WELBA WMS-100 Series User manual

104193 V2.7 - © by WELBA - 14.10.2019
WELBA
Universal Milking Control
WMS-100
WMS-100 G1
Installation and operating instructions
for plant engineering companies
WELBA GmbH
Electronic Control Engineering
Gewerbepark Siebenmorgen 6
D-53547 Breitscheid
+49 (0)2638 / 9320-0
+49 (0)2638 / 9320-20
[email protected]
www.welba.de
Phone:
Fax:
E-mail:
Net:

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WMS-100 104193 V2.7 - 14.10.2019
Appliance description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Technical data of regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sensor dimensions and technical data . . . . . . . . . . . . . . . . . . . . . . 8
Working level description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Washing programme description . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation of working levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
,Button functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
,Meaning of LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
,Overview of operating possibilities . . . . . . . . . . . . . . . . . . . . . . . 21
,Start options for cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjustment of parameters in general . . . . . . . . . . . . . . . . . . . . . . . 23
Operation of the 'cleaning parameters, running times' level . . . . . 25
Operation of the 'cleaning parameters, configuration’ level . . . . . . 27
Operation of the level “User-defined cleaning functions” . . . . . . . . 31
Operation of the level “Service parameters”. . . . . . . . . . . . . . . . . . 32
Sensor correction procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Adjustment of level control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fault indication on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
General measures when using electronic control systems. . . . . . . 36
Electro circuit diagram WTS-100-2 G1 . . . . . . . . . . . . . . . . . . . . . . 39
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Contents

The control unit type WMS-100 is designed to operate the automatic
washing systems of all common types of milking plant.
The device controls all the main plant components via a cleaning pro-
gramme that offers maximum programming flexibility and is easy to ope-
rate.
Detergent use is adjustable both using beakers and through measuring
pumps (with automatic detergent management).
In order to ensure optimum cleaning, various air injection systems for
optimum bubble formation are supported.
The individual adaptability of the operating phases increases the poten-
tial to economise on the consumption of natural resources such as
detergents, energy and water.
The control unit has three different operating modes:
!OFF mode
The control unit is on stand-by. The display shows 'OFF', the LEDs
are out and all output replays are deactivated.
The operating modes milking and washing can only be selected
from the OFF mode. It is not possible to switch directly from
one of them to another.
The 'manual milk pump operation' function can also only be selec-
ted from OFF mode.
CAUTION: The control unit is live even when switched off.
!Milking mode
The vacuum pump runs permanently until OFF button has been
pushed.
!Washing mode
The washing timer controls water intake as either by time or level,
selected. All running times (heater, pump, detergent injection) can
be set separately. Detergent switchover from acidic to alkaline can
also be set.
The WMS-100 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.
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WMS-100 104193 V2.7 - 14.10.2019
Appliance description

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 milking control type WMS-100 is used to control vacuum
pumps, solenoid valves, heaters and dosing pumps in milking plants.
Any other use of the device is permitted only with prior written permis-
sion from the manufacturer.
The universal milking 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 cleaned.
The device is fitted with a resistance temperature sensor.
The device must not be installed in potentially explosive
atmospheres.
The universal milking control type WMS-100 fulfils the EC
requirements for electromagnetic compatibility (EMC) and the
Low Voltage Directive (LVD).
The safety components meet the VDE regulations.
WMS-100 104193 V2.7 - 14.10.2019
Intended use
Safety
The universal milking 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 milking control contains live components
and must not be opened up.
lt must not be used if the housing or connection terminals
are damaged.
No fluids must penetrate the housing.
The universal milking control may not be exported to the
USA without the manufacturer's express permission.
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Fitting the sensor
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. See the
section "Setting the actual value correction" on page 34.
40 mm
6,0 mm
6,1 mm
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 fluctuating 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
For fixing 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.
!Attach the holding frame in the rear position as shown by the picture.
!Fasten the housing by using the screws provided.
WMS-100 104193 V2.7 - 14.10.2019
166
95
157
96
R3
Installation
Drilling diagram
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Installation
Connection diagram
!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 heater.
!Do not feed digital inputs with external voltage! Use potential-free
switches.
WMS-100 104193 V2.7 - 14.10.2019
Digital inputs
12 13 14
15
17 18
19
20
A1 A2
21 22
23
24
Pump down
(Milk pump)
Airinjektor
230VAC
+/-10%
Level electrodes
Sensor
KTY 81-210
External Start/Stop
milking
Savefty switch
milking/washing
External contacts must be potential-free
11
16
External start during
STOP phase
25 27
12
3
4
56
26
LED
Niv. OK
LN 1 2 345 6 78 9 10
N N N N N N N N N L
Cold water Warm water
Alkaline
Acidic
Outlet valve 1
Vacuum pump
Heater
Freely selectable
output function
in parameter E10
Freely selectable
output function
in parameter E11
Supply to outputs
12V
Freely selectable
output function
in parameter E9
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10
K12 K11
Dig.1 Dig.2 Dig.3
Sensitivity level
(The sensitivity level is factory-set
to average water quality)
Page 6
Dig. 2 Dig. 3 Dig. 1 Dig. 4 Dig. 5 Dig. 6
Dry-running protect.
Add water /
circulation
without function
Dig.4 Dig.5 Dig.6

WMS-100 104193 V2.7 - 14.10.2019
Installation
Disposal
Electrical connection
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 maxi-
mum values indicated on the relays should be connected
to the relay contacts
Use contactors.
Downstream contactors must be fitted with an RC protecti-
on circuit. (see also page 36).
You will find the circuit diagram for your tank control on the back of the
housing above the connection terminals.
For the purposes of disposal, the device is classified as waste electronic
equipment within the meaning of European Directive 2002/96/EC
(WEEE) and must not be included with household waste. It must be
disposed of through the correct channels.
Local and current legislation must be observed.
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WMS-100 104193 V2.7 - 14.10.2019
Operating voltage 230V AC +/-10%, 50 Hz
Relay contacts 10 make-contacts
max. switching current 8 x each 10A AC1 - 250V AC
2 x each 16A AC1 - 250V AC
max. switching voltage 250V AC - 50..60 Hz
Display 13 mm LED - Display, 3 digits
LED switching status displays 3 mm
Display range -99 .. 999
Sensor type KTY 81-210
Sensor cable lenght 2 metres (or as required)
Measurement range -5° .. +70°C
Temperature resolution 0,1°C
Level detection via 2 electrodes (optional)
Digital inputs 6 (via opto coupler)
Connection Plug-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 depht 45 mm
Protection (housing front) IP 64
Environment specifications:
- Operation temperature 0° .. +50°C
- Storage temperature -20° .. +70°C
- max. humidity 75% (no dew)
Technical Data
40 mm
6,0 mm
6,1 mm
Sensors other than our standard type are available on request
(different bush from or cable length).
Some of the options are shown here.
Sensor dimensions and technical data
Sensor element
Bush material
Bush length
Bush diameter
Cable material
Measurement range
Cable lenght
Protection type
KTY sensor
1.4301(V2A)
40 mm
6.0 mm +/- 0.1
PVC
-10 .. 70° C
Standard 2 metres
IP 65
Technical data subject to changes.
Page 8

Operation of the WMS-100 takes place at various levels:
Working level:
… for normal daily operation.
!OFF mode = switch control to STAND-BY
!Start “milking mode”
!Start “washing mode”
!select detergent
!manual start milk pump
The subsidiary parameters are accessed by entering a code in
order to avoid their accidental alteration.
Cleaning parameter running times
The running times of the various milking plant components are adjusted
here.
Cleaning parameter Configuration
For programming the control unit's individual tank-specific washing
functions.
User-defined cleaning functions
Used to programme user-specific cleaning functions.
Service parameters
Parameters for starting the system.
Only for service engineer!
WMS-100 104193 V2.7 - 14.10.2019
Working level description
Working level
for normal daily operation
Code 471 Code 454 Code 382 Code 567
Page 9
Cleaning parameter
Configuration
(E-parameters)
Cleaning parameter
running times
(P-parameters)
Service parameters
(t-parameters)
User-defined
cleaning functions
(b-parameters)

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WMS-100 104193 V2.7 - 14.10.2019
Washing programme description
The running time of each individual programme phase can be adjusted (P10 to P69). Which water valves (E75–E80), which drain valves (E81–E86) or which air injector (E65-E70) are to be used can be selected separately for each washing stage. The injection times are adjustable via separate parameters (P71-P74). Washing stages 1, 2, 4 and 6 can be repeated up to five times, or they can be deselected.
After the first or second washing stage, a pause can be inserted which is ended by a set time, pressing a button (cleaning) or digital input. In phases P10/P20/P30+H/P40/P50+H/P60 during water intake, the vacuum pump can be switched on as an option. The injection position is adjustable.
Cold water valve Warm water valve
Injektion pump alkaline Injektion pump acidic Outlet valve 1 Vacuum pump
Heater Air-Injektor Milk pump
Outlet valve 2 Vacuum increase
MMS Valve
Circulation valve Suction valve Sponge valve Air-Injektor 2 Hot water valve User-defined 1 User-defined 2
Temp. P82/84 Temp. P84
K1 K2 K3 K4 K5 K6 K7 K8 K12
K9 to K11
Level Level Level Level LevelLevel
DDDD
10 11 12 13 14 15 16 17 20 21 22 23 24 25 26 27
Stop
30 31 32 33 34 35 36 37
H40 41 42 43 44 45 46 47 60 61 62 63 64 65 66 67 68 69
Stop
Program step Program step Program step Program step Program step
50 51 52 53 54 55 56 57
H
Program step
Washing stage 1
Pre-rinse 1
Washing stage 2
Pre-rinse 2
Washing stage 3
Main wash 1
Washing stage 4
Intermediate rinse
Washing stage 6
Final rinse
Washing stage 5
Main wash 2
Functions allocated to fixed relays Functions which can be allocated to three fixed relays