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7. Tank monitor and general fault handling

Page 32

Informative alarm -

Milk may be drawn off.

Green = flashing
Red = off

Informative alarm
(

)

Press RESET button

7.2

collection

Tank monitor: Milk

YES or NO

No alarm –

Milk may be drawn off.



The driver goes to the

and checks the tank monitor.

Gala-Kool Pro

If the green LED is on, milk may be drawn off.



Once the milk has been taken, the driver starts the cleaning process.



The driver goes to the

and checks the tank monitor.

Gala-Kool Pro

The green LED is flashing – an error code is displayed.
Milk can be drawn 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 and the error code con-
tinues to be displayed -> even after the next cleaning cycle.

Examples of use of tank monitor.

Green = on
Red = off

No alarm

Informative alarm

after RESET

Green = on
Red = off

CAUTION:

Do not simply cancel a tank monitor alarm.

It is essential to investigate and remedy the cause, in order to avoid a
harmful effect on the milk.

Содержание DARI-KOOL GALA-KOOL Pro

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 29: ...Page 29...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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