WELBA MRF-2-PA2 User manual

1. Introduction
106187 –MRF-2-PA2 -E - V1.3 - 24.01.2023 Page 1
Freely programmable
pasteur controller
MRF-2-PA2
Installation and operating instructions
for plant engineering companies,
installers and service engineers
Firmware V1.3
Messen - Steuern - Regeln
alles aus einer Hand
Programmable via
configuration software
WELBA „KONSOFT"

1. Introduction
Page 2106187 –MRF-2-PA -E -V1.3 –24.01.2023
1. Introduction................................................................................................................................................ 4
1.1 Information about this operating instructions ................................................................................ 4
1.2Limitation of liability ....................................................................................................................... 5
1.3 Warning notices in these operating instructions............................................................................ 6
1.4 Model / type plate .......................................................................................................................... 7
1.5 Items supplied ............................................................................................................................... 8
1.6 Disposal......................................................................................................................................... 8
1.7 Cleaning instructions ..................................................................................................................... 8
1.8 Dimensions.................................................................................................................................... 9
1.9 Technical data regulator .............................................................................................................. 10
1.10 Sensor dimensions und technical data sensor............................................................................ 11
2. Safety ...................................................................................................................................................... 12
2.1 General Information..................................................................................................................... 12
2.2 Intended use................................................................................................................................ 13
2.3 Wiring, screening, earthing.......................................................................................................... 14
2.4 Electrical safety ........................................................................................................................... 14
3. Installation ............................................................................................................................................... 15
3.1 Location and climatic conditions.................................................................................................. 15
3.2 Unpacking and storage ............................................................................................................... 15
3.3 Installation of housing.................................................................................................................. 15
3.4 Fitting the sensor ......................................................................................................................... 16
3.4.1 Changing the sensor cable length............................................................................................... 16
4. Electrical connection ............................................................................................................................... 17
4.1 Safety during installation ............................................................................................................. 17
4.2 Procedure .................................................................................................................................... 18
4.3 Wiring / circuit diagram ................................................................................................................ 19
4.3.1 Wiring the digital input ................................................................................................................. 19
5. Operation................................................................................................................................................. 20
5.1 Function overview........................................................................................................................ 20
5.2 The configuration software KONSOFT........................................................................................ 22
5.3 Operation in levels....................................................................................................................... 23
5.4 Operation of working level........................................................................................................... 24
5.4.1 Button functions........................................................................................................................... 24
5.4.1 Operation in general .................................................................................................................... 25
5.4.2 Select and start a predefined program ........................................................................................ 25
5.4.3 Selection "FILLING QUANTITY in %" before program start ....................................................... 26
5.4.4 Switch on agitator in stand-by ..................................................................................................... 26
5.4.5 Program sequence with (control) phases.................................................................................... 27
5.4.6 Manual operation......................................................................................................................... 29

1. Introduction
106187 –MRF-2-PA2 -E - V1.3 - 24.01.2023 Page 3
6. Parameterization ......................................................................................................................................30
6.1 Change and save parameters......................................................................................................30
6.1.1 Enter level code: ..........................................................................................................................30
6.1.2 Display and change parameter value ..........................................................................................31
6.1.3 Save parameters and return to work level ...................................................................................31
6.2 Level "Temperatures and expiry times" (C parameters) .............................................................32
6.3 Level “Sequence program configuration (P parameters) ..........................................................33
6.4 Level “Control parameter” (r parameters) ................................................................................37
6.4.1 Explanation of the control parameter sets ...................................................................................37
6.4.2 Selection "FILLING QUANTITY in %" in the working level ..........................................................38
6.4.3 Control parameter sets WARM UP ..............................................................................................39
6.4.1 Control parameter sets COOLING DOWN ..................................................................................40
6.5 Level “Hardware configuration” (A parameters).......................................................................41
6.6 Level “I/O test parameter” (o. parameters) ..............................................................................42
7. Other Notes..............................................................................................................................................43
7.1 Fault messages ............................................................................................................................43
7.1.1 Sensor fault ..................................................................................................................................43
7.1.2 Behaviour in the event of a power failure.....................................................................................44
7.2 Functions digital input ..................................................................................................................45
7.3 Setting the actual value correction...............................................................................................45
7.4 Temperature control during holding times ...................................................................................46
7.5 ‚End‘ message on the display ......................................................................................................47
7.5.1 ‚End‘ message also via relay output ............................................................................................47
7.6 Interface RS485 ...........................................................................................................................47
7.7 Determination of the agitator activation per control phase ..........................................................48
7.8 General measures when using electronic control systems..........................................................49
Publisher:
Welba GmbH
Electronic Control Engineering
Gewerbepark Siebenmorgen 6
D-53547 Breitscheid
Fon:
Fax:
+49 (0)2638 / 9320-0
+49 (0)2638 / 9320-20
[e-mail]
www.welba.de

1. Introduction
Page 4106187 –MRF-2-PA -E -V1.3 –24.01.2023
1. Introduction
1.1 Information about this operating instructions
These operating instructions are intended for the use by plant engineers, installers
or service technicians of the MRF-2-PA2 pasteur regulator. This manual contains all
necessary suggestions, information, recommendations and advice for the safe and
proper installation and commissioning of the pasteur regulator. It is only with the
knowledge of this operating instruction that errors at the regulator can be avoided
and a trouble-free operation is guaranteed.
Read the assembly instructions carefully and adhere to the recommendations de-
scribed in order to ensure proper operation. In addition, the local accident preven-
tion regulations and general safety regulations are to be observed for the field of
application of the pasteur regulator.
When delivered, the parameterization of the MRF-2-PA2 does not
necessarily correspond to the intended use. This must be ad-
justed accord-ingly during the installation.
Basically, the installer of the system is responsible for the com-
missioning of the regulator.
Operation instruction for the operator
The plant engineers, the installer or the service technician must prepare operating
instructions for the operator of the pasteur regulator. In this case the parameteriza-
tion of the delivery state must be clearly documented.
We recommend to only document those parameters which the operator of the regu-
lator 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 instruc-
tions before the installation of the regulator or in case of any
other work with the regulator!
The manufacturer accepts no liability for errors and reserves the right to make tech-
nical 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.
WELBA „KONSOFT"
The free of charge configuration Software KONSOFT provides a simple parameter-
ization and updating of the milk temperature regulator as well as a comfortable eval-
uation of the determined data.
See also section 5.2
WARNING
NOTICE
NOTICE

1. Introduction
106187 –MRF-2-PA2 -E - V1.3 - 24.01.2023 Page 5
1.2 Limitation of liability
The proper function of the MRF-2-PA2 depends on many external
factors on which the manufacturer has no influence. The manu-
facturer assumes no liability for damage to the cooling tank, the
connected components or the product to be tempered.
All information and instructions in this manual have been compiled taking into ac-
count the applicable standards and regulations, the state of the art and our long-term
experiences.
These instructions have been compiled with maximum care and attention. However,
their content does not constitute an assurance of product features.
The manufacturer accepts no liability for errors and reserves the right to make tech-
nical changes at any time. All rights reserved.
WELBA GmbH does not assume any liability for damages due to:
- Non-observance of the installation instruction
- Improper use
- Installation by unqualified staff
- Non-approved outdoor installation
- Unauthorized modifications
- Technical modifications
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 con-
tract are applicable.
We reserve the right to make technical changes in the context of improving the prop-
erties of use and further developments.
WARNING

1. Introduction
Page 6106187 –MRF-2-PA -E -V1.3 –24.01.2023
1.3 Warning notices in these operating instructions
Important safety information in these assembly instructions are identified by sym-
bols. 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.
DANGER!
ATTENTION
NOTICE
WARNING

1. Introduction
106187 –MRF-2-PA2 -E - V1.3 - 24.01.2023 Page 7
1.4 Model / type plate
These instructions apply to all controllers in the series MRF-2-PA2.
The type designation and the exact connection diagram for your controller can be
found on the controller as a connection sticker.
Example:
Controller type designation:
and

1. Introduction
Page 8106187 –MRF-2-PA -E -V1.3 –24.01.2023
1.5 Items supplied
- Pasteur regulator MRF-2-PA2
- Accompanying documentation
- Holder
- Rubber seal
- Temperature sensor TF1A-2
- Fixing screws
- Optional accessories that may have been ordered
1.6 Disposal
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 in-
cluded with household waste. It must be disposed of through the correct channels.
Local and current legislation must be observed.
1.7 Cleaning instructions
The enclosure front (front foil) can be cleaned with usual detergents.
ATTENTION: The enclosure front is not resistant to aggressive
acids and alkalis, abrasive cleaners and cleaning with high-pres-
sure cleaners!
The use of these cleaners and cleaning methods may lead to damages!
ATTENTION

1. Introduction
106187 –MRF-2-PA2 -E - V1.3 - 24.01.2023 Page 9
1.8 Dimensions
Front panel cutout
87 x 56 mm

1. Introduction
Page 10 106187 –MRF-2-PA -E -V1.3 –24.01.2023
1.9 Technical data regulator
Operating voltage
230V AC +/-10%, 50/60 Hz
Relay contact
1 changer contact, 2 make contacts,
potential-free
max. switching current
2 make contacts = 12A AC1 / 230V AC
1 changer contact = 10A AC1 / 230V AC
max. switching voltage
250V AC - 50..60 Hz
Display
13 mm LED-Display, 3 digits
Display range
-99 .. 999
Switching status displays
3 mm LEDs
Number of sensors
1
Usable sensors
KTY 81-110
KTY 81-210
PT 100
PT 1000
Measurement range
- KTY 81-110
- KTY 81-210
- PT 100
- PT 1000
(depending on the sensor used)
-50° .. +150°C
-50° .. +150°C
-99° .. +400°C
-99° .. +400°C
Sensor cable length
2 metres
Temperature resolution
0,1°C
Control mode
two-step / PID controller, depending on setting
Digital input
2 via optocoupler
Interface
RS-485
Housing
- Front dimension
- Front panel cutout
- Insertion depth
86 x 106 mm
56 x 87 mm
47 mm
Installation conditions
Built-in device - installation depth 45 mm
Protection
- Housing front
- Rear
The control is open on the rear, as it is designed
for installation in a closed housing.
IP 64
IP 00
Electrical safety
Protection class II,
Overvoltage category III, pollution degree I
Pollution degree
Electrically conductive pollution must not enter
the housing interior
Rated impulse voltage
1500V
Connection
Plug-in screw connections
for cables up to 2.5 mm²
Environment specifications:
- Operation temperature
- Storage temperature
- max. humidity
0° .. +50°C
-20° .. +70°C
75% (no dew)
Technical data subject to change.

1. Introduction
106187 –MRF-2-PA2 -E - V1.3 - 24.01.2023 Page 11
1.10 Sensor dimensions und technical data sensor
In contrast to our standard sensors, we also offer sensors with other
sleeve shapes and diameters or other cable lengths.
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
40 mm
6,0 mm 6,1 mm

2. Safety
Page 12 106187 –MRF-2-PA -E -V1.3 –24.01.2023
2. Safety
2.1 General Information
The plant engineering company, the installer or the service engi-
neer 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, espe-
cially the chapter on “Safety”, account must be taken of local reg-
ulations.
The parameter settings of the regulator as supplied do not corre-
spond to the intended use. This can lead to undefined behaviour
by individual components when the system is commissioned.
The general principle is that the plant constructor is responsible
for putting the regulator into operation.
These operating instructions contain important technical and
safety information. Please read carefully before installation and
before any work on or with the regulator.
It is the duty of the party commissioning the system to ensure
compliance with the following guidelines.
The regulator may only be installed by an authorised electro spe-
cialist, observing all local safety requirements.
Access to the environment when connected must be restricted to
specialised personnel.
The regulator contain live components. They must be built into
the plant in such a way that contact with such live components is
impossible.
The regulator is not suitable for use in explosive atmospheres.
Danger of explosion. Use only outside areas subject to explosive
atmospheres.
The regulator must not be used if the housing or connection ter-
minals are damaged.
No fluids must penetrate the housing.
The regulator may not be exported to the USA without the manu-
facturer's express permission!
WARNING
NOTICE
WARNING

2. Safety
106187 –MRF-2-PA2 -E - V1.3 - 24.01.2023 Page 13
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!
The MRF-2-PA2 pasteurizer controller is used to control heaters, compressors, agi-
tator motors and other components in open tubs. Any other use of the device is
permitted only with prior written permission from the manufacturer.
The regulator is intended only for incorporating into machinery, display panels or
switchboxes etc. and when fitted corresponding to protection class 2 (double or re-
inforced insulation). It is only allowed to be put into operation in installed state. The
use of the regulator is permitted in devices of protection class 1 and 2. The regulator
must not be modified or converted in any way!
The regulator is ready for use only when the parameters have been set appropriately.
Commissioning without the appropriate parameter setting is not sensible and can
also result in damage to the tub and the medium to be tempered.
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 MFR-2-PA2.
The regulator is fitted with a resistance temperature sensor.
The pasteur regulator MRF-2-PA2 is not suitable for use in explosive atmospheres.
Danger of explosion. Use only outside areas subject to explosive atmospheres.
The regulator fulfils the EC requirements for electromagnetic compatibility (EMC)
and the Low Voltage Directive (LVD).
The safety components meet the VDE regulations.
NOTICE

2. Safety
Page 14 106187 –MRF-2-PA -E -V1.3 –24.01.2023
2.3 Wiring, screening, earthing
When selecting wiring materials and installing and connecting the temperature con-
troller 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 regula-
tions (e.g. based on IEC 60364).
- Wherever possible, keep input, output and supply leads and sensor cable phys-
ically 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.
2.4 Electrical safety
- The regulator itself and the associated control circuits and load circuits must be
protected separately and in accordance with the local regulations.
- The separate protection of the control- and load circuit must be carried out ac-
cording 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 independent 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 K12) must be fused in accordance with the
connected components.
- The connection of external voltages to the digital inputs can lead to the destruc-
tion of the control.
- Caution: All cables to the digital inputs must be shielded and kept as short as
possible. EMC.

3. Installation
106187 –MRF-2-PA2 -E - V1.3 - 24.01.2023 Page 15
3. Installation
3.1 Location and climatic conditions
It is essential not to install the device under the following conditions:
- severe jolting, vibration or magnetic fields
- permanent contact with water
- relative humidity of more than 90%
- sharply fluctuating temperatures (condensation)
- permanent and direct UV radiation
- dust, flammable gases, vapours, solvents,
- operation in an aggressive atmosphere (ammonia or sulphur fumes) - risk of
oxidation
- operation in the immediate vicinity of radio transmitters with high levels of spu-
rious radiation.
A physical separation between the device and inductive consumers is recom-
mended.
3.2 Unpacking and storage
If the packaging is damaged or something is missing, do not fit the temperature con-
troller. In this case please contact Welba.
If you keep the temperature controller for a period before using it, store it in a clean
dry place at a temperature of between -20°C and +70°C.
3.3 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.
Front panel cut-out
87 x 56 mm

3. Installation
Page 16 106187 –MRF-2-PA -E -V1.3 –24.01.2023
3.4 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).
When setting the temperature regulator 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 ther-
mometer should be used for this purpose.
See section 7.3
Pay attention to the permitted temperature range for sensor cable
exposure.
3.4.1 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 section 7.3
40 mm
6,0 mm 6,1 mm
WARNING
WARNING

4. Electrical connection
106187 –MRF-2-PA2 -E - V1.3 - 24.01.2023 Page 17
4. Electrical connection
4.1 Safety during 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 regula-
tor and to the equipment!
The controller may only be put into operation when installed.
The regulator should be disconnected from the mains voltage
while connecting plant components or the sensor.
No appliances with current levels in excess of the maximum val-
ues indicated in the technical data should be connected to the
relay contacts.
No other consumers may be connected to the controller's mains
terminals.
WARNING

4. Electrical connection
Page 18 106187 –MRF-2-PA -E -V1.3 –24.01.2023
4.2 Procedure
In order to avoid injury to persons connections must in all cases
be undertaken in the following order!
De-energize the system.
Pull out all the regulator’s plug-in terminals.
Put the controller in position in the housing or switchboard. See section 3.3
Connect all components and sensors in accordance with section 4.3 (Circuit dia-
gram) to the plug-in terminals.
Plug the terminals into the controller!.
Make sure that the plug-in terminals are not twisted when plugged
into the sockets! See photo for correct position.
Close the switchbox and turn on the mains voltage.
The controller is now ready for parameterization.
Parameterise the controller as described in the chapter 'Operation'.
(possibly using the optional WELBA-KONSOFT configuration software).
WARNING
ATTENTION

4. Electrical connection
106187 –MRF-2-PA2 -E - V1.3 - 24.01.2023 Page 19
4.3 Wiring / circuit diagram
Correct wiring in accordance with the information in the accompanying description
and local regulations is essential.
Please note the following:
- Use cable bushes.
- Make sure that cables cannot chafe!
- Take particular care to ensure that the AC supply is not connected to the sensor
input or other low-voltage inputs or outputs.
- The relay contacts may only be connected with the same voltage.
- When connecting the regulator and selecting the wiring materials to be used, it
is essential to comply with the provisions of DIN VDE 0100 “Erection of power
installations with rated voltages below 1000” or the relevant national regula-
tions.
Connect the system components according to the wiring diagram.
Compressors and heaters must not be connected directly to the relays on the con-
trol unit. This must be switched using an additional contactor. In individual cases,
it must be checked whether additional motor protection switches or other safety
devices are to be installed
Contactors are to be fitted with an RC protective circuit. See section 7.8.
4.3.1 Wiring the digital input
Terminals "i1+i2" may only be connected to the potential at terminal "A1".
The correct circuit dia-
gram for your regulator
is affixed to the housing.
Sensor
Relays K1 to K3 may only
be connected to a uniform
voltage!
Terminals "i1+i2" may
only be connected to the
potential at terminal "A1".

5. Operation
Page 20 106187 –MRF-2-PA -E -V1.3 –24.01.2023
5. Operation
5.1 Function overview
The freely programmable pasteur controller MRF-2-PA2 can be used either for 2-
point or for PID control. It is designed for milk pasteurization, the production of
cheese, yoghurt, etc.
STAND-BY
If all LEDs below the display are off, the controller is in 'standby'. All relays have
dropped out, no control functions are active.
Program memory locations 1 to 4
The controller has 4 freely programmable program memory locations, each with an
associated LED. Each of the program memory locations can optionally be set up as
- sequence program with control phases or as
- manual operation
Internally, the controller has 4 sets of control parameters for different applications.
These control parameter sets can be linked with the sequence programs as required
(see section 6.4.1).
In the P-parameters, each sequence program can be parameterized,
- whether it should be an automated program sequence or a simple manual pro-
gram (only heating or cooling function),
- the type of control (PID or 2-point - independent for heating and cooling),
- whether the stored setpoint temperature is to be changed manually by the op-
erator before the start of a program,
- which control parameter set should be used,
- at which program phases the agitator should be activated.
Alternatively: Power levels for different fillings
- Alternatively, the control parameter sets can be used to define 4 different power
levels for different filling levels in the tub: These filling levels are queried by the
controller when the program starts. See section 5.4.3