WELBA TW-31 User manual

1. Introduction
105466 –TW-31-E - V1.9 - 06.04.2021 Page 1
Tank monitor
TW-31
Installation and operating instructions
for plant engineering companies,
installers and service engineers
Firmware V1.9
Measuring - Controlling - Regulating
All from the same source
Programmable via
configuration software
WELBA „KONSOFT"

1. Introduction
Page 2105466 –TW-31-E - V1.9 - 06.04.2021
1. Introduction................................................................................................................................................ 4
1.1 Information about this operating instructions................................................................................... 4
1.2 Limitation of liability.......................................................................................................................... 5
1.3 Warning notices in these operating instructions.............................................................................. 5
1.4 Device description............................................................................................................................ 6
1.5 Type designation.............................................................................................................................. 7
1.6 Item supplied.................................................................................................................................... 7
1.7 Dimensions ...................................................................................................................................... 7
1.8 Technical data of control unit........................................................................................................... 8
1.9 Sensor dimensions and technical data............................................................................................ 9
2. Safety ...................................................................................................................................................... 10
2.1 General Information....................................................................................................................... 10
2.2 Intended use .................................................................................................................................. 12
2.3 Safety during installation................................................................................................................ 13
2.4Wiring, screening, earthing............................................................................................................ 13
2.5 Electrical safety.............................................................................................................................. 14
2.6 Notes on wiring .............................................................................................................................. 15
3. Installation ............................................................................................................................................... 16
3.1 Location and climatic conditions.................................................................................................... 16
3.2 Unpacking and storage.................................................................................................................. 16
3.3 Fitting the sensor ........................................................................................................................... 17
3.4 Cleaning instructions...................................................................................................................... 17
4. Electrical connection ............................................................................................................................... 18
4.1 GUIDELINE for the electrical connection....................................................................................... 18
4.2 Design of the control...................................................................................................................... 19
4.3 Automatic detection of the operating mode................................................................................... 20
4.4 Error detection (Example).............................................................................................................. 21
4.5 Connection of external signal transmitters and sensors................................................................ 22
5. Operation................................................................................................................................................. 24
5.1 First commissioning ....................................................................................................................... 24
5.2 The configuration software KONSOFT.......................................................................................... 25
5.3 Reading out the tank guard LOG file ............................................................................................. 25
5.4 Setting the date and time............................................................................................................... 26
5.5 Operation in levels ......................................................................................................................... 27
5.6 Operating and display elements .................................................................................................... 28
5.6.1 Button functions ................................................................................................................ 28
5.6.2 Description of the LEDs .................................................................................................... 29

1. Introduction
105466 –TW-31-E - V1.9 - 06.04.2021 Page 3
6. Operation and fault handling....................................................................................................................30
6.1 Description of tank monitor operation.............................................................................................30
6.2 Milk removal YES or NO.................................................................................................................32
6.3 Handling multiple faults...................................................................................................................35
6.4 Display fault memory......................................................................................................................35
6.5 Listing fault memory and description..............................................................................................36
6.5.1 Critical tank monitor alarms (red).......................................................................................36
6.5.2 Informative tank monitor alarms (green)............................................................................37
6.5.3 System alarms...................................................................................................................38
6.5.4 System alarms external sensors........................................................................................39
6.5.5 Test alarm..........................................................................................................................39
7. Setting of parameters...............................................................................................................................41
7.1 GUIDELINE for the correct parameterization.................................................................................41
7.1.1 Enter customer and tank number ......................................................................................41
7.2 Change and save parameter values...............................................................................................42
7.3 Level “General tank monitor parameters” (h parameters) ..........................................................44
7.4 Level “Extended tank monitor parameters” (H parameters) ..........................................................48
7.5 Level “Alarm - Event assignment” (F parameters) ..........................................................50
7.6 Level “Hardware configuration” (A- parameters).........................................................52
7.7 Level “Sensor adjustment“ (C- parameters).........................................................56
7.8 Level “Service parameters” (E- parameters).........................................................57
7.9 Ebene “I / O test parameters” (o- parameters).........................................................58
8. Other informations ...................................................................................................................................60
8.1 Detection of mode “cooling” - parameter [h1].................................................................................60
8.2 Safety function: “First milk in the tank” [h2] ....................................................................................60
8.3 Detection of mode “Cleaning” - parameter [h4]..............................................................................61
8.4 Definition of term “milk temperature too high for too long” .............................................................62
8.5 Definition of term “cooling time” + target temperature first milking”................................................62
8.6 Activation delay tank monitor [H90]................................................................................................63
8.7 Sensor correction procedure ..........................................................................................................63
8.8 Function second temperature sensor.............................................................................................64
8.9 Setting of the level control ..............................................................................................................64
8.10 Monitoring of detergent dispenser..................................................................................................64
8.11 Function power pack + regular exchange ......................................................................................65
8.12 Monitoring of detergent dispenser..................................................................................................66
8.12.1 Cancellation of the recorded temperatures in the diagram................................................67
8.13 Test functions .................................................................................................................................67
8.13.1 Test alarm F99...................................................................................................................67
8.13.2 Function test "Do-Not-Load LED" and "external alarm light".............................................67
8.14 General measures when using electronic control systems............................................................68
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 4105466 –TW-31-E - V1.9 - 06.04.2021
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 TW-31 tank monitor. This manual contains all necessary
suggestions, information, recommendations and advice for the safe and proper in-
stallation and commissioning of the tank monitor. It is only with the knowledge of this
operating instruction that errors in the tank monitor 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 monitor.
When delivered, the parameterization of the TW-31 does not neces-
sarily correspond to the intended use. This must be adjusted accord-
ingly during the installation.
The setting or changing of parameters may only be carried out by the
system manufacturer or the service technician.
Basically, the installer of the system is responsible for the commission-
ing of the tank monitor.
Operation instruction for the operator
The plant engineers, the installer or the service technician must prepare operating
instructions for the operator of the tank monitor (farmer).
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 tank monitor or in case of any other work with the
tank monitor!
These instructions have been prepared with the utmost care. However, the infor-
mation contained herein is not an assurance of product characteristics.
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
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1.2 Limitation of liability
The proper function of the TW-31 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 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 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
- incorrect or improper parameterization
- 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 possible property damage.
Failure to observe this warning signs can lead to further damage to the system, loss
of data or damage to the milk.
Nature and source of danger
This warning signs warns of possible operating faults. Failure to observe these warn-
ing signs can lead to loss of data or damage to the milk.
Note
General notes contain application tips and particularly useful information, but no
warnings about dangers.
WARNING
WARNING
NOTICE
DANGER!
ATTENTION

1. Introduction
Page 6105466 –TW-31-E - V1.9 - 06.04.2021
1.4 Device description
The tank monitor TW-31 fully automatically monitors all processes (cooling, storage
and cleaning processes) in milk cooling tanks. The objective here is to be able to
remedy problems with the milk storage early enough by early alerting in order to
prevent economic damage.
The TW-31 can be connected to all conventional tank brands and different system
types such as VMS or common milking systems.
Automatic detection of the operating mode
The TW-31 detects independently the mode (cooling, cleaning or empty) of the con-
nected milk cooling tank. Depending on the mode it stores the temperature of the
tank at different intervals. If the temperatures are beyond the set limits, the farmer or
the tank driver is alerted visually as well as acoustically. The exact error cause can
be determined via the alarm code shown on the display.
Alarms
The TW-31 distinguishes between informative and critical alarms.
- The informative alarm (blinking green LED) signals to the farmer an improper
operation -> action required
- The critical alarm “DO NOT LOAD” (blinking red LED) addresses the driver of
the milk-collecting-truck. Together with the farmer the driver decides what to
do next.
In addition to the two warning LEDs, an external warning light, an audible signal
device or dialer can be connected.
You will find the description of the operation method in section 6.1.
Function monitoring
In addition to the temperatures the proper functioning of all agitators and the proper
cleaning process of the milk tank are monitored. In case of errors the corresponding
alarms are also generated.
Power failure
With the integrated power pack the temperatures are monitored and stored even in
the case of a power failure. Thus the TW-31 can continue its work during a power
failure and activate an alarm.
Data storage/-evaluation
The determined data of the last 300 days (max.) temperatures, alarms, operating
mode changes, etc.) are stored in the CSV-format and can thus be opened in other
programs.
The data can be read out by simply inserting a standard USB-stick into the USB
socket - without further operation of the tank monitor.
EMAIL or SMS remote maintenance modems
By an optional Email or SMS remote maintenance modem error messages can be
sent via Email or SMS to inform the farmer at an early stage.

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WELBA „KONSOFT"
For easier parameterization and updating of the TW-31 as well as for the evaluatiion
of the data determined Welba provides its PC Software "Konsoft", which is free of
charge. See section 5.2
NOTE: 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.
1.5 Type designation
The type designation of your controller is attached to the holder frame.
1.6 Item supplied
- Tank monitor TW-31 ready for connection
- Sensor TF1A-2
- Accompanying device documentation
- Electro circuit diagram
Any optional accessories ordered.
1.7 Dimensions
305
225
NOTICE

1. Introduction
Page 8105466 –TW-31-E - V1.9 - 06.04.2021
1.8 Technical data of control unit
Operating voltage
230V AC +/-10%, 50 Hz
Relay contacts
3 performance relays
max. switching current
1 x each 6A AC1 bei 250V AC
2 x each 10A AC1 bei 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
Switching status displays
3 mm LED
Number of sensor
1 or 2
Measurement range
-5° .. +95°C
Temperature resolution
0,1°C
Sensor input
for KTY 81-210 (optionally PT-100)
Water detection
via independent level monitor
Digital inputs
- for 230 V
- for low voltage
6 (via optocoupler)
6 (via optocoupler)
Interface
2x RS-485
1xx USB master (for USB stick only)
Connection
Plug-in screw connections
for cables up to 2.5 mm²
Housing
- Dimensions (LxBxH)
- Material
305 mm x 225 mm x 120 mm
Housing and cover ABS (UV-resistant)
screws PA
Protection
IP 65 (DIN EN 60529)
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.

1. Introduction
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1.9 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 sensor
Bush material
1.4301 (V2A)
Bush lenght
40 mm
Bush diameter
6,0 mm +/- 0,1
Cable material
PVC
Measurement range
-10 .. 70° C
Cabel lenght
standard 2 metres
40 mm
6,0 mm 6,1 mm

2. Safety
Page 10 105466 –TW-31-E - V1.9 - 06.04.2021
2. Safety
2.1 General Information
These operating instructions contain important technical and safety
information. Please read carefully before installation and before any
work on or with the tank monitor.
It is the duty of the party commissioning the system to ensure compli-
ance with the following guidelines.
Tank monitors must only be installed by an authorized electrician ac-
cording to the electro-technical rules (for example EN 60204, DIN VDE
0100/0113/0160). The local safety regulations have to be observed!
Access to the environment when connected must be restricted to spe-
cialised personnel.
The tank monitor may only be opened by an authorized electrician!
The tank monitor is not suitable for use in explosive atmospheres. Dan-
ger of explosion. Use only outside areas subject to explosive atmos-
pheres.
The tank monitor may not be exported to the USA without the manufac-
turer's express permission.
Do not simply confirm the alarms of the tank monitor.
It is essential to investigate and remedy the cause of the alarm in order
to avoid harmful effects on the milk!!!!!!
Even without an alarm message, the operator of the equipment has to
ensure the transportability of the milk!!!!
DANGER!
ATTENTION