Fabdec DARI-KOOL GALA-KOOL Pro Installation And Operation Manual Download Page 1

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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

Summary of Contents for DARI-KOOL GALA-KOOL Pro

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: ...s 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 Handl...

Page 3: ...larm 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 Pag...

Page 4: ...sing 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 tempe...

Page 5: ...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 functi...

Page 6: ...ndent 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...

Page 7: ...alled 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...

Page 8: ...f 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...

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 wheneve...

Page 10: ...etting 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...

Page 11: ...arms 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 paramet...

Page 12: ...de 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 c...

Page 13: ...r 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...

Page 14: ...ANU 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 Cool...

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 ag...

Page 16: ...nk 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 Paramet...

Page 17: ...ess 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 ap...

Page 18: ...anks 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 a...

Page 19: ...lve 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 Mete...

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 tempe...

Page 21: ...e 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...

Page 22: ...ally 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...

Page 23: ...witch 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...

Page 24: ...h 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...

Page 25: ...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 star...

Page 26: ...hether 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 sett...

Page 27: ...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...

Page 28: ...eaning 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 pr...

Page 29: ...Page 29...

Page 30: ...lay 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...

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 RESE...

Page 32: ...wn 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 continuous...

Page 33: ...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 a...

Page 34: ...ical 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 th...

Page 35: ...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 furth...

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 triggere...

Page 37: ...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 star...

Page 38: ...ancelled 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 a...

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 h...

Page 40: ...tirring 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 mil...

Page 41: ...t 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 communicatio...

Page 42: ...ars 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...

Page 43: ...arts 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 Pr...

Page 44: ...een 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 agi...

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...

Page 46: ...get 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...

Page 47: ...bot 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...

Page 48: ...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 co...

Page 49: ...ode 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 coo...

Page 50: ...hover 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...

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...

Page 52: ...take 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 cle...

Page 53: ...mp 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...

Page 54: ...e 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...

Page 55: ...ing 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...

Page 56: ...n 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...

Page 57: ...ever 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 pul...

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

Page 59: ...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 cur...

Page 60: ...he 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...

Page 61: ...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 temperatur...

Page 62: ...inimum 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 m...

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...

Page 64: ...tor 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...

Page 65: ...fly 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 th...

Page 66: ...onsideration 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 Allo...

Page 67: ...elay 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 assignmen...

Page 68: ...utton 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...

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 functio...

Page 70: ...itator 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...

Page 71: ...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...

Page 72: ...ernal 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...

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...

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 manu...

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...

Page 76: ...ivated 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...

Page 77: ...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...

Page 78: ...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...

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...

Page 80: ...n 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...

Page 81: ...ll 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...

Page 82: ...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...

Page 83: ...ure 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 p...

Page 84: ...stment 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 wa...

Page 85: ...ermine 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...

Page 86: ...he 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...

Page 87: ...ration 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 t...

Page 88: ...s 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 Installatio...

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 ru...

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...

Page 91: ...age 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...

Page 92: ...otected 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...

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