Liscarroll Engineering LE-300 User manual

EST. 1973
Installation and Operating Instructions
for Installers and Service Engineers
Universal Tank Controller:
LE-300
Simply Better . . . by Design

2
Contents Introduction 5
1.1 Information about this operating instructions 5
1.2 Limitation of liability 6
1.3 Warning notices in these operating instructions 6
1.4 Device description 7
1.5 Type designation 7
1.6 Item supplied 8
1.7 Dimensions 8
1.8 Sensor dimensions and technical data 8
1.9 Technical data of control unit 9
2. Safety 10
2.1 General Information 10
2.2 Intended use 11
2.3 Wiring, screening, earthing 12
2.4 Electrical safety 12
3. Installation 13
3.1 Location and climatic conditions 13
3.2 Unpacking and storage 13
3.3 Installation of housing 13
3.4 Fitting the sensor 14
4. Electrical connection 15
4.1 Safety during installation 15
4.2 Procedure 15
4.3 Wiring 15-16
4.4 Connection diagram (Delivery conguration) 16
4.5 Wiring the digital inputs 17
4.6 Connection robot 17
4.7 Connection of external pressure sensor (optional) 18
5. Operation 19
5.1 Function overview 19
5.1.1 OFF mode (stand-by) 19
5.1.2 Cooling mode 19
5.1.3 Continuous stirring mode 20
5.1.4 Cleaning mode 20
5.2 The conguration software KONSOFT. 21
5.3 Guideline for the initial installation / parameterization 22
5.4 Setting the date and time 23
5.5 Operation in levels 24
5.5.1 Operating levels explanation 25
5.6 Operation of working level 26
5.6.1 Button functions 26
5.6.2 Meaning of the LED‘s 28
5.6.3 Operation modes 30

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LE-300
6. Cleaning 35
6.1 Abort of the cleaning 35
6.1.1 Cleaning cycle completely nished 35
6.1.2 Manual abort of the cleaning 35
6.1.3 Abort of the cleaning due to faults 35
6.1.4 Power failure during cleaning 36
6.2Cleaning parameters / conguration (r-level) 36-38
6.3 Cleaning parameters / step times (n-level) – ECO main wash 39
6.4 Cleaning parameters / step times (d-level) – Descale wash 40
6.5 Cleaning parameters / step times (u-level) – Quick wash 41
6.6 Cleaning parameters 42
6.7 Cleaning parameters 43
6.8 Water and Detergent Usage Eco Wash 5 Cycle: 30 Minutes 44
6.9 Water and Detergent Usage Eco Wash 5 Cycle: 50 Minutes 45
6.10 Water and Detergent Usage Eco Wash 5 Cycle: 75 Minutes 46
6.11 Water and Detergent Usage DESCALE Wash 5 Cycle: 33 Minutes 47
6.12 Water and Detergent Usage DESCALE Wash 5 Cycle: 50 Minutes 48
6.13 Water and Detergent Usage DESCALE Wash 5 Cycle: 75 Minutes 49
7. Tank monitor and general fault handling 50
7.1 Description of tank monitor operation 50
7.2 Tank monitor: Milk removal YES or NO 52-53
7.3 Tank monitor: Handling multiple faults 54
7.4 Tank monitor: Display fault memory 54
7.5 Listing fault codes and their description 55
7.5.1 Critical tank monitor alarms (red) 55
7.5.2 Informative tank monitor alarms (green) 56
7.5.3 System alarms - cleaning 57
7.5.4 System alarms - cooling 60
7.5.5 System alarms - external sensors 61
7.5.6 System alarms in general 61
7.5.7 Test alarm 61
8. Setting of parameters 62
8.1 Change and save parameter values 62-63
8.2 General cooling parameters (C-level) 64
8.3 Level “General cooling parameters” (c parameters) 65-66
8.4 Level “Extended cooling parameters” (P parameters) 67-73
8.5 Level “Extended cooling parameters” (P parameters) 74-77
8.6 Adjustment of Cleaning Step Times 78
8.7 Setting of parameters 79
8.8 Cleaning parameters / conguration (r-level) 80-81
8.9 Setting of parameters 82
8.10 Cleaning parameters / step times (n-level) – ECO main wash 83
8.11 Cleaning parameters / step times (d-level) – Descale wash 84
8.12 Cleaning parameters / step times (u-level) – Quick wash 85
8.13 Setting of parameters 86-87
8.14 Setting of parameters 88-90
8.15 Setting of parameters 91-92
8.16 Setting of parameters 93
8.17 A Parameters 94-100
8.18 Setting of parameters 101-103
8.19 Setting of parameters 104
8.20 A Parameters 105

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9. Other information – General 106
9.1 Buttery valve (manual or pneumatic) 106
9.2 Safety switch for manual buttery valve 106
9.3 Sensor correction procedure 107
9.4 Function second temperature sensor 107
9.5 Test functions 18
9.5.1 Test alarm F99 18
9.5.2 Function test “Do-Not-Load LED” and “external alarm light” 18
9.6 Procedure following power failure 108-109
9.7 Power pack or operation via external power supply 110
9.8 Agitator monitoring module (optionally) 111
9.9 I/O Expansion module ESIO 112
9.10 USB module ESUSB 112
9.11 Integrated multifunction-time relay 112-114
9.12 Safety chain for ‘remote start’ functions 115
9.13 RS485 interface 116
9.14 General measures when using electronic control systems 117-118
9.15 Robot control 119
9.15.1 Cleaning release by robot 120
9.15.2 Compressor switch-on delay / pre-agitating 121
9.15.3 Compressor lock via digital input (by robot) 121
10. Other information - Cooling 122
10.1 Automatic start continuous agitating or cooling mode 122
10.1.1 Automatic start to continuous agitating mode after exiting cooling mode 122
10.1.2 Automatic start to cooling mode after successful cleaning 122
10.2 Different variants for cooling start delay 123-124
10.3 Emergency cooling / Sensor fault 125
10.4 Level alarm during cooling (Fault code F52) 125
10.5 Connection /Parameterization external analogue pressure sensor 126
10.6 Tanks and silos with multiple cooling stages (cooling step control) 127
10.7 Tank overow protection 128
10.8 Anti-freezing protection by means of low pressure monitoring 129
10.9 Thermal protection - / Fault monitoring compressor [P72] 130
10.10 Fault messages low pressure (F80) 131
10.11 Fault Messages High Pressure (F81) 131
11. Other information - Cleaning 132
11.1 Detergent supply via beaker 132
11.2 Setting of a break in the cleaning programme 132
11.3 Level control setting 133
11.4 Relay function ‘set level 2 to relay’ 133
11.5 Function of pressure switch – Effect on pump and heater 134
11.6 Air in the cleaning pump -> automatic venting 134
12. Other information - Tank monitor 135
12.1 Activation delay tank monitor [H90] 135
12.2 EMAIL-, alarm + remote maintenance module ESIPM 135
12.3 SMS, alarm + remote maintenance module ESGSM 135
13. Appendix 1- Display Unit LE 300 wiring information 136-147

5
LE-300
1. Introduction
1.1 Information about this operating instructions
These operating instructions are intended for the use by Installation
Engineers, installers or service technicians of the LE-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. It is only with the knowledge of this
operating instruction that errors in the tank control system can be avoided and
a trouble-free operation is guaranteed.
Read the assembly instructions carefully and adhere to the recommendations
described in order to ensure proper operation. In addition, the local accident
prevention regulations and general safety regulations are to be observed for
the eld of application of the tank control.
When delivered, the parameterization of the LE-300 does not necessarily
correspond to the intended use. This must be adjusted accordingly during
the installation.
Basically, the installer of the system is responsible for the commissioning
of the control.
Operation instruction for the operator
The plant engineers, the installer or the service technician must prepare
operating instructions for the operator of the tank control (farmer). In this
case the parameterization of the delivery state must be clearly documented.
We recommend to only document those parameters which the operator of the
tank control needs.
When preparing the operating instructions for the operator the local
regulations have to be observed – see chapter “Safety”.
These operating instructions include important technical and safety
information. It is vital to carefully study all these instructions before the
installation of the control or in case of any other work with the control!
The manufacturer accepts no liability for errors and reserves the right to make
technical changes at any time. All rights reserved.
NOTICE for storing the operating instructions
This instruction manual is part of the product and must always be readily
available for the service technician.
NOTICE
WARNING

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1.2 Limitation of liability
The proper function of the LE-300 depends on many external factors
on which the manufacturer has no inuence. The manufacturer accepts
no liability for any damages on the milk cooling tank, the connected
components or the milk. The integrated tank monitor supports only
the control of the milk quality and does neither absolve the farmer (as
operator of the milk tank) nor the driver of the milk collecting truck
from the duty of care. Both parties have to ensure that the milk is
transportable before it is removed from the tank.
All information and instructions in this manual have been compiled taking into
account the applicable standards and regulations, the state of the art and our
long-term experiences.
WELBA GmbH does not assume any liability for damages due to:
- Non-observance of the installation instruction
- Improper use
- Installation by unqualied staff
- Non-professional installation by third parties
- Unauthorized modications
- Technical modications
- 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 contract are applicable.
We reserve the right to make technical changes in the context of improving
the properties of use and further developments.
Important safety information in these assembly instructions are identied
by symbols. These instructions on occupational safety must be adhered to
and followed. In these cases, behave particularly carefully in order to avoid
accidents, personal injury and property damage.
In addition to the information in these assembly instructions, the general and
local safety and accident prevention regulations must also be observed and
instructed!
Nature and source of danger
This warning signs warns of an imminent danger to health and life of people.
Failure to comply with this warning will result in extremely serious injuries,
including death.
Nature and source of danger
This warning signs warns of a possibly dangerous situation for the health of
people. Failure to observe these warning notices can result in serious injuries,
including death.
Nature and source of danger
This warning sign warns of a possibly dangerous situation for the health of
people. Failure to observe these warnings can lead to minor or moderate
injuries.
Note
General notes contain application tips and particularly useful information, but
no warnings about dangers.
1.3 Warning notices in these operating instructions
DANGER!
WARNING
WARNING
ATTENTION
NOTICE

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LE-300
NOTICE These operating instructions contain important technical and safety
information. Please read carefully before installation and before any work
on or with the regulator.
These instructions have been compiled with maximum care and attention.
However, their content does not constitute an assurance of product features.
The manufacturer cannot be held liable for errors and may at any time make
changes serving technical progress. All rights reserved.
1.4 Device description
The LE-300 is an universal tank control unit that combines various basic
functions in one unit
a milk cooling thermostat
- an extensive cleaning control
- an extended robot interface
- an extended tank monitoring system
All functions can be parameterised separately and universally.
The control unit has various operating modes:
- OFF mode (tank is empty)
- Cooling mode
- Continuous stirring mode
- Cleaning mode
WELBA “KONSOFT”
The free of charge conguration Software KONSOFT provides a simple
parameterization and updating of the LE-300 as well as a comfortable
evaluation of the determined data.
See section 5.2
The KONSOFT PC-Software has been thoroughly tested and has proven itself
hundreds of times in customer use. Despite all care, we point out that the use of the
free PC-Software is at your own risk. WELBA does not accept any liability for damages
or loss of data resulting from the installation or use of the Software.
NOTICE
1.5 Type designation The type designation of your controller is attached to the holder frame.

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1.7 Dimensions
1.8 Sensor dimensions and technical data
Sensor element KTY 81-210
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
A Sensors other than our standard type are available on request (different
bush form or cable length).
Some of the options are shown here.
1.6 Item supplied - Controller LE-300
- Holder
- Rubber seal
- Sensor TF1A-2
- Fixing screws
- Any optional accessories ordered.

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LE-300
Operating voltage 230V AC +/-10%, 50/60 Hz
Relay contact 12 performance relays
expandable by 6 relays*
max. switching current 6 x each 6A AC1 - 250V AC
4 x each 10A AC1 - 250V AC
2 x each 12A AC1 - 250V AC
max. current per terminal 12A - 250V AC
max. switching voltage 250V AC - 50..60 Hz
Display 13 mm LED-Display, 4 digits
Display range -999 .. 9999
LED switching status displays 3 mm LED
Number of sensor inputs 1 or 2
Measurement range -5° .. +95°C
Temperature resolution 0,1°C
Sensor input for KTY 81-210 (optionally PT-100)
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 standard adjusting 8°C
T1* Target temperature T2* standard adjusting 4°C
Digital inputs 8 (via optocoupler)
expandable by 5 digital inputs*
Interface 2x RS-485
Supply ext. pressure sensor 12V +/-3V max. 40 mA
Connection Plug-in screw connections
for cables up to 2.5 mm²
Housing
- Front dimension 177 x 106 mm
- Front panel cut out 157 x 97 mm
- Insertion depth 45 mm
Protection The control is open on the rear, as it is
designed for installation in a closed
housing IP 64
- Housing front IP 00
- Rear IP 20
Electrical safety Protection class II,
Overvoltage category III, pollution degree I
Environment specications:
- Operation temperature 0° .. +50°C
- Storage temperature -20° .. +70°C
- max. humidity 75% (no dew) 75% (no dew)
1.9 Technical data of control unit
Technical data subject to change.
* via I/O expansion module ESIO-001

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2. Safety
2.1 General Information
The plant engineering company, the installer or the service engineer must
prepare operating instructions for the operator, taking account of the
controller’s parameters as supplied.
We recommend referring only to the parameters which the end user
needs for safe operation.
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 LE-300 as supplied do not correspond
to the intended use. This can lead to undened behaviour by individual
components when the system is commissioned.
For this reason, no actuators should be connected when starting
operation. Load circuits should be separated.
The general principle is that the plant constructor is responsible for
putting the controller into operation.
IMPORTANT NOTICE ON LIABILITY
The faultless function of the LE-300 depends on many external factors, which
the manufacturer has no inuence on. The manufacturer assumes no liability
for damage to the milk cooling tank, the connected components or the milk.
The integrated tank monitor thus only sup-ports the milk quality and does
not release the farmer (as operator of the milk cooling tank) or the driver of
the milk collecting truck from the duty of care. These must ensure, before
withdrawing from the tank, that the milk is transportable.
WARNING
NOTICE
WARNING
DANGER!
IMPORTANT NOTICE ABOUT THE ACCUMULATORS
See section 9.7
(required when using the tank monitor)
The life of the accumulators is limited. The built-in accumulators must be
replaced by new ones every two years at the latest.
Only (!) charged accumulators of the following specication may be used:
1.2 V NiMh - size AA (min. 2.000 mAh)
DO NOT USE BATTERIES !!! EXPLOSIVE !!!!!