Академический Документы
Профессиональный Документы
Культура Документы
db^ c~ q J q K
Contents
1
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
1.2
4
5
1.3
1.4
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
2.2
7
8
2.3
2.4
8
9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1
3.2
Correct applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Changes to the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3
3.4
3.5
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1
4.2
4.3
4.4
4.5
4.6
Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Information on disposing of packing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1
5.2
5.3
5.4
Initial Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1
6.2
6.3
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1
7.2
7.3
7.4
7.5
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Agitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5.1
7.5.2
7.5.3
7.5.4
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21
21
22
22
23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.1
8.2
8.3
8.4
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.1
9.2
10
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
11
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11.1
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11.2
Quick-reference guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3300-9001-520
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Preface
Information on the instructions
Preface
1.1
They should be kept close at hand and remain with the equipment even if
the equipment is sold.
We reserve the right to make changes due to technical developments in the data
and images given in this manual.
Reproduction, translation or copying in any form, including extracts, requires
written authorization from WestfaliaSurge.
Abbreviations, units, specialist terms, special names or specialist terminology
are explained in more detail in the Appendix.
Pictograms used
This pictogram indicates information that will help towards a better
understanding of the working processes.
This pictogram indicates a special tool required for installation.
A correction bar in the margin indicates changes to the previous
edition.
This pictogram refers to another document or chapter.
If a manual number is given, the middle 4 figures indicate the language, as
follows:
Language
Language
Language
-9000- German
-9001- English (Great
Britain)
-9013- Dutch
-9015- English (America)
-9032- Serbian
-9034- Slovakian
-9002-9003-9004-9005-9007-9008-
-9016-9021-9022-9023-9024-9025-
-9036-9038-9039-9040-9041-9043-
French (France)
Italian
Romanian
Spanish
Swedish
Norwegian
Polish
Danish
Hungarian
Czech
Finnish
Croatian
Lithuanian
Portuguese (Brazil)
French (Canada)
Latvian
Estonian
Spanish (North
America)
-9009- Russian
-9027- Bulgarian
-9010- Greek
-9029- Slovene
Possibly not all above-mentioned languages are available.
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Preface
Customer service
1.2
Manufacturers address
WestfaliaSurge GmbH
Siemensstrae 25-27
D-59199 Bnen
Deutschland
Tel.: +49 (0) 2383 / 93-70
Fax: +49 (0) 2383 / 93-80
e-mail: contact@westfalia.com
www.westfaliasurge.com
1.3
Customer service
If necessary, please contact your nearest authorised technical dealer.
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Preface
Declaration of Incorporation
1.4
Declaration of Incorporation
Declaration of Incorporation in accordance with the Machinery Directive:
D 2006/42/EC - Appendix:II B
Manufacturer:
Product category:
Name / Model:
A4
The named product is in conformity with the requirements of the following European directives:
2006/95/EC
Low voltage guideline
2004/108/EC
Electromagnetic compatibility directive
Conformity with the requirements of these directives is testified by complete adherence to the following
standards:
D
Attention!
We would point out that start-up is not permitted until it has been established that the
machine/installation in which this product is installed, meets the requirements of the guideline on which
it is based.
Person responsible for compiling the
relevant technical documents:
Bnen, 03.12.2009
Josef Schrer
GEA WestfaliaSurge GmbH
Siemensstrae 25-27
D-59199 Bnen (Germany)
+49 (0) 2383 / 93-70
Reinhard Frenser
(Head of Research and
Development)
The undersigned is acting by virtue of power of attorney from the management of:
GEA WestfaliaSurge Japy SAS, Route de Gray, B.P. 18, F-21850 Saint Apollinaire (France)
This declaration certifies compliance with the guidelines indicated, but does not establish any guarantee in the sense of paragraphs
443, 444 BGB.
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Safety
Owners obligation of care
Safety
2.1
Anyone who has to carry out work on the product can look at the instructions
at any time.
Specific rules have been set up for its use, which also take account of the
safety aspects.
The product
- Should only be used for its intended purpose.
- Should only be used if it is in perfect operating condition and, in
particular, the safety equipment should be regularly checked to make
sure it is in perfect operating condition.
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Operating personnel who require training may only work on the product
under the supervision of an experienced person. The successful completion
of training is to be confirmed in writing.
Safety signs, plates and decals, which are attached to the product, must be
replaced immediately if they become illegible or lost!
All safety or warning instructions applied are not removed and remain
legible.
Safety
Basic safety instructions
2.2
2.3
There are risks involved in the operation and maintenance of equipment for
dairy farms. For your own safety, read and follow the operating manual
carefully (especially the section entitled Safety information)!
When working with cleaning and disinfecting agents observe the notes on
dangers and protective measures (risk of caustic burns)!
When working with products from other manufacturers always observe the
warnings from the safety data sheets and operating instructions from the
product manufacturer!
Always keep the control cabinet, all electricity supply units, and electrical
control units closed. Access is only permitted to authorized personnel with
a key or special tool.
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Safety
Personnel qualification
2.4
Personnel qualification
All personnel who perform work on or with the product must carefully read and
understand the instructions and act in accordance with them!
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Description
Changes to the product
Description
3.1
Correct applications
WestfaliaSurge products and equipment are designed exclusively for
agricultural (mostly dairy) farms.
The A4 compact controller is intended exclusively for controlling the cooling and
agitation functions in milk cooling systems.
Any applications that are not listed here are not part of the intended purpose and
are therefore considered as improper use!
The manufacturer/supplier is not liable for any resulting damage. The user
alone bears the risk.
Correct use also includes reading the instructions and observing the inspection
and maintenance conditions.
3.2
The installation or use of such products can have a negative effect on the
specified characteristics of WestfaliaSurge products and can put people and
animals at risk.
The manufacturer cannot be held liable for injury to people and animals or
damage to WestfaliaSurge products caused as a result of using non-original
parts or accessories or by incorrect settings.
10
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Description
Technical Data
3.3
3.4
3.5
An electronic card (CPU) with inputs and outputs for the relays.
Agitation cycles
Functions
Technical Data
Electrical data
Power supply
Ambient temperature
Set-point adjustment
+2 ... +30C
Differential gap
Temperature sensor
8416
8006
7619
7252
TC
7
8
9
10
6905
6576
6266
5971
11
Transport
Information on disposing of packing material
Transport
4.1
4.2
4.3
4.4
There is a fire hazard due to the highly inflammable packing material - naked
flames and smoking prohibited!
dimensions
(mm)
Weight
(kg)
370x170x75
0,8
Includes
Check the goods supplied against the packing list enclosed for completeness
and damage.
4.5
Storage conditions
When storing the goods supplied, the location must provide protection against:
4.6
Moisture
Frost
Direct sunlight
12
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Installation
Safety instructions for installation
Installation
If necessary, please contact your nearest authorised technical dealer.
5.1
5.2
Before installation, look for any damage caused during transport. Do not use
damaged components!
Also read the chapter on Safety.
Injury can be caused by the electrical current from live cable ends and
components.
If the bending radius is too small, it should be removed.
3300-9001-520
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13
Installation
Fitting the control unit
5.3
Legend:
A4 A4 electronic card
KA1 Agitation relay
KA2 Cooling relay
KM1 Compressor switching contact
M10 Agitator motor
F1.1 Under-pressure switch (optional)
F1.2 Over-pressure switch
F1.4 Compressor motor protection (Klixon)
Q1 Compressor motor protecting switch (optional)
Y1 Solenoid valve, coolant
S2 Safety switch, cooling tank cover
R70 Temperature sensor
14
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Initial Commissioning
Safety instructions for initial commissioning
5.4
Initial Commissioning
6.1
6.2
Before starting for the first time, check that all tools and other parts have
been removed from the danger area.
Also read the chapter on Safety.
Incorrectly wired
components.
connections
may
destroy
electrical/electronic
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15
Initial Commissioning
Settings
6.3
Settings
Note!
The settings are entered in programming mode!
For more information on this subject please see the section on:
Operation / Operating / Programming mode
Code
P00
P01
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Function
Default (range)
Program version
Configuration 1
1.1
135
(0 255)
P11
User setting
0.1
1
Yes
No
16
32
64
128
128
128
135
135
Temperature adjustment
Adjust (calibrate) temperature
Limit value, switch-off temperature
Determine the setting range (lowest shut-off
temperature) for the operator.
0,0
(-3 - +3)
2,0
(0,0 10,0)
1 (C)
P13
30,0
(0,7 99,9)
1 (C)
P14
0,7
(0,7 2)
0,1 (C)
P15
0,5
(-5 - +99,9)
0,1 (C)
P16
40,0
(-5 - +99,9)
0,1 (C)
P18
Agitation on
Operating time of agitator(s) during cyclic
agitation and agitation after refrigeration has
stopped.
2
(1 30)
1 (min)
P19
Agitation pause
Rest time of agitator(s) during cyclic agitation.
13
(1 30)
1 (min)
P12
16
Increments
(unit)
1 (C)
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Initial Commissioning
Settings
Increments
(unit)
Code
Function
Default (range)
P20
189
(164 - 210)
1 (V)
P21
257
(244 281)
1 (V)
P24
Calibrate voltage
Calibration of the voltage displayed in test mode.
Start delay (min)
Delayed start of the cooling function (1st milking).
The switch-off temperature is displayed (flashing).
-3
(-20 - +20)
20
(0 255)
1 (V)
P27
5
(0 30)
1( min)
P30
210
(0 255)
1 (min)
P34
Cooling speed
8
(0 255)
1
(min/C)
P42
Rapid cooling points to a low level in the tank. The thermostat stops cooling at the restart
point and prevents excessive cooling of the milk.
Example: set-point temperature: 3.2C / 4C. If temperature drops from 5 to 4C in less
than 8 minutes, the thermostat switches off at 4C.
This function is connected with the setting P27 (pause time). (P27)
2nd temperature range (C for thermostat 2)
0,0
1 (C)
Selection of the 2nd set-point.
(-9,9 - +30)
Set a second switch-on and switch-off
temperature with reference to thermostat 1.
Example: P42 = 5 increases the switch-on and
switch-off temperature by 5C.
P25
P43
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0
(0 99)
User setting
1 (min)
1 (h)
17
Operation
Safety instructions for operation
Operation
7.1
7.2
Before operating, make sure you are adequately familiar with the following:
D
the equipment
Operating mode
Check and make sure that all operating media is suitable, present and
connected.
Check and make sure that only authorized personnel are in the work area
of the machine and no other people will be endangered by the machine
starting.
In normal operation:
18
Operation
Description of the operating elements
7.3
7.4
Stop
COOLING mode
Agitation
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8.8.8.
Display
LED display (3-figure and 7-segment display.
Main display
19
Operation
Description of the operating elements
Menu structure
Standby
Option
. . .
Thermostat 1
Stop
Thermostat 2
Stop
3.0
8.0
3s
3s
P25
(C)
24.3
3s
(3.0
Thermostat 1
Stop
(3.0
KA2
3s
(4.0
Thermostat 1
ON
(4.0
.
KA1
3s
p00
1.1
3s
p01
135
135
+
3s
p43
tst
241
rel
r0
KA1
(On)
r1
KA2
(On)
flashes
slowly
quickly
20
(V)
sup
dsp
8.8.8.
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Operation
Operating
7.5
Operating
The A4 control unit has 3 operating modes.
D
Standby
COOLING mode
Agitation
7.5.1
short
> 0,5 s
long
>3s
Standby
. . .
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Push-b
utton
Display
3.0
0,5s
24.3
3s
.
0,5s
.
p00
3s
21
Operation
Operating
7.5.2
Cooling
D
3.0
flashes
24.3
Note!
Rapid cooling points to a low level in the tank. The thermostat stops
cooling at the restart point and prevents excessive cooling of the milk.
Example: set-point temperature: 3.2C / 4C. If temperature drops
from 5 to 4C in less than 8 minutes, the thermostat switches off at 4C.
This function is connected with setting P27 (pause time).
Push-b
utton
Display
3.0
8.0
0,5s
3s
7.5.3
. . .
3.0
3.0
flashes
Agitation
Start agitation by pressing the agitation button.
22
Push-b
utton
Display
. . .
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Operation
Operating
7.5.4
Programming mode
Programming mode is started from standby.
Press button (>3s) to start programming mode.
P00
Settings displayed
Note!
Programming mode is automatically abandoned if no buttons are
pressed for 30 seconds while a Code 30 is being displayed.
Key functions in programming mode
Push-button
=ESC
Select parameter
Change parameter value +
3s
Push-b
utton
p00
1.1.
p25
20
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Display
20
flashes
3s
. . .
23
Troubleshooting
Safety instructions for troubleshooting
Troubleshooting
If necessary, please contact your nearest authorised technical dealer.
8.1
8.2
Ensure that safe disconnection can be carried out by a second person at any
time.
Also read the chapter on Safety.
24
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Troubleshooting
Troubleshooting possible faults
8.3
d13
Possible cause
time Cooling time is longer than
P30 (210min)
Remedy
D Check compressor.
Check temperature of
the milk in the tank.
Temperature
The
milk
temperature
taken
during measured is higher than
cooling too high P16 (40C).
(sensor default)
Check temperature of
the milk in the tank.
d21
d22
Restore defaults
d19
d20
8.4
Malfunction
Cooling
exceeded
Disturbance
to
the
electronic board affecting
the programme sequence.
Remedy
D Check
incorrectly
Check
Check
Check
Check
The compressor
working.
is
Control unit
connected.
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25
Decommissioning
Safety instructions for decommissioning
Decommissioning
9.1
9.2
Make sure that operating media are disposed of without harming the
environment.
Also read the chapter on Safety.
26
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Spare parts
10
Spare parts
40
3300-9001-520
12-2009
70
30
20
50
60
Pos.
Part no.
Description
20
3300-0857-379
A4 WS +3,5 m - 1x230-50/60
20
3300-0605-926
A4 WS +3,5 m - 1x230-50/60
30
40
50
50
50
60
70
3300-0222-983
3300-0857-290
3300-0857-365
3300-0221-740
3300-0222-118
3300-0611-229
3300-0592-294
Keypad foil
Electronic controller
Temperature sensor
Temperature sensor
Temperature sensor
Bracket
Balancing resistor
A4 - WestfaliaSurge
A4-230-50/60
A3/A4/Pylot/Expert-L=2m
A3/A4/Pylot/Expert-L =3,5m
A3/A4/Pylot/Expert-L=7m
A4-CV/CVS
A3/A4/Pylot/Expert
27
Appendix
Abbreviations
11
Appendix
11.1
Abbreviations
Term
Meaning
Phase
Units
28
Degrees (angles)
Degrees Celsius/ Centigrade
Second
min
Minute
(in)
mm
Millimeters
cm
Centimeters
Meter
mm2
Square millimeter
mm3
Cubic millimeter
Gram
kg
Kilograms
kPa
Kilopascal
kW
Kilowatt
Amp (current)
Volt (voltage)
Ohm (resistance)
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Appendix
Quick-reference guide
11.2
Quick-reference guide
Push-b
utton
Display
Standby
D
. . .
0,5s
Cooling
D
3.0
flashes
0,5s
3.0
8.0
24.3
3s
Agitation
D
Malfunction
d13
d19
d20
d21
d22
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Possible cause
The cooling time is longer than P30 (210min)
The milk temperature measured is below P15 (0.5C).
The milk temperature measured is above P16 (40C).
The supply voltage has been higher than P21 (257 V) or
lower than P20 (189 V) for more than 5 seconds.
Disturbance to the electronic board affecting the programme
sequence.
29
Appendix
Quick-reference guide
db^ c~ q
q K
db^ c~ q
GEA WestfaliaSurge Japy SAS
Route de Gray, B.P. 18, F-21850 Saint Apollinaire (France)
30
3300-9001-520
12-2009