WELBA WTS-300 User manual

1. Introduction
105204 –WTS-300-E - V4.1 - 20.01.2022 Page 1
Universal tank control
WTS-300
Installation and operating instructions
for plant engineering companies,
installers and service engineers
Firmware V4.3
Measuring - Controlling - Regulating
All from the same source
Programmable via
configuration software
WELBA „KONSOFT"
WTS-300 G1

1. Introduction
Page 2105204 –WTS-300-E -V4.1 - 20.01.2022
1. 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................................................................................................................................ 12
2.3 Wiring, screening, earthing.......................................................................................................... 13
2.4 Electrical safety ........................................................................................................................... 13
3. Installation ............................................................................................................................................... 14
3.1 Location and climatic conditions.................................................................................................. 14
3.2 Unpacking and storage ............................................................................................................... 14
3.3 Installation of housing.................................................................................................................. 14
3.4 Fitting the sensor......................................................................................................................... 15
4. Electrical connection ............................................................................................................................... 16
4.1 Safety during installation ............................................................................................................. 16
4.2 Procedure.................................................................................................................................... 16
4.3 Wiring .......................................................................................................................................... 17
4.4 Connection diagram (Delivery configuration)............................................................................. 18
4.5 Wiring the digital inputs ............................................................................................................... 19
4.6 Connection robot......................................................................................................................... 19
4.7 Connection of external pressure sensor (optional) ..................................................................... 19
5. Operation................................................................................................................................................. 20
5.1 Function overview........................................................................................................................ 20
5.1.1 OFF mode (stand-by)........................................................................................................ 20
5.1.2 Cooling mode.................................................................................................................... 20
5.1.3 Continuous stirring mode.................................................................................................. 21
5.1.4 Cleaning mode.................................................................................................................. 21
5.2 The configuration software KONSOFT........................................................................................ 23
5.3 Guideline for the initial installation / parameterization................................................................. 24
5.4 Setting the date and time ........................................................................................................... 26
5.5 Operation in levels....................................................................................................................... 27
5.6 Operation of working level........................................................................................................... 28
5.6.1 Button functions ................................................................................................................ 29
5.6.2 Meaning of the LED‘s........................................................................................................ 30
5.6.3 Operation modes............................................................................................................... 32
6. Cleaning .................................................................................................................................................. 36
6.1 Cleaning methods (cooling tank-configurations)......................................................................... 36
6.1.1 Circulation cleaning with a beaker .................................................................................... 36
6.1.2 Circulation cleaning with two dosing pumps..................................................................... 36
6.1.3 Displacement cleaning with feed container, dosing pumps in circulation pipe................. 37
6.1.4 Displacement cleaning with feed container and dosing pumps........................................ 37
6.2 Cleaning programme diagram (Maximum configuration)........................................................... 38
6.3 Explanation and programming of the cleaning process.............................................................. 40
6.3.1 Factory setting................................................................................................................... 40

1. Introduction
105204 –WTS-300-E - V4.1 - 20.01.2022 Page 3
6.3.2 Determination of the number of individual rinsing cycles ..................................................40
6.3.3 Different methods of water intake......................................................................................41
6.3.4 Cleaning with alkaline or acidic detergents .......................................................................42
6.3.5 Disinfection ........................................................................................................................42
6.3.6 Time of detergent dosing...................................................................................................42
6.4 Parameterization of the cleaning stages......................................................................................43
6.4.1 Cleaning methods..............................................................................................................43
6.5 Abort of the cleaning ....................................................................................................................56
6.5.1 Cleaning cycle completely finished...................................................................................56
6.5.2 Manual abort of the cleaning ............................................................................................56
6.5.3 Abort of the cleaning due to faults .....................................................................................56
6.5.4 Power failure during cleaning ............................................................................................57
6.6 Dosing of detergent and / or water intake by flow metering.........................................................58
6.6.1 General information and first steps....................................................................................58
6.6.2 Dosing of the quantity-controlled detergent and disinfectant.............................................59
6.6.3 Quantity-controlled water intake........................................................................................59
6.6.4 Testing / determining the number of pulses of the flow sensors per litre ..........................60
7. Tank monitor and general fault handling .................................................................................................61
7.1 Description of tank monitor operation ..........................................................................................61
7.2 Tank monitor: Milk removal YES or NO.......................................................................................63
7.3 Tank monitor: Handling multiple faults.........................................................................................66
7.4 Tank monitor: Display fault memory ............................................................................................66
7.5 Listing fault codes and their description.......................................................................................67
7.5.1 Critical tank monitor alarms (red).......................................................................................67
7.5.2 Informative tank monitor alarms (green)............................................................................68
7.5.3 System alarms - cleaning ..................................................................................................70
7.5.4 System alarms - cooling.....................................................................................................72
7.5.5 System alarms - external sensors .....................................................................................73
7.5.6 System alarms in general ..................................................................................................73
7.5.7 Test alarm..........................................................................................................................73
8. Setting of parameters...............................................................................................................................74
8.1 Change and save parameter values............................................................................................74
8.2 Level “General cooling parameters” (c parameters)......................................................76
8.3 Level “Extended cooling parameters” (P parameters).....................................................78
8.4 Level “General cleaning parameters” (n parameters)......................................................88
8.5 Level “Extended cleaning parameters 1” (r parameters)......................................................92
8.6 Level “Extended cleaning parameters 2” (L parameters) .....................................................98
8.7 Level “Service parameters” (E parameters)...................................................100
8.8 Level “General tank monitor parameters” (h parameters) ...................................................102
8.9 Level “Extended tank monitor parameters” (H parameters) ..................................................104
8.10 Level “Alarm - Event assignment” (F parameters)...................................................106
8.11 Level “Configuration” (A parameters) ..................................................108
8.12 Level “I/O test parameters” (o. parameters) ..................................................116
9. Other information –General ..................................................................................................................119
9.1 Butterfly valve (manual or pneumatic) .......................................................................................119
9.2 Safety switch for manual butterfly valve.....................................................................................119
9.3 Sensor correction procedure......................................................................................................120
9.4 Function second temperature sensor ........................................................................................120
9.5 Test functions.............................................................................................................................121
9.5.1 Test alarm F99.................................................................................................................121
9.5.2 Function test "Do-Not-Load LED" and "external alarm light"...........................................121
9.6 Procedure following power failure..............................................................................................122
9.7 Power pack or operation via external power supply ..................................................................123
9.8 Agitator monitoring module (optionally) .....................................................................................124

1. Introduction
Page 4105204 –WTS-300-E -V4.1 - 20.01.2022
9.9 I/O Expansion module ESIO ..................................................................................................... 125
9.10 USB module ESUSB................................................................................................................. 125
9.11 Integrated multifunction-time relay............................................................................................ 126
9.12 Safety chain for 'remote start' functions .................................................................................... 128
9.13 RS485 interface......................................................................................................................... 129
9.14 General measures when using electronic control systems....................................................... 130
9.15 Robot control............................................................................................................................. 133
9.15.1 Cleaning release by robot............................................................................................... 134
9.15.2 Compressor switch-on delay / pre-agitating.................................................................... 135
9.15.3 Compressor lock via digital input (by robot).................................................................... 135
10. Other information - Cooling................................................................................................................... 136
10.1 Automatic start continuous agitating or cooling mode............................................................... 136
10.1.1 Automatic start to continuous agitating mode after exiting cooling mode....................... 136
10.1.2 Automatic start to cooling mode after successful cleaning............................................. 136
10.2 Different variants for cooling start delay.................................................................................... 137
10.3 Emergency cooling / Sensor fault.............................................................................................. 139
10.4 Level alarm during cooling (Fault code F52)........................................................................... 139
10.5 Connection /Parameterization external analogue pressure sensor .......................................... 140
10.6 Tanks and silos with multiple cooling stages (cooling step control).......................................... 141
10.7 Tank overflow protection ........................................................................................................... 142
10.8 Anti-freezing protection by means of low pressure monitoring ................................................. 143
10.9 Thermal protection - / Fault monitoring compressor [P72]........................................................ 144
10.10 Fault messages low pressure (F80).......................................................................................... 145
10.11 Fault Messages High Pressure (F81)........................................................................................ 145
11. Other information - Cleaning................................................................................................................. 146
11.1 Detergent supply via beaker...................................................................................................... 146
11.2 Setting of a break in the cleaning programme .......................................................................... 146
11.3 Heating control .......................................................................................................................... 147
11.4 Influence on the temperature of the tank wall ........................................................................... 147
11.5 Boost pump function (booster pump)........................................................................................ 147
11.6 Level control setting................................................................................................................... 148
11.7 Relay function 'set level 2 to relay'............................................................................................ 148
11.8 Function of pressure switch –Effect on pump and heater........................................................ 149
11.9 Air in the cleaning pump -> automatic venting.......................................................................... 149
11.10 Service functions for testing the cleaning cycle ........................................................................ 150
11.10.1 Start cleaning with the desired cleaning stage (0 to 8)................................................... 150
11.10.2 Single step function during cleaning ............................................................................... 150
12. Other information - Tank monitor .......................................................................................................... 151
12.1 Activation delay tank monitor [H90]........................................................................................... 151
12.2 EMAIL-, alarm + remote maintenance module ESIPM ............................................................. 151
12.3 SMS, alarm + remote maintenance module ESGSM................................................................ 151
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
105204 –WTS-300-E - V4.1 - 20.01.2022 Page 5
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 WTS-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 de-
scribed in order to ensure proper operation. In addition, the local accident prevention
regulations and general safety regulations are to be observed for the field of appli-
cation of the tank control.
When delivered, the parameterization of the WTS-300 does not neces-
sarily correspond to the intended use. This must be adjusted accord-
ingly during the installation.
Basically, the installer of the system is responsible for the commission-
ing 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 parameteri-
zation 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 in-
formation. 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 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.
WARNING
NOTICE

1. Introduction
Page 6105204 –WTS-300-E -V4.1 - 20.01.2022
1.2 Limitation of liability
The proper function of the WTS-300 depends on many external factors
on which the manufacturer has no influence. 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 op-
erator 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 transport-
able before it is removed from the tank.
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.
WELBA GmbH does not assume any liability for damages due to:
- Non-observance of the installation instruction
- Improper use
- Installation by unqualified staff
- Non-professional installation by third parties
- Unauthorized modifications
- Technical modifications
- 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 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.
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.
WARNING
WARNING
DANGER!
ATTENTION
NOTICE

1. Introduction
105204 –WTS-300-E - V4.1 - 20.01.2022 Page 7
These operating instructions contain important technical and safety in-
formation. Please readcarefully 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
Die The WTS-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 configuration Software KONSOFT provides a simple
parameterization and updating of the WTS-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 result-
ing from the installation or use of the Software.
1.5 Type designation
The type designation of your controller is attached to the holder frame.
NOTICE
NOTICE

1. Introduction
Page 8105204 –WTS-300-E -V4.1 - 20.01.2022
1.6 Item supplied
- Controller WTS-300
- Holder
- Rubber seal
- Sensor TF1A-2
- Fixing screws
- Any optional accessories ordered.
1.7 Dimensions
1.8 Sensor dimensions and technical data
A Sensors other than our standard type are available on request (dif-
ferent bush form or cable length).
Some of the options are shown here.
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
177
106
45
T1
T2
°C
RESET
Robot
STOP
Mode
Valve open
RobotStop
Data
40 mm
6,0 mm
6,1 mm

1. Introduction
105204 –WTS-300-E - V4.1 - 20.01.2022 Page 9
1.9 Technical data of control unit
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 T1*
Target temperature T2*
standard adjusting 8°C
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
- Front panel cut out
- Insertion depth
177 x 106 mm
157 x 97 mm
45 mm
Protection
- Housing front
- Rear
The control is open on the rear, as it is de-
signed for installation in a closed housing IP 64
IP 00
IP 20
Electrical safety
Protection class II,
Overvoltage category III, pollution degree I
Environment specifications:
- Operation temperature
- Storage temperature
- max. humidity 75% (no dew)
0° .. +50°C
-20° .. +70°C
75% (no dew)
Technical data subject to change.
* via I/O expansion module ESIO-001

2. Safety
Page 10 105204 –WTS-300-E -V4.1 - 20.01.2022
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 WTS-300 as supplied do not correspond
to the intended use. This can lead to undefined behaviour by individual
components when the system is commissioned.
For this reason, no actuators should be connected when starting oper-
ation. 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 WTS-300 depends on many external fac-
tors, which the manufacturer has no influence 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.
NOTICE
WARNING