Liscarroll Engineering LE-200 User manual

EST. 1973
Installation and Operating Instructions
for Installers and Service Engineers
Universal Tank Controller:
LE-200
Simply Better . . . by Design

2
Notes

3
LE-200
4 Appliance description
5 Safety
5 - Intended use
6 Installation
6 - Installation of housing
6 - Intended Use
7 - Fitting the sensor
7 - Changing the sensor cable length
7 - Electrical connection
8 - Connection diagram
9 Technical data
9 - Control
9 - Sensor
10 Operating levels
11 Operation of working level
11 - Operation
11 - Button functions
12 - Meaning of LEDs
13 - Operating modes
13 - Cooling mode
14 - Deep cool
14 - Stirring in Cooling Mode
14 - Cleaning Mode
14 - Quick wash
14 - Descale
15 Cleaning program description
15 - Cleaning Cycle
15 - Manual stop of the cleaning
16 - Power failure during the cleaning process
16 - Service functions for testing the cleaning cycle
17 Adjusting of Parameters in General
18 Adjustment of Cleaning Step Times
19 Parameters
19 - General Cooling Parameters
19 - Extended Cooling Parameters
20 - Cleaning Parameters
21 - Cleaning Parameters Main Wash
21 - Cleaning Parameters Descale
22 - Cleaning Parameters Quick Wash
22 - Input/Output Test Parameters
22 - Input/Output Test Parameters
23 Fault Indication on the Display
24 Water and Detergent Usage - 30 mins
25 Water and Detergent Usage - 50 mins
26 Water and Detergent Usage - 75 mins
27 Water and Detergent Usage - Descale 30 mins
28 Water and Detergent Usage - Descale 50 mins
29 Water and Detergent Usage - Descale 75 mins
30 Other information
30 - Function “Intermediate stirring”
30 - “Continuous stirring” function
30 - Setting the actual value correction
31 - Procedure following power failure
32 & 33 - General measures when using electronic control systems
34 Backup Cooling Functions
35 CAREL Easy Milk Chiller
35 - Setting the Setpoint (desired temperature)
36 - Default Parameters CAREL
37 - Default Parameters CAREL
 38 - TechnicalSpecications
38 - Wiring Diagram
39 - How to use the Programming Key
40 Appendix 1 - Main Wiring Diagram
41 Appendix 2 - Card Wiring Diagram
42 Appendix 3 - Wash Program -v- Tank Size
Contents

4
Appliance Description
The LE-200 is a universal tank control unit combining a modern milk cooling
regulator and a complete cleaning program control system in one.
This combined with the backup cooling function provided by the Carel Thermostat
makes the LE200 controller the most robust system in the market.
The control unit is on stand-by. The display shows ‘OFF’ and all output replays are
deactivated. In the OFF mode the agitator can be switched on and off by pressing
a button. In parameter [C25] a time can be set after which the agitator switches off
automatically. The following operating modes can only be selected from the OFF
mode. It is not possible to switch directly from one of them to another.
CAUTION: The control unit is live even when switched off.
The LE-200 has 2 adjustable target Temperatures.
(1) T1 is the STANDARD selection (Default 4 °C)
(2) T2 is the DEEP COOL selection (Default 2 °C)
The current milk temperature, as measured, is permanently displayed. If the milk
temperature exceeds the selected target temperature (T1 or T2) by the differential
value, the compressor relay and agitator are automatically activated. Once the
target temperature is reached, the compressor switches off, while the agitator
continues to operate for the pre-set ‘after-stirring’ time.
The DEEP COOL function also has an adjustable time setting (Default 30 minutes)
and the LE-200 will automatically switch back to T1 when this time is reached.
During non-cooling periods the agitator switches on at pre-set intervals in order
to ensure an even temperature throughout the milk. Independently of this a short
or long ‘intermediate stirring’ period can be selected during cooling by pressing a
button.
Ifthedelayedstartisactivated(parameter[P62]),coolingstartsfortherstmilking
after a delay. If the cooling button is pressed twice, cooling starts immediately.
The cleaning timer controls water intake by time.
The LE-200 has the following built-in programs to cater for all tank sizes and to
allow for varying on-farm conditions.
(1) MAIN WASH ALKALINE: 3 Programs: 30 Minute, 50 Minute, 75 Minute
(2) DESCALE WASH (Alk + Acid): 3 Programs: 33 Minute, 50 Minute, 75 Minute
(3) Quick WASH: 2 Cycles : 3 Programs: 8 Minute, 12 Minute, 18 Minute
All running times (pump and detergent injection) can be set separately. Detergent
switchover from alkaline to descale can also be set. The LE-200 controls the various
processes and times needed for a thorough wash fully automatically.
Following a power failure, the control unit restarts in the mode in which it was
operating before the outage.
The control unit has various operating modes:
OFF mode
(with continuous stirring function)
COOLING mode
CLEANING mode
4

5
LE-200
Safety
These operating instructions contain important technical and safety information.
Please read carefully before installation and before any work on or with the
regulator.
The universal tank control must be installed by an authorised specialist observing
local safety regulations.
Access to the environment when connected must be restricted to specialised
personnel.
The universal tank control contains live components and must not be opened up.
lt must not be used if the housing or connection terminals are damaged.
Nouidsmustpenetratethehousing.
The universal tank control may not be exported to the USA without the
manufacturer’s express permission.
Intended use
The universal tank control is ready for use once the parameters have been set.
lt should not be used before this has been done as this might result in damage to
the plant and the item to be cooled or heated.
Thedeviceisttedwitharesistancetemperaturesensor.
The device must not be installed in potentially explosive atmospheres.
TheuniversaltankcontroltypeLE-200fulllstheECrequirementsfor
electromagnetic compatibility (EMC) and the Low Voltage Directive (LVD).
The safety components meet the VDE regulations.
!

6
Installation
Forxingthehousingpleasefollowtheinstructions:
• Place the seal carefully in the groove. Ensure it is not twisted.
• Insert the housing from the front through the switchboard cut-out and
fasten using the screws provided.
• Carry out the electrical wiring and sensor connection in accordance
with the following description.
Drilling diagram
4
It is essential not to install the device under the following conditions:
• severe jolting or vibration
• permanent contact with water
• relative humidity of more than 90%
• sharplyuctuatingtemperatures(condensation)
• operation in an aggressive atmosphere (ammonia or sulphur fumes)
- risk of oxidation
• operation in the immediate vicinity of radio transmitters with high levels
of spurious radiation.
Installation of Housing
Intended use

7
LE-200
Installation
Before connecting ensure that the mains voltage is the same as indicated on the
device’s type plate.
Incorrect electrical connection can cause damage to the tank control and to the
equipment.
The mains voltage should not be switched on until all components including the
sensor are connected.
No appliances with current levels in excess of the maximum values indicated on the
relays should be connected to the relay contacts Use contactors.
DownstreamcontactorsmustbettedwithanRCprotectioncircuit.
!
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tted),the
“actual value correction” parameter must be adjusted accordingly.
See the section “Setting the actual value correction”.
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
!
Fitting the sensor
Changing the sensor
cable length
Electrical connection

8
Installation
• 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 and compressor.
• Do not feed digital inputs with external voltage! Use potential-free switches.
Note: see wiring diagram in Appendix 1
Connection diagram

9
LE-200
Technical Data
Control
Operating voltage 230V AC +/-10%, 50 Hz
Relay contacts 10 performance relays
max. switching current each 5A AC1 - 250V AC
max. switching voltage 250V AC - 50 Hz
Display 13 mm LED - Display, 3 digits
LED switching status displays 3 mm
Display range -99 .. 999
Number of Sensors 1
Sensor type KTY 81-210
Sensorcablelength 2metres(orasrequired)
Measurement range -5° .. +70°C
Temperature resolution 0,1°C
Control mode two-step-controller
Hysteresis* 0,1 K .. 10,0 K (standard adjusting 0,7 K)
Water detection via level monitor (optionally)
Target temperature T1* standard adjusting 4°C
Target temperature T2* standard adjusting 4°C
Digital inputs 3 (via optocoupler)
Connection Push-in screw connections for cables up to 2.5 mm²
Housing FEG 106/175 M
- front dimension 106 x 175 mm
- front panel cut out 156 x 96 mm
- insertion depth 45 mm
Protection (housing front) IP 65
Environmentspecications:
- Operation temperature 0° .. +50°C
- Storage temperature -20° .. +70°C
- max. humidity 75% (no dew)
Sensor
Sensor element KTY sensor
Bush material 1.4301(V2A)
Bush length 40 mm
Bush diameter 6.0 mm +/- 0.1
Cable material PVC
Measurement range -10 .. 70° C
Cable length Standard 2 metres
Protection type IP 65
Sensorsotherthanourstandardtypeareavailableonrequest
Some of the options are shown here.

10
Operating Levels
Code: 212
Code: 345
Code: 567
Code: 0E5
Operation of the LE-200 takes place at various levels:
Working level:
… for normal daily operation.
• OFF mode = control unit switched off.
• Start cooling mode.
• Start cleaning mode.
The subsidiary parameters are accessed by entering a code in order to
avoid their accidental alteration.
General cooling parameters
Parameters such as target values, hysteresis etc. are set here.
Extended cooling parameters
Forprogrammingthecontrolunit’sindividualtank-speciccoolingfunctions.
Extended cleaning parameters
Forprogrammingthecontrolunit’sindividualtank-speciccleaningfunctions.
I/O test parameters
Used to test the relay output relays.
CODE
Working level
for normal daily operation
General cooling parameters
Extended cooling parameters
Extended cleaning parameters
I/O test parameters

11
LE-200
Operating of Working Levels
CODE
Working level
for normal daily operation
General cooling parameters
Extended cooling parameters
Extended cleaning parameters
I/O test parameters
The working level is for normal daily milk-cooling operation. In cooling mode,
the current milk temperature as measured is permanently displayed.
Operation
Button functions To change to a different mode always press the ‘OFF/SET’ button rst.
Active modes are closed down by pressing the ‘OFF’ button.
OFF / Set button
• Switch regulator to STANDBY
• Switch off continuous stirring
• Acknowledge error
• Switch to programming mode (press button for 3 seconds)
COOLING button
Press once = T1 Start Cooling
Press twice = T2 Deep Cool
AGITATOR button
in OFF mode = Continuous stirring
in COOLING mode (press 1 sec.) = Intermediate stirring SHORT
in COOLING mode (press 3 sec.) = Intermediate stirring LONG
See also section: ‘Intermediate stirring options’ .
WASHING button
in OFF mode = Start cleaning
During the cleaning process = Special function when Commissioning/Service
(See page 16)
Code: 212
Code: 345
Code: 567
Code: 0E5

12
Operating of Working Levels
Meaning of LEDs LED “AGITATOR”
in all mode - Agitator is switched on
LED “COMPRESSOR”
Continuous: Compressor contactor is switched on
Blinking: Minimum switch-off time (swing protection) is still active
LED “T1”
Target temperature ‘T1’ active
LED “T2”
Target temperature ‘T2’ active
LED “WASH END”
Continuous cleaning is completed
LED “COOLING MODE”
Blinking: Cooling start delay is active
Continuous: “Cooling mode” is active
LED “CLEANING MODE”
Continuous: “Cleaning mode” is active

13
LE-200
Operating of Working Levels
Operating modes OFF mode
(with continuous stirring function)
If the display shows “OFF“ the control is in standby-mode.
Permanent stirring function:
In the OFF mode the agitator can be switched on with the button “agitator” and
switched off with the button “OFF”. During the stirring cycle, a rotating bar
appears on the display.
If the agitator is not switched off manually or switched to another mode, an
automatic switching off takes place according to the time set in [C25]. (If the
parameter is set to ‘0’ there is no automatic switch off).
The cooling and the cleaning mode can only be selected from OFF mode and it is
not possible to switch directly between them.
CAUTION: The control unit is live even when switched off.
COOLING mode
Press “COOLING” button on foil keyboard in OFF-mode:
- EitherLED‘T1’or‘T2’ashes(fortargettemperature1or2).
- T1 is the normal target temperature (4°C)
- T2 is the deep cool function (2°C)
- Atthesametimethedisplaybrieyshowsthecurrenttargettemperature
before the current medium temperature appears.
- If the other target temperature is desired: Press the “COOLING” button again
(The switching from T1 to T2 can be blocked via parameter [P80]).
- If ‘Cooling start delay’ [P62] for the 1st milking is programmed cooling will not
start immediately. During the delay the cooling mode LED blinks. Press the
‘COOLING’ button twice in succession to start cooling without a delay.
- The milk will now be cooled to the set target temperature. The agitator motor
runs continuously. If the milk temperature is already lower than the target
temperature only the agitator operates.
- When the target temperature is reached the compressor switches off.
- The agitator switches off at the end of the ‘after-stirring’ time [C20].
- During cooling pauses, the agitator switches on periodically: in accordance with
the ‘pause time’ set [C21], for the duration of the ‘after-stirring’ time [C20],
in order to ensure an even temperature throughout the milk.
- If the milk temperature exceeds the selected target temperature by the set
‘differentials’ value [C10 or C11] the compressor and agitator automatically
start again.

14
Operating of Working Levels
Deep cool
Press the ‘COOLING’ button twice activates the T2,
(Deep cool, function: default 2°C)
Stirring in cooling mode = INTERMEDIATE STIRRING
Brieypress‘AGITATOR’incoolingmode:
A short intermediate stirring period [duration = C23] is triggered.
Press ‘AGITATOR’ in cooling mode for around 5 seconds:
A long intermediate stirring period [duration = C24] is triggered.
See also the section: ‘Intermediate stirring options’.
Cleaning mode
Press ‘WASHING’ button: (out of OFF mode)
The cleaning program will be carried out automatically according to your
default settings. Depending on the setting in [r97], the display indicates
the current cleaning stage or the temperature.
Quick wash
• Press the ‘QUICK WASH’ button for 3 seconds
The “Quick Wash” cleaning program will be carried out
automatically according to preset default settings.
Descale
• Press the ‘DESCALE’ button for 3 seconds Automated descale
can be activated using r7
Special function for commissioning / Service
For commissioning- and Service purposes all rinsing steps can be
manually switched.

15
LE-200
Cleaning Program Description
Acleaningcycleconsistsofvedifferentpresetcleaningstages.
Main, ECO, Descale and Quick Wash parameters and times are all pre set with the
programs. Selecting the wash time will activate the pre set program steps
and times
The ECO wash is activated by selecting peracetic acid in the main wash’s
nalrinse(r5=1)
Automatic descale can be activated by turning on r7.
You can select the descale to be automatically turned on after 1-5 washes by
changing the r7 value to the wash that you want automated.
During the cleaning process the following can be is displayed.
(Setable in parameter [r97]: default ‘4’).
0: Display of program step
1: Display of temperature
2: Display change between step and temperature
3: Display of remaining wash program time
4: Display changes between temperature and remaining wash program time
Start quick wash or descale wash
Tostartthewashprogram“quickwash“or“descalewash“,presstherespective
button for about 3 seconds. The program “main wash” starts directly when
pressing the button Cleaning
Cleaning is manually stopped by the OFF-button:
• cleaning stops,
• the display alternately shows ‘AbL’ and the current temperature,
• for the time [n70] drain valve is opened (can be stopped by repeated
pressing of the Off-button).
• control switches into the OFF-mode.
Cleaning cycle
Manual stop of
the cleaning

16
Cleaning Program Description
After return of voltage in case of a power failure:
• display shows the current temperature
• drain valve is opened for the time [n70]
• control continues the cleaning at the start of the cleaning stage in which
the interruption happened
• control switches into the OFF-mode .
Start cleaning with the desired cleaning stage
• Press CLEANING button: A cleaning cycle starts with the selected cleaning
stage and then runs through to the end.
• Thenextcleaningcyclestartsagainwiththerstcleaningstage.
Switch on the cleaning cycle with single step function
Inordertobeabletotestacleaningcyclemorequickly,itispossibletoswitchthe
cycle manually from one program step to the next without having to wait until it
has been completely processed.
• First, set the ‘Display during Cleaning parameter ‘r97’ to ‘0’.
• By repeatedly pressing the CLEANING button, the cycle can now be
progressed step by step.
• Can be terminated via OFF button at any time, with drain phase.
• Whennishedset‘r97’backto‘4’.
Power failure during
the cleaning process
Service functions for
testing the cleaning cycle

17
LE-200
Adjusting of Parameters in General
Exit the parameter levels by simultaneously pressing the two buttons UP and
DOWN for about 3 seconds.
Proceed as follows (control unit must be in OFF mode):
• Press ‘OFF’ button for 3 seconds: ‘000’ appears in the display
 -therst‘0’blinks.
• Usethearrowsbuttonstoselecttherstdigitoftherequiredcode.
• Conrmthecorrectdigitbypressing‘SET’.
The digit is accepted and the second ‘0’ blinks.
• Use the arrow buttons to set the second digit.
• Conrmthecorrectdigitbypressing‘SET’.Thethird‘0’blinks.
• Use the arrow buttons to set the third digit.
• Conrmthecorrectdigitbypressing‘SET’.
 Therstparameteroftheselectedlevelnowappears.
If an incorrect code is entered the control unit switches back into OFF mode.
If no buttons are pressed for 60 seconds the control automatically switches
back to the working level.
Attention: Any changes will not be accepted!
Display parameter value:
• Use the arrow buttons to select the desired parameter.
• Press the ‘SET’ button: the parameter value is displayed.
Change parameter value:
Saving the changed parameters and switching back to the working level:
(possible from any parameter)
• Press UP and DOWN buttons simultaneously for approx. 5 seconds.
The device switches to the OFF mode.
The controller has different parameter levels:
To get into the parameter levels, the OFF button must be pressed for approx. 5
seconds in OFF-mode!
The parameter levels have different codes:
Level 1: Cooling parameter 1 C parameter code: 212
Level 2: Cooling Parameter 2 P-Parameter Code: 345
Level 3: Cleaning Parameters 2 r-Parameter Code: 567
Level 4: Step times ECO main wash n-Parameter Code: 111
Level 5: Step times Descale wash d-Parameter Code: 222
Level 6: Step times Quick wash u-Parameter Code: 333
Level 7: Service parameter E-Parameter Code A03
Level 8: I / O Test Parameter o. Parameter Code: 0E5

18
Adjustment of Cleaning Step Times
Code: 111
Code: 222
Code: 333
ThesteptimesassetinParametersr1,r2andr3arexedandcannotbealtered.
USER DEFINED PROGRAM TIMES
But should it be necessary to make adjustments this can be done selecting
Parameter ‘r4’
How to proceed
• Parameter ‘r4’ is used to make a copy of the wash programs ‘r1’, ‘r2’ and ‘r3’
• Set ‘r4’ to position ‘2’
• This makes a copy of the programs under ‘r1’, ‘r2’ and ‘r3’
• Hold the UP and DOWN buttons simultaneosly for 3 secs to save
• Proceedtochangetherequiredsteptimesbyenteringtherelevant
ACCESS CODE
• Now you can proceeed to change the step times in ‘n’, ‘d’ and ‘u’ parameters
• After every change, hold the UP and DOWN buttons simultaneosly
for 3 secs to save
• After all changes are complete Set ‘r4’ to position ‘1’
• ‘r4’ position ‘1’ now contains the active cleaning programs
• To revert to the original default programs set ‘r4’ back to ‘0’
CODE
Step Times
Main Wash: ‘n’ parameters
Descale Wash: ‘d’ parameters
Quick Wash: ‘u’ parameters

19
LE-200
Cooling Parameters
Code 345 EXTENDED COOLING PARAMETERS P
Parameter Description Range LE-200 Default
Temperature Settings
C1 Target temperature T1 2,0 – 12,0 °C 4,0
C2 Target temperature T2 (Deep cool) 2,0 – 12,0 °C 2,0
C10 Differential for T1 0,1 – 2,0 °C 0,5
C11 Differential for T2 (Deep cool) 0,1 – 2,0 °C 0,2
Agitator Settings
C20 Duration of after-stirring 0-999 sec 60
C21 Pause duration 0-999 min 15
C23 Duration of ‘intermediate stirring SHORT’ 1-60 min 2
C24 Duration of ‘intermediate stirring LONG’ 1-60 min 5
C25 Maximum continuous stirring period in OFF mode 1 - 60 min 7
Cooling Time Monitoring
C81 Maximumcoolingtimeforrstmilking 0 - 999min 0
Sensor Setting
C90 Display actual temperature
C91 Sensor correction -10 to +10k
Software Version
C98 Software version
The software version installed is shown to help service technicians.
Parameter Description Range LE-200 Default
Setting Range Limit
P10 Lower limit for target temperature T1 0 – 50.0 °C 2
P11 Upper limit for target temperature T1 0 – 50.0 °C 8
P12 Lower limit for target temperature T2 (Deep cool) 0 50.0 °C 2
P13 Upper limit for target temperature T2 (Deep cool) 0 – 50.0 °C 8
P15 Lower limit for differential T1 0.1 – 30.0 °C 0.1
P16 Upper limit for differential T1 0.1 – 30.0 °C 2
P17 Lower limit for differential T2 (Deep cool) 0.1 – 30.0 °C 0.1
P18 Upper limit for differential T2 (Deep cool) 0.1 – 30.0 °C 2
Setting Agitator
P22 Function intermediate stirring 0 or 1 1
0: deactivated
1: short / long
Setting Cooling Start
P62 Duration of cooling start delay 0…999 min 30
Setting Compressor
P71 Minimum pause time compressor 0…999 sec 120
Setting Deep Cool
P81 Duration of T2 deep cool 0…100 min 30
Code 212: GENERAL COOLING PARAMETERS C

20
Cleaning Parameters
Code 567 CLEANING PARAMETERS / conguration (r-level)
Parameter Description Range LE-200 Default
Setting Wash Program Times
Time selection main wash
1: 75 min
2: 50 min 1...3 3
3: 30 min
Time selection descale wash
1: 75 min
2: 50 min 1...3 3
3: 33 min
Time selection quick wash
1: 18 min
2: 12 min 1...3 3
3: 8 min
User dened program times
0: Deactivated
1: Activated (program times from n, d and u parameters are used)
 2: Activatedbychangingthexedtimesassetinr1,r2andr3inthe 0...2 0
  userdenedtimes(n,danduparameters)
This setting is automatically set to 1 (activated)
after the parameters have been changed
Detergent Settings
Main and quick wash with Peracetic ACID
0: Deactivated 0...1 1
1: Activated
Separate output relay for Descaling ACID
0: Acid and Peracetic Acid on the same relay K6
(Must be switched by the farmer before the wash cycle) 0...1 0
1: Descaling ACID on a separate relay K7
Automatic descaling
0: Deactivated
1 ... 5 = x times main wash, then once descale wash.
Is started by button “cleaning”.
(Attention, this function is only active if either the descaling pump 0...5 0
has its own output (r6 = 1) or the Peristaltic Pump is
 deactivatedinthemainandquickwash(r5=0).
NB: If automatic descaling is activated, the descaling button has no function.
Display During Cleaning
0: Display of program step
1: Display of temperature
r97 2: Display changes between step and temperature 0...4 4
3: Display of remaining wash program time
4: Display changes between remaining wash program time and temperature
r1
r2
r3
r4
r5
r6
r7