compressor switch-on delay / pre-agitating9 Page 80
9 Page .6 Emergency cooling / sensor failure 80
9 Sensor correction procedure Page .7 80
.8 Function second temperature sensor9 Page 81
9 Page .9 during coolingLevel alarm 81
9 Page .10 Automatic / convenience functions 81
.11 Heating control9 Page 82
9 Page .12 Function of pressure switch – Effect on pump and heater 82
.13 Air in the cleaning pump -> automatic 9 venting Page 83
9 Page .14 Level control setting 84
.15 Detergent injection position 9 Page 85
.16 Configuration of the different stages9 Page cleaning 85
9.17 Setting of a break in the cleaning programme Page 86
9.18 Page 86Function test alarm
9.19 Activation delay tank monitor Page 87
. Procedure following power failure 889 20 Page
9 21 Power Page . pack (optional) 88
9 22 Page . Agitator monitoring module (optional) 89
9.2 Page 3 90General measures when using electronic control systems

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1. Introduction
Gala-Kool Pro is a universal tank control unit which combines all the
basic functions in one device:
- milk cooling control
- comprehensive cleaning control
i- an extended robot nterface
- an extended tank monitor
All basic functions can be selected and operated from the working
level. The control unit can also be adapted to a wide range of different
system types and sizes. This takes place through the thematically
organised parameter levels.
1.1 Function overview
Within the working level the control unit differentiates between various operating
modes:
OFF mode (stand-by)
Shows the current time
All LEDs are out
(Exceptions: outlet valve and tank monitor LEDs may be lit)
All output relays are deactivated
) (Exceptions: outlet valve and tank monitor alarms may be active
The other operating modes can only be selected from OFF mode. It is not
possible to switch directly between the different modes.
CAUTION: The control unit is live even when switched off.
Cooling mode
Two freely definable target temperatures can be selected by pressing a button.
If the milk temperature exceeds the selected target temperature (T1 or T2) by
the hysteresis value, the compressor contactor and agitator are switched on
automatically. Once the target temperature is attained, the compressor
contactor switches off, while the agitator continues to run for the set “after-
stirring“ period.
During cooling breaks the agitator switches on periodically, in accordance with
the set 'pause time', in order to ensure an even temperature throughout the milk.
Independently of this, during cooling, short or long “intermediate stirring” can be
switched on by pressing a button.
Cooling can be triggered in different ways:
manually using the “START COOLING“ button
via digital input “Remote start to cooling“
(by robot or external button)
automatically following cleaning (only in conjunction with robot)
Cooling now starts in accordance with the pre-set starting mode:
Immediately or after a cooling start delay, with periodic cooling boosts, etc.
Working level
for normal daily operation
General cooling parameters
Extended cooling parameters
General cleaning parameters
Extended cleaning parameters
Service parameter
General tank monitor parameter
Extended tank monitor parameter
Alarm configuration
Configuration
I/O test parameter

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Continuous stirring mode
From OFF mode, the agitator can be switched on by pressing a button and then
switched off again by pressing the OFF button.
Parameter [C25] can be used to set the time after which the agitator is to switch
off automatically.
The countdown can be interrupted at any time using the OFF button.
If [C25] is set to '0', the agitator will run continuously, but can be switched off at
any time using the OFF button.
Cleaning mode
The cleaning timer controls the water intake by time or level, as desired. All
running times (heater, pump, detergent injection) can be set separately. The
automatic switchover from acidic to alkaline detergent is also adjustable.
The controls the different processes and times fully automati-Gala-Kool Pro
cally.
Following a power failure the control unit will restart in the mode it was in
Robot interface
Depending on the parameter settings, the control unit includes a built-in robot inter-
face with the following functions:
- „Robot start / stop“ and
- “Butterfly valve open / closed“
These functions are controlled via the keypad.
Tank monitor function
During the entire cooling and cleaning process, the built-in tank monitor keeps check
on the correct operation of all components, in order to guarantee the perfect state of
the milk.
In particular, the following are monitored:
- minimum and maximum milk temperatures during cooling
- power failure (optionally power pack required!)
- agitator function (optionally agitator monitoring module required
- minimum and maximum temperatures during cleaning
- etc.
Any faults are indicated by two LEDs, and associated f codes flash in the display.ault
In the case of errors which may jeopardise the milk quality, the red LED “Don't add
milk” lights up.
1. Introduction

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The controller itself and the associated control circuits and load circuits must be pro-
tected separately and in accordance with the local regulations.
The separate protection of the control- and load circuit must be carried out according
to local conditions!
In order to prevent destruction of the relay or semiconductor relay outputs in the event
of a short-circuit, the load circuit should be fused to the maximum permissible output
current.
As well as incorrect installation, wrong parameter settings can also adversely affect
the correct functioning of the controller. For this reason, safety devices that are inde-
pendent of the controller should always be used, e.g. high and low pressure valves
or temperature limiters. Account should be taken of the local safety regulations in
this connection.
The load circuit (relay outputs K1 to K1 ) must be fused in accordance with the con-3
nected components.
The connection of external voltages to the digital inputs can lead to the destruction of
the control.
Caution: All cables to the digital inputs must be shielded and kept as short as possi-
ble. EMC.
Important note concerning the external fuse
The transformer, which is installed in the , has a two-chamber safety Gala-Kool Pro
winding, which is only short-circuit-proof due to the built-in thermal protection. If the
temperature exceeds 145 ° C, there is a risk of damage!
Protect control unit with an external fuse of 160mA!
2. Safety
2.1 Electrical safety

Universal tank controllers are designed to control systems, con-Gala-Kool Pro wash
densing units, alarms etc. in milk cooling tanks as well as to monitor milk quality. Fur-
thermore, connected milking robots can be controlled. 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. and when fitted correspond to protection class 2 (double or rein-ing
forced insulation) It is only allowed to be put into operation in installed state. The use .
of the control is permitted in devices of protection class 1 and 2. The controller must
not be modified or converted in any way.
The controller is ready for use only when the parameters have been set universal tank
appropriately. Its use before this has been done would have no benefits and could also
damage the equipment or adversely affect the m to be temperature-controlled.ilk
Responsibility for the faultless functioning of the connected devices lies with the plant
engineer or the installer or the service engineer who has installed and commissioned
the .Gala-Kool Pro
The device is fitted with a resistance temperature sensor.
The controller is not suitable for use in explosive atmospheres. Danger of explosion.
Use only outside areas subject to explosive atmospheres.
The fulfils the EC requirements for electromagnetic compatibility Gala-Kool Pro
(EMC) and the Low Voltage Directive (LVD).
The safety components meet the VDE regulations.
2. Safety
2.2 Intended use
These operating instructions contain important technical and safety
information. Please read carefully before installation and before any
work on or with the regulator.
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Wherever possible, keep input, output and supply leads and sensor cable physically
separate from each other and do not lay them parallel to each other.
Mains voltage cables and low-voltage cables must not be laid in one cable.
Use screened and twisted interface and sensor cables.
Earth the screening of temperature sensors unilaterally in the switchbox.
Ensure correctly wired potential equalisation.
When selecting wiring materials and installing and connecting the temperature control-
ler to the electricity supply, account must be taken of DIN VDE 0100 “Erection of power
installations with rated voltages below 1000” or the relevant national regulations (e.g.
based on IEC 60364).
2.3 Wiring, screening, earthing

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3.1 Connection diagram
Default configuration
3. Electrical connection
Electrical connections must be as shown in the diagram below.
Use cable bushes.
Make sure that cables cannot chafe.
Observe relay current rating.
In all cases use contactors for pump, compressor and heater.
Do not feed digital inputs with external voltage! Use potential-free
The assignment of components to the is set in relay outputs
the A parameters (A1 to A1 ). 3 (See section 8.10)
The assignment of components to the is set in digital inputs
the A parameters (A21 to A28). (See section 8.10)
GND * = capacitively decoupled from GND
If the tank housing is to be used as one of
the two level poles, this pole must be
connected to GND*.
K13
K12
K11 K10 K9 K8 K7 K6 K5 K4 K3 K2 K1
10 9 8 7 6 5 E2 4 3 2 1 E1 E1 NC A1 A2
22 23 24 25 26 27 28 29 30 31
RX/TX-(B)
RX/TX+(A)
RS-485
49 48 47 46
IO-BUS
13 14 15
16 17 18
19 20 21
Tank Monitor - Alarms
Robot Stop
General Alarms
Level 1
Level 2
Temp. Sensor 1
Temp. Sensor 2
KTY81-210
KTY81-210
12V DC EXT.
+
-
B
A
LN
230VAC
50..60HZ
Important note:
Above diagram shows manufacturer default relay configuration. See page 67 for market
specific settings.

4.1 Technical data of control unit
Operating voltage 230V AC +/-10%, 50/60 Hz
Relay contact 1 relays3
max. switching current x A AC1 - 250V AC11 10
x 1 A AC1 - 250V AC2 6
max. switching voltage 250V AC - 50..60 Hz
Display 4 13 mm LED-Display, digits
Display range -999 ... 9999
LED switching status displays 3 mm
Number of sensor inputs 1 or 2
Measurement range -5° ... +95°C
Temperature resolution 0.1°C
Sensor input KTY 81-210
Control mode two-step controller
Hysteresis* 0.1 K .. 99,9 K (standard adjusting 0.7 K)
Water detection via 2 independent level monitors
Target temperature T1* standard adjusting °C4
Target temperature T2* standard adjusting 4°C
Digital inputs 8 (via optocoupler)
Interface 2x RS 485
Connection Plug-in screw connections
for cables up to 2 5 mm².
Environment specifications:
- Operation temperature 0° .. +50°C
- Storage temperature -20° .. +70°C
- max. humidity 75% (no dew)
Technical data subject to change
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4. Technical Data
4.2 Fitting the sensor
When setting the temperature controller parameters (and whenever the sensor is
replaced) the “actual value correction” [Parameter C91] must be adjusted so that the
temperature measured corresponds to that shown on the display. A reference thermo-
meter should be used for this purpose.
Pay attention to the permitted temperture range for sensor cable exposure.
40 mm
The sensor cable must not be chafed or kinked.
There must be no substantial mechanical pressure on the sensor tube.
Do not place the sensor and the high-voltage cable in the same cable
conduit (not even within the switchbox).
Temperature range sensor cable -10°C .. +70°C
Changing the sensor cable length
lf it is necessary to shorten or lengthen the sensor cable on installation (or if a sensor
other than the one supplied is to be fitted), the "actual value correction" parameter
must be adjusted accordingly.

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Year
Date
Time
5.1 Setting the date and time
When the power is connected ...
... there are two possible displays:
1.) Time is lost: 4 dashes are shown:
The date and time must be re-entered. Proceed as follows:
Press one of the arrow keys: the year appears, flashing.
Set the time as described below.
2.) Time is still preserved:
During initialisation, 4 rotating bars are shown, then the current firmware
appears briefly, then the time is displayed. If it is not correct, adjust it as
follows.
Setting the time during normal operation
Press OFF button: a time is displayed. the
Hold the SET button down until the year appears, flashing.
(in between, the tank temperature is shown briefly)
Use the arrow keys to set the correct year
Press the SET button: the month appears, flashing.
Use the arrow keys to set the correct month.
Press the SET button: the day appears, flashing.
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.
actual timeSetting is completed, and the is displayed.
In the event of a power cut, the date and time are retained for up to 5
days. After that they must be re-entered.
5. Operation