WELBA TW-32 User manual

1. Introduction
106106 –TW-32-E - V1.7 - 06.04.2021 P6age 1
Tank monitor
TW-32
for two separate milk tanks
Quick start for the farmer
Measuring - Controlling - Regulating
All from the same source
Programmable via
configuration software
WELBA „KONSOFT"

1. Introduction
Page 2 106106 –TW-32-E - V1.2 - 06.04.2021
1. Introduction................................................................................................................................................ 3
1.1 Information about this operating instructions................................................................................... 3
1.2 Device description............................................................................................................................ 3
1.3 Warning notices in these operating instructions.............................................................................. 4
1.4 Limitation of liability.......................................................................................................................... 4
1.5 Function power pack + regular exchange........................................................................................ 5
2. Operation................................................................................................................................................... 6
2.1 Setting the date and time................................................................................................................. 6
2.2 Operating and display elements ...................................................................................................... 7
2.2.1 Button functions .................................................................................................................. 7
2.2.2 Description of LEDs ............................................................................................................ 8
2.3 Reading out the tank guard LOG file ............................................................................................... 9
3. Operation and fault handling................................................................................................................... 10
3.1Description of tank monitor operation............................................................................................ 10
3.2 Optical presentation of alarms....................................................................................................... 11
3.3 Milk removal YES or NO................................................................................................................ 12
3.4 Handling multiple faults.................................................................................................................. 15
3.5 Display fault memory ..................................................................................................................... 15
3.6 Listing fault memory and description ............................................................................................. 16
3.6.1 Critical tank monitor alarms (red)...................................................................................... 16
3.6.2 Informative tank monitor alarms (green)........................................................................... 17
3.6.3 System alarms .................................................................................................................. 19
3.6.1 System alarms external sensors....................................................................................... 19
4. Cleaning instructions............................................................................................................................... 20
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
106106 –TW-32-E - V1.7 - 06.04.2021 P6age 3
1. Introduction
1.1 Information about this operating instructions
This quick start is for the operator of the tank monitor. The document comprises all
instructions and information for the operation of the tank monitor.
Read this document carefully and follow the instructions provided to ensure a smooth
operation of the. In addition, the local accident prevention regulations and general
safety regulations for the application area of the tank monitor must be observed.
1.2 Device description
The tank monitor TW-32 monitors simultaneously and fully-automtatic all processes
(cooling, storage and cleaning process) of two separate 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.
Automatic detection of the operating mode
The TW-32 detects independently the mode of the connected milk cooling tanks
(cooling, cleaning or empty). Depending on the mode it stores the temperature of the
tank. If the temperatures are beyond the set limits, the farmer or the tank driver is
alerted visually as well as acoustically. The exact cause of the fault of the respective
tank can be determined via the alarm code shown on the display.
Alarms
The TW-32 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 3.1.
Function monitoring
In addition to the temperatures the proper functioning of all agitators and the proper
cleaning process of the milk tanks 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-32 can continue its work during a power
failure and activate an alarm.

1. Introduction
Page 4 106106 –TW-32-E - V1.2 - 06.04.2021
to section 1.2: Device description
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.
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.
1.4 Limitation of liability
The proper function of the TW-32 depends on many external factors on
which the manufacturer has no influence. The manufacturer accepts no
liability for any damages on the milk cooling tanks, 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 tanks) nor the driver of the milk collecting truck from the duty of
WARNING
WARNING
NOTICE
DANGER!
ATTENTION

1. Introduction
106106 –TW-32-E - V1.7 - 06.04.2021 P6age 5
care. Both parties have to ensure that the milk is transportable before
it is removed from the tanks.
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 setting or changing of parameters may only be carried out by the
system manufacturer or the service technician!
Important information on operation
The tank monitor must not be operated, when
- the housing is open or damaged
- the front foil is damaged (leaking)
- the time and date are not set correctly
If four bars appear in the display after a longer power failure, the time
setting is lost and must be set again! See section 2.1
No liquid may get inside the housing!
1.5 Function power pack + regular exchange
Charged (!) Batteries must be used at all times for the tank guard to
function properly!
The batteries are used to maintain the tank guard function in the event of a power
failure. During the power failure, the error code (F30) flashes in the display.
Fault message (F39)
If the fault message (F39) appears, the battery voltage is too low. The batteries can
be removed and recharged by a qualified electrician. Are the batteries older than two
years => replace!
IMPORTANT NOTICE ABOUT THE ACCUMULATORS
The life of the accumulators is limited. The built-in accumulators must
be replaced by new ones every two years at the latest.
Only (!) charged accumulators of the following specification may be
used: 1.2 V NiMh - size AA (min. 2.000 mAh)
Since the tank guard may not be opened by laypeople, the replacement
of the batteries may only be carried out by a qualified electrician
DO NOT USE BATTERIES !!! EXPLOSIVE !!!!!
DANGER!
ATTENTION
WARNING

2. Operation
Page 6 106106 –TW-32-E - V1.2 - 06.04.2021
2. Operation
2.1 Setting the date and time
During the "standard operation" - i.e. in case of no fault messages - the current
time is indicated. The right display remains dark.
In the event of a power cut the date and time are retained for up to 5 days. After
that they must be re‑entered.
When the power is connected...
... there are two possible displays:
1) Time is lost: 4 dashes are shown:
The date and time must be re-entered. Proceed as follows:
Press one of the arrow keys: the year appears, flashing.
Set the time as described below.
2.) Time is still preserved:
During initialisation, 4 rotating bars are shown, then the current firmware appears
briefly, then the time is displayed. If it is not correct, adjust it as follows.
Setting the time during normal operation
Press the SET button: a time is displayed.
If the correct time is displayed, no further steps are necessary.
If the wrong time is displayed
Hold the SET button down until the year appears, flashing.
(in between, the tank temperature is shown briefly)
Use the arrow keys to set the correct year
Press the SET button: the month appears, flashing.
Use the arrow keys to set the correct month.
Press the SET button: the day appears, flashing.
Use the arrow keys to set the correct day.
Then set the hour and minute displays in the same way.
When finished press the SET button.
The setting is finished. Depending on the operation mode of the cooling tank the
display shows the current temperature in the tank or the time.
INFORMATION: Switching to summer- / winter time
The tank monitor can be configured for "automatic summer / winter time change-
over". Talk to your service technician.
Year
Date
Time
NOTICE

2. Operation
106106 –TW-32-E - V1.7 - 06.04.2021 P6age 7
2.2 Operating and display elements
2.2.1 Button functions
In case of a trouble-free working process the TW-32 does not require any handling
with the following exception:
- in case of setting the clock (see section 2.1)
- in case of reading and confirming error codes (see section 3.5).
„SET“ button
Hold for 3 seconds: set the date and time
„ARROW BUTTONS“for setting the time or adjusting parameters
„RESET“ button for the respective tank
Operation by the driver of the milk-truck
Confirmation of the message “Do not load”. See section 6.2
ALARM-TEST -> Press reset button for 5 seconds: the alarm will go off for 10
seconds.
Button „INFO“ for the respective tank
Serves for the parameterization of the parameters [h / H / F] to switch between
tank 1 and tank 2. See section 7.2.
If one of the two red LEDs reports faults:
Press INFO-button: Fault code is displayed.
On the "standard display"
the current time is indicated
on the left display, the right
display remains dark.
Tank 1

2. Operation
Page 8 106106 –TW-32-E - V1.2 - 06.04.2021
2.2.2 Description of LEDs
Display of the modes for the respective tank
“TANK EMPTY” detected
After a successful cleaning the tank can be filled with milk.
Operating mode “COOLING” detected
Cooling operation is active
Operating mode “CLEANING” detected
The cleaning operation is active
All LEDs off
Check the tank content
Tank monitor for the respective tank
LED (green) ”MILK COLLECTION OK”
permanent
blinking
off
everything is ok –milk can be loaded
informative alarm
a) if red LED is flashing or blinking
b) after the confirmation of an informative alarm
LED (red) ”DO NOT LOAD!”
blinking
permanent
critical alarm
critical alarm –has already been confirmed
Data transfer
LED (blue) "Data”
blinking
permanent flashing
and goes off after 5 sec.
off
USB-stick inserted: Data are transferred
USB-stick inserted:
Data transfer successfully completed
No USB-stick inserted
For the procedure for reading out the LOG files, see next page.

2. Operation
106106 –TW-32-E - V1.7 - 06.04.2021 P6age 9
2.3 Reading out the tank guard LOG file
Proceed as follows:
Insert a standard USB stick (FAT-32) into the USB socket of the tank monitor:
- The blue "DATA" LED begins to look slowly after a short time =>
The tank monitor LOG file is transferred to the USB stick!
Depending on the evaluation period [parameter h90], this transfer can take
several minutes.
- Has the data transfer been completed without faults:
The blue "DATA" LED lights up permanently for approx. 5 seconds and then
goes out.
- If the data transfer is faulty:
The blue "DATA" LED flashes quickly for approx. 5 seconds and then goes
out.
Try again or use a different USB stick.
If the LED has gone out: remove the USB stick and close the cover cap tightly.
File names of the tank monitor LOG files:
When reading out the tank monitor data on a USB stick, the tank monitor automati-
cally defines the file name of the data file:
DATA-000.CSV
If this file name is already on the stick, the next higher number is used:
DATA-001.CSV
The files on the USB stick can be displayed with the Welba KONSOFT.
NOTICE

3. Operation and fault handling
Page 10 106106 –TW-32-E - V1.2 - 06.04.2021
3. Operation and fault handling
3.1 Description of tank monitor operation
During the entire cooling and cleaning process the tank monitor checks the operation
of all processes of both tanks to guarantee the perfect condition of the milk. Errors
are displayed flashing on the respective display via corresponding error codes. De-
pending on the type of alarm two LEDs (red and green) flash or blink additionally.
In case of errors which may jeopardise the milk quality, the problem is indicated by
the respective red LED as a “critical alarm”. In this case milk must not be filled into
the respective tank unless a careful check has been carried out!
The tank monitor “knows” the following alarm types:
Critical tank monitor alarms (red LED + error code in the display)
During cooling mode:
- minimum and maximum milk temperature
- agitator function and stirring intervals
- duration of power failure
- milk temperature too high for a long period of time
During cleaning:
- cleaning temperatures
- cleaning time
Informative tank monitor alarms (green LED + error code in the display)
During cooling mode:
- milk temperature too high for a long period of time
- milk temperature too low
- malfunction agitator and agitator times
- maximum time until next cleaning
- duration of the power failure
During cleaning:
- cleaning temperatures
- detergent dosage and exposure time
Additional system-alarms (only error code on display)
(Depending on parameterization they can be both, critical or informative).
During cooling mode:
- cooling time first milking
- broken sensor
- short-circuit of sensor, etc.
During cleaning:
- monitoring of butterfly valve, rinsing pump,
cleaning pump etc.
- times for water intake and outlet
- heating times, etc.
A list of all system-alarms and their corresponding configuration can be found in
section Fehler! Verweisquelle konnte nicht gefunden werden.