Fabdec CB2-1L120000 Installation And Operation Manual Download Page 18

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6. Cleaning

6.1 Cleaning methods (cooling tank-configurations)

6.1.2 Circulation cleaning with two dosing pumps

Cleaning method for milk cooling tanks, where alkaline and acidic detergents are
supplied by separate dosing pumps.

Cleaning method for milk cooling tanks, where alkaline and acidic detergents are
supplied either by a drawer or a fixed beaker.

6.1.1 Circulation cleaning with a beaker

Drain valve

Pump

Heater

Agitator

Metering pump

for alcaline

detergent

Hot

water

Drain valve

Pump

Heater

Agitator

alcaline /

or acid

detergent

Cold

water

Hot

water

Cold

water

Hot water

valve

Cold water

valve

Hot water

valve

Cold water

valve

Metering pump

for acid

detergent

Page 18

Summary of Contents for CB2-1L120000

Page 1: ...Page 1 2020A Part No GPRO MAN V2 5 EN Installation and Operation Manual GALA KOOL Pro Universal Tank Control Standard version 2 5 REV F ...

Page 2: ...ns for testing the cleaning cycle 7 Tank monitor and general fault handling 7 Page 1 Description of tank monitor operation 30 7 Page 2 Tank monitor Milk removal YES or NO 32 7 Page 3 Tank monitor Handling multiple faults 35 7 Page 4 Tank monitor Display fault memory 35 7 Listing fault codes and their description Page 5 36 5 1 Critical tank monitor alarms red 7 Page 36 5 2 Informative tank monitor ...

Page 3: ...alarm 81 9 Page 10 Automatic convenience functions 81 11 Heating control 9 Page 82 9 Page 12 Function of pressure switch Effect on pump and heater 82 13 Air in the cleaning pump automatic 9 venting Page 83 9 Page 14 Level control setting 84 15 Detergent injection position 9 Page 85 16 Configuration of the different stages 9 Page cleaning 85 9 17 Setting of a break in the cleaning programme Page 86...

Page 4: ...ssing a button If the milk temperature exceeds the selected target temperature T1 or T2 by the hysteresis value the compressor contactor and agitator are switched on automatically Once the target temperature is attained the compressor contactor switches off while the agitator continues to run for the set after stirring period During cooling breaks the agitator switches on periodically in accordanc...

Page 5: ...g a power failure the control unit will restart in the mode it was in Robot interface Depending on the parameter settings the control unit includes a built in robot inter face with the following functions Robot start stop and Butterfly valve open closed These functions are controlled via the keypad Tank monitor function During the entire cooling and cleaning process the built in tank monitor keeps...

Page 6: ...endent 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 K1 must be fused in accordance with the con 3 nected components The connection of external voltages to the digital inputs can lead to the destruction of the control Caution All cables ...

Page 7: ...talled and commissioned the Gala Kool Pro The device is fitted with a resistance temperature sensor The controller is not suitable for use in explosive atmospheres Danger of explosion Use only outside areas subject to explosive atmospheres The fulfils the EC requirements for electromagnetic compatibility Gala Kool Pro EMC and the Low Voltage Directive LVD The safety components meet the VDE regulat...

Page 8: ...of components to the is set in digital inputs the A parameters A21 to A28 See section 8 10 GND capacitively decoupled from GND If the tank housing is to be used as one of the two level poles this pole must be connected to GND K13 K12 K11 K10 K9 K8 K7 K6 K5 K4 K3 K2 K1 10 9 8 7 6 5 E2 4 3 2 1 E1 E1NC A1 A2 22 23 24 25 26 27 28 29 30 31 RX TX B RX TX A RS 485 49 48 47 46 IO BUS 13 14 15 16 17 18 19 ...

Page 9: ... 0 50 C Storage temperature 20 70 C max humidity 75 no dew Technical data subject to change Page 9 4 Technical Data 4 2 Fitting the sensor When setting the temperature controller 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 Areference thermo meter should be used fo...

Page 10: ...Setting the time during normal operation Press OFF button a time is displayed the 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 c...

Page 11: ...larms Alarm configuration F parameter Here an individual behaviour can be assigned for each fault Configuration A parameter Determination Parameterisation of the hardware configuration I O test parameters o parameter Is intended for commissioning the control system The working level is used for operation and control in every day operation The is Gala Kool Pro parameterized in 10 different paramete...

Page 12: ...ode start cooling press 2x bypass the cooling start delay if set press long new start of the cooling start delay in cooling mode change target temperature T1 T2 AGITATOR button in OFF mode start mode continuous stirring in cooling mode press for 1 second Intermediate stirring SHORT press for 3 seconds Intermediate stirring LONG See also section Cooling mode at the end of WASHING button in OFF mode...

Page 13: ...or T2 T1 on Set target temperature for T1 is active T2 on Set target temperature for T2 is active LED ERROR flashing The control is in error mode and must be acknowledged with the OFF button LED END OF CLEANING TANK EMPTY permanent Cleaning successfully finished tank is ready for further filling LEDs in cooling mode LEDs in cleaning mode T1 T2 T1 T2 T1 T2 Page 13 Mode Cooling Agitation Washing Pne...

Page 14: ...MANU LLY by pressing the COOL button A DIGITALLY via digital input Remote start to cooling by robot or external button AUTOMATICALLY following cleaning if programmed Subject Cooling start delay If Cooling start delay P6 is programmed the compressor starts after a 1 P62 delay in order to prevent a small amount of milk in the tank from freezing During the cooling start delay LED operation mode COOLI...

Page 15: ... be blocked via parameter P80 The milk is now cooled down to the set target temperature and the agitator runs continuously during cooling If the milk temperature is already below the target just the agitator runs for the time being When the target temperature is reached the compressor switches off At the end of the set after stirring period c20 the agitator also switches off During cooling breaks ...

Page 16: ...ank outlet Press the WASH button To draw off a small quantity of milk tanks with pneumatic butterfly valve If milk is to be taken from the tank while cooling mode is running proceed as fol lows Parameter P32 Setting 1 Button function The butterfly valve opens immediately and remains open for as long as the button is held down When the button is released the valve closes immediately Parameter P32 S...

Page 17: ...ress OFF button for 3 seconds The cleaning programme switches to the stop phase ABL and F43 flash alternately in the display indicating outlet valve open All currently active relays are de energised apart from Cleaning active and Robot stop The outlet valve opens for a pre set time and then closes again The WASHING LED blinks code F43 flashes in the display yellow The control unit switches to OFF ...

Page 18: ...tanks where alkaline and acidic detergents are supplied either by a drawer or a fixed beaker 6 1 1 Circulation cleaning with a beaker K4 K3 K1 Drain valve K2 Pump Heater K6 Agitator Metering pump for alcaline detergent K7 K8 K5 K4 K7 Hot water K3 K1 Drain valve K2 Pump Heater K6 Agitator alcaline or acid detergent K5 Cold water Hot water Cold water Hot water valve Cold water valve Hot water valve ...

Page 19: ...alve K2 Pump Heater K6 Agitator K7 K8 Level 1 Level 2 K5 Feed container K4 K3 K1 Drain valve K2 Pump Heater K6 Agitator Level 1 Level 2 K5 Feed container K7 Metering pump for alcaline detergent K8 Metering pump for acid detergent K7 K8 Hot water Cold water Hot water Cold water Hot water valve Cold water valve Hot water valve Cold water valve Metering pump for alcaline detergent Metering pump for a...

Page 20: ... n parameters For the first parameter of each cleaning stage the following can be parameterised Water intake by level Adjustment of dosing times for detergents Heat up time variable until the set temperature is reached During the cleaning process the current programme step is displayed The flashing point indicates activity 6 Cleaning Level 1 Level 2 Level 1 Level 2 Level 1 Level 2 Level 1 Level 2 ...

Page 21: ...ne s which one cycle with acid detergent will be carried out The is always time controlled intake of the detergent uring dosing he display show D t s ALC alkaline detergent is dosed ACI acid detergent is dosed Here you can select whether the detergent is to be dosed in programme step D1 or D2 or in the feed container Parameter r20 6 Cleaning Cleaning stage Level 1 Level 2 Level 1 Level 2 Level 1 L...

Page 22: ...mally closed Applies to all cleaning stages Cleaning stage 1 PRE RINSE 1 Parameter r41 0 Cleaning stage 1 disabled Parameter r41 1 5 Cleaning stage 1 execute x times In case of cleaning method green it is set in programme step n10 how often the feed container is filled with water up to level 2 and water is pumped back up to level 1 As long as the rinsing pump is running the drain valve is open Wat...

Page 23: ...switch off Drain valve opens for the pre set time n26 See also n25 Cleaning stage 3 MAIN WASH 1 Parameter r43 1 not changeable In case of cleaning method green it is set in programme step n30 how often the feed container is filled with water up to level 2 and water is pumped backup to level 1 The drain valve remains closed up to cleaning step n35 n36 Settings for version 6 1 4 dosing in pre hopper...

Page 24: ...ch the drain valve opens agitator and cleaning pump continue to run Agitator and pump switch off Drain valve opens for the pre set time n36 See also n35 Cleaning stage 4 INTERMEDIATE RINSE 1 Parameter r44 0 Cleaning stage 4 disabled Parameter r44 1 5 Cleaning stage 4 execute x times In case of cleaning method green it is set in programme step n 0 how often 5 the feed container is filled with water...

Page 25: ...e pre set time r37 the control unit continues with the program but a fault report is displayed at the end See sec tion 5 3 F44 7 If a switch on delay r36 has been parameterized for heating heating starts only after this time has elapsed This is to ensure that water is in the heater Main circulation time The water circulates for the pre set time n54 During the main circulating time a post heating t...

Page 26: ...whether cold hot or mixed water is to be taken in Agitator and pump start to run Water circulates in the tank Another option is to select an additional water intake time using n73 Depending on the setting of the parameter r20 acidic detergent is injected at the end of the water intake time n72 or the subsequent water intake time n73 The duration of the detergent dosing is set in parameter n103 If ...

Page 27: ...e using n83 The water circulates for the pre set time n84 An additional time can be defined in parameter n85 in which the drain valve opens agitator and cleaning pump continue to run Agitator and pump switch off Drain valve opens for the pre set time n86 See also n85 Cleaning stage 9 RINSE OUT Parameter r4 0 Cleaning stage disabled 9 9 9 9 Parameter r4 1 5 Cleaning stage execute x times Water is t...

Page 28: ...leaning cycles to be executed consecu tively with the single step function NB An aborted cleaning counts here as a completed cleaning By repeatedly pressing the CLEAN button the cycle can now be ING progressed step by step Can be terminated via OFF at any time with drain phase button Tank function and alarms monitoring are deactivated Short wash program Set appropriate short wash sequence in param...

Page 29: ...Page 29 ...

Page 30: ...elay or the SMS function must be activated The tank monitor of the has the following alarm types Gala Kool Pro Critical tank monitor alarms red LED fault code in the display During cooling min and max milk temperature agitator function and stirring intervals duration of power failure milk temperature too high for too long During cleaning temperatures cleaning wash duration Informative tank monitor...

Page 31: ... button must be pressed several times See section 7 3 Informative alarm Critical alarm Informative and critical alarm is displayed as a blinking display code only System alarm critical alarm after RESET Turns off when cleaning cycle runs for at least 10 minutes Each alarm has its own display code Informative and critical alarms are also indicated by LED as follows Turns off when cleaning cycle run...

Page 32: ...awn off The farmer must be informed The farmer investigates and remedies the cause of the fault and presses the RESET button The farmer presses the RESET button again the green LED is now on continuously The informative alarm is accepted and deleted with the pushbutton Once the milk has been taken the driver starts the cleaning process NB If the informative alarm is not reset the green LED flashes...

Page 33: ...t table See section 8 9 The farmer and driver then decide together whether the milk can be transferred to the tanker despite the alarm The farmer first presses the RESET button to cancel the critical alarm The farmer presses the RESET button again the red LED is lit continuously The farmer then cancels the informative alarm the green LED turns off Once the tank is emptied the washing process must ...

Page 34: ...tical alarm codes are taken from the display and identified using the fault table See section 8 9 The farmer and driver then decide together whether the milk can be transferred to the tanker despite the alarm The farmer presses the RESET button to cancel the alarm The farmer presses the RESET button again the red LED is lit continuously Once the tank is emptied the washing process must be started ...

Page 35: ...t The first informative example F34 blinks in the display fault Identify the fault using the list of faults Press RESET button The green LED continues to flash in order to indicate that there are further informative faults The next informative fault example F20 flashes in the display When the last informative fault has been reset the green LED goes out while the red LED stays on permanently It is ...

Page 36: ... not reached Alarm is triggered if in the main washing stages the minimum water temper ature selected in H30 is not reached F12 Minimum cleaning temperature not maintained long enough Alarm is triggered if in the main washing stages the minimum water temper ature selected in H30 has not had enough time to act Minimum acting time H31 F15 Agitator fault in cooling mode milk not stirred Alarm functio...

Page 37: ...a power cut F31 Max time without cooling starts when cooling ends manually Safety function This is to prevent that after manual interruption of the cooling mode is forgotten to reactivate it or to start the cleaning after the milk removal Timer starts as soon as cooling mode is switched off manually The alarm is triggered if a new cooling period or washing cycle is not started within time h31 F32 ...

Page 38: ...cancelled using the OFF button F40 Safety switch for butterfly valve only if r10 1 or 2 washing stops outlet valve is opened for time n100 during the emptying phase the display alternates between F40 and AbL the red LED FAULT then flashes with error code F40 During washing the digital input for the tank outlet safety switch r10 was triggered Possible cause of fault manual butterfly valve on tank o...

Page 39: ... at the end of cleaning washing completed level electrode reports water the red LED FAULT flashes At the end of the draining phase there is still water in the tank Possible cause of fault Water valve has not closed is faulty Draining phase set too short Function is activated in parameter r33 F48 Timeout heating time during cleaning washing completed the red LED FAULT flashes During the heating pha...

Page 40: ...stirring unit activity although stirrer was switched on stirring unit activity although stirrer was not switched on F55 Timeout volume depended cooling start Timeout compressor downtimel in case of milk volume dependent cooling start delay See also parameter P55 Alarm is only active if parameter P61 is parameterized to 6 or 7 F56 Temperature sensor fault The control unit is not receiving any signa...

Page 41: ...lt no communication with the agitator monitoring module or only for module 003 Phase error or only for module 003 phase twisted when connected See also section 9 22 F61 SMS module fault no communication with GSM SMS Modul F62 External IO module fault 7 5 6 Test alarm F99 Test alarm see section 9 18 Page 41 ...

Page 42: ...ears If an incorrect code is entered the control switches back to the OFF mode 8 1 Change and save parameter values Gala Kool Pro is configured in 10 different parameter levels To change parameters in one of the lower levels enter the corresponding level code Working level for normal daily operation CODE General cooling parameters code C212 Extended cooling parameters code D345 General cleaning pa...

Page 43: ...tarts to run Note first release the arrow button In order to store the value in the memory and then the SET button Return to working level possible from any parameter Standard saving the values with Press both arrow buttons simultaneously The display shows STOR for a short time changes are accepted The control switches to the OFF mode the display shows the current time Return saving the values wit...

Page 44: ...ween agitator switching off and switching on again for the duration of the after stirring period selected c Duration of intermediate stirring SHORT 23 0 999 min 2 Period in minutes during which the agitator operates if the UP arrow button is pressed for during a cooling pause approx 1 second c Duration of intermediate stirring 24 LONG 0 999 min 10 Period in minutes during which the agitator operat...

Page 45: ... sensor 1 10 10 K A correction can be applied to the value measured by the sensor Then applies it cumulatively throughout the entire measurement range c92 Display actual temperature sensor 2 hidden if A50 0 c9 Sensor correction 3 sensor 2 10 10 K hidden if A50 0 A correction can be applied to the value measured by the sensor Then applies it cumulatively throughout the entire measurement range Soft...

Page 46: ...rget temperature T2 o C2 0 50 0 C 8 0 f r P15 Lower limit for hysteresis T1 o C10 0 1 30 0 K 0 1 f r P16 Upper limit for hysteresis T1 o C10 0 1 30 0 K 2 0 f r P17 Lower limit for hysteresis T2 o C11 0 1 30 0 K 0 1 f r P18 Upper limit for hysteresis T2 o C11 0 1 30 0 K 2 0 f r Agitator settings Range Default P22 Function intermediate stirring 0 2 1 see section 5 6 3 0 deactivated 1 short long 2 to...

Page 47: ...obot stopped Alarm Water detection in cleaning pipe Range Default Alarm prevention of water intake into tank during cooling mode see also section 9 9 P36 Milk transfer function settings 0 0 deactivated 1 level controlled high active when signal an input stops pumping with timeout 2 level controlled low active if no signal at the input stops pumping with timeout 3 only time P37 Milk transfer pump m...

Page 48: ...t values per liters of milk the compressor runs seconds 20 60 70 litres of milk 210 seconds compressor running time P54 Minimum milk quantity in the tank until 10 200 999 litres switching to regular cooling operation P55 Error message if no milk feed is detected for 0 300 min 60 X minutes from the last stop of the compressor a switchover to the regular cooling mode does not take place Cooling star...

Page 49: ...mode active after cooling start delay uses the times in P63 P64 0 1 0 0 deactivated 1 activated Compressor settings Range Default P70 Compressor stop via digital input 0 0 4 Possible control of the cooling start by robot 0 deactivated 1 ignal at the digital input blocks the compressor s 2 no signal at digital input blocks the compressor 3 as 1 with deactivation possibility via cooling button until...

Page 50: ...chover to T2 at time P82 and P83 with switch back after period P81 if only one time is to be used P82 and P83 must be set to the same time Manual switchover to T2 for period P81 by pressing the Cooling button In the case of 2 and 3 If T1 is active the LED for T1 is permanently on If T2 is active the LED for T2 flashes and shows that switch back to T2 will happen automatically 4 toggled externally ...

Page 51: ... 0 999 sec 0 n26 Drain time 0 999 sec 60 Running times cleaning stage 3 main rinse 1 hidden if r43 0 n30 Water intake by feed container displacement cleaning 0 6 0 n31 Water intake by level 1 0 1 0 n32 Water intake by time 0 999 sec 70 n33 circulation Additional water intake time 0 999 sec 40 n34 Main circulation time 0 999 sec 180 n35 Rinse out time 0 999 sec 0 n36 Drain time 0 999 sec 70 Switch ...

Page 52: ...ntake by time 0 999 sec 70 n63 circulation Additional water intake time 0 999 sec 40 n64 Main circulation time 0 999 sec 180 n65 Rinse out time 0 999 sec 0 n66 Drain time 0 999 sec 70 Running times cleaning stage 7 disinfection hidden if r47 0 n70 Water intake by feed container displacement cleaning 0 6 0 n71 Water intake by level 1 0 1 0 n72 Water intake by time 0 999 sec 60 n73 circulation Addit...

Page 53: ...emp main cleaning stage 1 alkal acid 0 99 9 C 4 0 8 hidden if r35 0 n107 Pre heat temp main cleaning stage 2 acid 0 99 9 C 4 0 8 hidden if r35 0 or 1 n108 Pre heat temp main cleaning stage disinfection 0 99 9 C 0 30 hidden if r35 1 or 2 n109 Post heating temp during circulation 0 99 9 C 40 0 in main cleaning stage 1 n34 hidden if r35 0 n110 Post heating temp during circulation 0 99 9 C 40 0 in mai...

Page 54: ...ee section and 15 6 2 9 Default 2 0 dosing in feed container displacement cleaning in cleaning diagram 1 position D1 2 position D2 in cleaning diagram r21 Detergent sequence in case of 3 cycles Default 1 if second main cleaning stage is deactivated 0 only alkaline 1 10 x times alkaline before one time acid r23 Setting of drain valve in pre rinse 2 during filling via water reservoir 0 drain valve c...

Page 55: ...ning stage activate alarm message F45 and alarm relays 2 Level 1 monitoring after each cleaning stage activate alarm message F45 and alarm relays 3 Level 2 monitoring only after the last cleaning stage activate alarm message F45 and alarm relays 4 Level 2 monitoring after each cleaning stage activate alarm message F45 and alarm relays r34 Inlet pipe water detection Max time above the level Default...

Page 56: ...an stage 7 isinfection D 1 4 1 r58 Valve selection clean stage 8 After rinse 1 4 1 r5 Valve selection clean stage inse 9 9 R out 1 4 1 1 Cold water 2 Warm water 3 Cold and arm water mixed w 4 Hot water 5 H and cold water ot water 6 H and warm water ot water 7 H and warm water and cold water ot water Selection of drain valve Range Default r60 Drain valve select clean stage 0 Rinse out 1 2 1 r61 Dra...

Page 57: ...wever unlimited impulses when rinsing cleaning stages 0 9 4 as 2 however unlimited impulses when rinsing cleaning stages 0 9 r81 Number of on off pulses cleaning pump im 3 Default Range 0 10 r82 ON pulse length cleaning pump im Default 3 Range 0 10 sec r83 OFF pulse length cleaning pump im Default 3 Range 0 10 sec Service settings for commissioning r92 Start cleaning at the beginning of cleaning s...

Page 58: ...Page 58 8 Setting of parameters ...

Page 59: ...n above the respectively set limit value E6 the last cleaning temperature reached 0 99 9 C Displays the maximum temperature during the last cleaning cycle E15 voltage battery 0 0V 12 0V Display the current voltage battery Only if optional pack is installed power General cooling parameters code C212 Extended cooling parameters code D345 General cleaning parameters code B454 Extended cleaning parame...

Page 60: ...the counter from cooling start h31 Max cooling interruption 0 deactivated F31 0 999 min 60 h32 Max time in off mode after cleaning F32 0 min 0 deactivated 5000 600 h33 Min cleaning cycle F33 0 250 h 78 0 deactivated h35 Detergent monitoring alkaline by float switch F35 0 2 0 0 deactivated 1 high aktiv 2 low aktiv h36 Detergent monitoring acid by float switch F36 0 2 0 0 deactivated 1 high aktiv 2 ...

Page 61: ...g h41 1 milk time 00 00 23 59 h42 2 milk time 00 00 23 59 h43 3 milk time 00 00 23 59 Setting for monitor LOG files h89 Recording additional information by Tank Monitor 0 3 0 0 deactivated 1 temperature 2 2 agitator power monitoring 3 no function Settings tank monitor LOG files Range Default h90 Selection period in days of the recording data onsoft K 1 365 90 h91 Logging intervals cleaning mode in...

Page 62: ...Minimum cleaning temperature F11 0 50 0 C 40 0 0 deactivated H31 For min time F12 0 999 min 2 0 deactivated Agitator monitoring H40 Agitator fault in cooling mode no of milk stirring 0 deac F15 0 999 min 450 H41 Timeout No agitator 0 deactivated F16 0 999 min 60 H42 Min run time agitator to H41 F16 0 500 sec 60 H parameters Code F94A General cooling parameters code C212 Extended cooling parameters...

Page 63: ... FFFF 0 Information on password protection The level extended tank monitor parameters can additionally be protected with another password For this purpose a 4 digit password not 0000 must be entered in parameter H98 In order to activate the password protection the password in parameter H99 must be repeated exactly If the level code is entered again the password is requested afterwards Page 63 ...

Page 64: ...itor parameters code 4711 Extended tank monitor parameters code F94A Alarm configuration code FFFF Configuration code A384 I O test parameters code 10E5 Switch to level Alarm configuration See section 8 1 8 9 Alarm Event assignment F parameters Level 1 2 3 4 5 6 7 8 9 10 11 12 13 Alarm effect Informativ tank monitor alarms green LED Critical tank monitor alarms red LED In this level each fault mes...

Page 65: ...rfly valve 1 13 6 F41 pressure switch cleaning pipe 1 13 6 F42 thermo cleaning pump protection 1 13 6 F43 manual interruption of cleaning 1 13 6 F44 timeout water intake by level 1 13 6 F45 water in the tank after draining 1 13 6 F46 water inlet time monitoring 1 13 6 F48 timeout heating time cleaning 1 13 6 F49 over temperature heater 1 13 6 F51 ank overflow protection t 1 13 6 F52 water in tank ...

Page 66: ...consideration to how you want to allocate all the various components to the relays and digital inputs Allocation of output relays In A1 toA12 the functions needed are assigned to the output relays Allocation of digital inputs In A21 toA28 input functions are assigned to the digital inputs Incorrectly set parameters can lead to serious malfunctions and damage to the milk cooling tank General coolin...

Page 67: ...relay K1 5 6 6 0 2 A2 assignment relay K2 5 5 5 0 2 A3 assignment relay K3 5 10 10 0 2 A4 assignment relay K4 5 9 9 0 2 A5 assignment relay K5 5 12 12 0 2 A6 assignment relay K6 5 4 0 2 21 A7 assignment relay K7 5 8 8 0 2 A8 assignment relay K8 5 3 3 0 2 A9 assignment relay K9 5 7 7 0 2 A10 assignment relay K10 5 1 11 0 2 1 A11 assignment relay K11 5 2 2 0 2 A12 assignment relay K12 5 4 0 2 1 18 A...

Page 68: ...button 23 Transfer function level sensor 24 Multifunction time relay 25 External T1 T2 toggle switch 26 Milk withdrawal button 27 Off Mode button 28 Wash Start button 29 Cooling Start button 30 Manual Agitation Start button 31 Robot Stop button 32 Outlet Valve Open Close button 33 Tank Monitor Reset button Range Default A21 assignment digital input 1 0 33 5 A22 assignment digital input 2 0 33 0 A2...

Page 69: ... alarm if closed 1 closing contact alarm if open non volatile 2 opening contact alarm if closed non volatile 3 opening contact alarm if opened A46 onfiguration alarm tank monitor C 0 see output function 1 previous page 0 closing contact alarm if closed 1 closing contact alarm if open non volatile 2 opening contact alarm if closed non volatile 3 opening contact alarm if opened A47 Configuration red...

Page 70: ...gitator 2 phases 400V 15 Two agitators 2 phases 400V over second module Note addressing Agitator monitoring without a separate module If monitoring is made via inductive agitator agitator sensor max 2 channels 8 one agitator 9 two agitators If monitoring is made via switch contact agitator of the Gala Kool Pro 10 one agitator 11 two agitators A73 ctivation GSM alarm module A monitoring 0 0 4 1 act...

Page 71: ...0 1 0 0 deactivated 1 activated Multifunction relay settings Range Default A86 Multifunction relay timer 0 6 0 0 eactivated d 1 ON delay T1 2 OFF delay T2 3 On and off delay T1 and T2 4 switch on pulse T1 5 OFF pulse T2 6 Clock T1 on T2 off A87 Multifunction time relay input assignment 0 25 0 0 Digital input 1 25 Every output function A1 can be used as a input signal A88 Multifunction time relay T...

Page 72: ...ternal relay 5 0 1 0 0 Off 1 On Meaning of the parameters All inputs and outputs of the individual components can be tested in this parameter level For this purpose the corresponding relays are set to I or 0 N However the two relays for the supply of acid and alkaline detergents are locked B against each other since never acid and alkaline detergents may enter the tank never together This operatin...

Page 73: ... Test digital input 5 0 1 o 26 Test digital input 6 0 1 o 27 Test digital input 7 0 1 o 28 Test digital input 8 0 1 o 29 Test of external digital input 1 0 1 o 30 Test of external digital input 2 0 1 o 31 Test of external digital input 3 0 1 o 32 Test of external digital input 4 0 1 o 33 Test of external digital input 5 0 1 0 switched 1 unswitched Test level inputs Range Default o 41 Level 1 10 10...

Page 74: ... a pneumatic butterfly valve this must be set in parameter A40 The corresponding function must then be assigned to a relay in one of parameters A1 to A1 Only then can the valve be opened or closed manually via the Butterfly valve 3 button Convenience function only with pneumatic butterfly valve Significance if the COOLING button is pressed in OFF mode the pneumatic butterfly valve is automatically...

Page 75: ... r10 Parameter r10 is not available if a pneumatic butterfly valve is configured in A40 Fault indication The butterfly valve LED flashes if in OFF mode the COOLING button is pressed while the valve is open the WASHING button is pressed while the valve is closed If the butterfly valve is closed in washing mode the cycle is interrupted provided r10 2 is configured Valve open 9 Other Information ...

Page 76: ...tivated while the robot is switched off the robot will start automatically In cooling mode switching to OFF mode the robot remains active If the button Robot Stop is pressed for 3 seconds the robot is stopped and cooling mode ends In cleaning mode The button Robot Stop does not have a function If a fault occurs during washing the robot is stopped When washing is successfully completed the robot is...

Page 77: ...e If the cleaning release in parameter r27 is set to active and the CLEANING button is pressed the display CLEn shows the mode LED lashes washing f As soon as the robot is released the cleaning process is started the mode LED remains lit permanent and the programme step for the cleaning process appears in ly the display Note The function can be deactivated by pressing the OFF key during the waitin...

Page 78: ...k pump impulses 5 periodic cooling phases after a number of milk pump impulses Cooling starts after the set number of milk pump impulses in the form of pre set periodic cooling phases at set intervals before then switching over to temperature regulation 6 Milk volume dependent cooling start delay from start cooling P50 P 55 Compressor starts according to the parameterized milk quantity in the tank...

Page 79: ... Depending on setting 6 or 7 the calculation of the milk quantity starts already Setting 6 only with the beginning of the cooling mode Setting 7 or in the cleaning mode Setting 7 is selected if during the cleaning of the main tank milk has already been milked into a buffer tank and this milk is pumped into the main tank after the end of cleaning to start the cooling mode This amount of milk is add...

Page 80: ...en using a robot If the milk cooling tank is filled by a robot filling from below takes place via the tank outlet For some tank types the temperature sensor is positioned very close to the tank outlet For this reason an increase in the milk temperature is measured during filling although the actual milk temperature has not yet risen due to a heat bubble at the outlet by the type of filling This le...

Page 81: ...ill be monitored during cooling In the case of systems with robot operation depending on the layout of the system the washing line may be connected permanently If for example a water valve jams and the water level rises water could be forced into the tank via the washing line In this case once the electrode is reached an alarm is given and the outlet valve is opened All relevant settings are found...

Page 82: ...r the heater can be set This applies only at the beginning of the heating up phase depending on whether this starts in programme stage D2 or H This delay can be used to prevent the system switching on to the next programme stage too soon if pre heated water e g from a boiler is cooled down by the cold walls of the tank and needs to be reheated or if as a result of pre set pump venting the pressure...

Page 83: ...sure via pressure switch After each switch on impulse the pressure switch is contacted If no pressure has been built up a further impulse interval follows If there is pressure in the line the washing pump switches on and runs continuously Parameter r81 is used to limit the maximum number of impulses r81 Max number of switch on and switch off impulses r82 Duration of switch on impulses A r83 Durati...

Page 84: ...ustment during cleaning only for the service technician This method works only when sensitivity has been set too low If at the start of the first washing stage water intake until level is reached no water is detected despite the level electrode having been reached water continues to enter The service technician can now adjust the sensitivity setting Hold down the SET button for 4 seconds The water...

Page 85: ...termine whether the cleaning cycle generally includes one or two main rinses r45 1 per cleaning cycle 1 alkaline 1 acidic wash wash r45 0 an acidic clean follows after x alkaline cleaning cycles Set x in r21 16 Configuration of the different cleaning stages 9 15 9 Detergent injection position Parameter r20 is used to determine whether the detergent is added in programme stage D1 or D2 or in the fe...

Page 86: ...the function 15 Start from rinse stop to a digital input A21 to A28 after a certain amount of time enter this time in parameter r72 at a certain time enter them in parameter r73 A parameterized elapsed time of the break or the countdown timer is displayed alternately with STOP 9 18 Function test alarm The function test alarm is required to test the impacts of an error on the parameterized outputs ...

Page 87: ...eration modes during the commissioning without activating false alarms Activation Delay is activated by the start of the and suppresses all errors from F1 Gala Kool Pro to F38 for a pre set time with the exception of F30 After expiration of the set time the tank monitor is set to the basic condition and then activated Page 87 ...

Page 88: ...ns are maintained during a power failure provided the optional power pack is installed see 8 15 Depending on the parameter settings the fault code is also displayed 21 Power pack optional 9 Installation Only the suitable original power pack may be connected Fabdec Connect the power pack to terminals observe polarity 40 41 The optional power pack offers enormous advantages for the Gala Kool Pro The...

Page 89: ... with 400VAC ESVAW 003 A The monitoring module is determining the power input independently for each connected motor and hereof it will be deduced whether the respective motor rotates and whether it runs with or without load so that a defective stirring wing can be de tected for example The module has to be configurated in parameter A71 For different applications different monitoring modules are a...

Page 90: ... practice this is possible only with difficulty as even a normal contactor without interference suppression produces interference pulses of up to 3 0 kV For this reason we recommend that the following principles be taken into account during installation Try to eliminate all sources of interference by carrying out interference suppression and minimising the interference level Radio interference sup...

Page 91: ...tage occurring can for example be limited by using self induction diodes varistors or suppresser diodes The diagram on the left shows one possibility using a self induction diode AC voltage In the case of a c voltage interference suppression as described above is not possible Instead an RC combination must be used An RC filter must be connected as directly as possible to the inductance in order to...

Page 92: ...rotected against excessive voltages for which mainly varistors RC combinations or choke coils are used The use of zero voltage switches is also recommended The suggestions made represent only a few of the possible ways of protecting a microprocessor controlled regulator system from interference The suggested measures have the advantage that they will increase the lifetime of the devices as lower i...

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Fabdec CB2-1L120000, Installation And Operation Manual

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