db^ c~ q

Compact controller for milk

cooling tank
- A4 Instruction Manual / Installation Instructions / Parts List
(Translation of the original operating instructions)
3300-9001-520
12-2009

db^ c~ q J q K

Contents
1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1
1.2

Information on the instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manufacturers address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4
5

1.3
1.4

Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5
6

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1
2.2

Owners obligation of care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Explanation of the safety symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7
8

2.3
2.4

Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
9

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.1
3.2

Correct applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Changes to the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3
3.4

Design of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.5

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.1
4.2

Special personnel qualification required for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Safety instructions for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.3
4.4

Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Includes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.5
4.6

Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Information on disposing of packing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.1
5.2

Special personnel qualification required for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety instructions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.3
5.4

Fitting the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Information on disposing of installation material after installation is finished. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Initial Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.1
6.2

Special personnel qualification required for initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Safety instructions for initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.3

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.1
7.2

Special personnel qualification required for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Safety instructions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7.3
7.4

Workplaces for operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Description of the operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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

Special personnel qualification required for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Safety instructions for troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

8.3
8.4

Fault messages and troubleshooting help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Troubleshooting possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

9.1
9.2

Special personnel qualification required for decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Safety instructions for decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

10

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

11

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

11.1

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

11.2

Quick-reference guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Preface
Information on the instructions

Preface

1.1

Information on the instructions

These instructions are supplied with the product.
D

It is designed modular and is only in relation to the mentioned product.

For details of the components which are relevant to the product, please refer
to the appropriate manuals.
This applies especially for safety information!

This applies especially for safety information!

They should be kept close at hand and remain with the equipment even if
the equipment is sold.

This manual is not covered by an amendment service. The current version

can be obtained through your technical dealer or directly from
WestfaliaSurge.

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.

3300-9001-520
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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.

3300-9001-520
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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:

GEA WestfaliaSurge Japy SAS

Route de Gray, B.P. 18
F-21850 Saint Apollinaire (France)

Product category:

Control unit for milk cooling tank

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

Harmonized European standards

EN ISO 13732
(2009-09)
EN 60204-1
(2007-06)

Food processing machinery

Bulk milk coolers on farms - Requirements for construction, performance, suitability for use, safety and
hygiene.
Electrical equipment of machines

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.

3300-9001-520
12-2009

Safety
Owners obligation of care

Safety

2.1

Owners obligation of care

The product has been designed and constructed while taking account of a
potential risk analysis and after careful selection of the harmonized standards
and other technical specifications to be complied with. It therefore guarantees
a maximum level of safety.
This safety can only be achieved in practice on the farm however when all of the
necessary measures have been taken. It is part of the owners obligation of care
to plan these measures and check that they are carried out.
In particular, the owner must ensure that
D

Everyone who works with or performs activities in connection with the

product must carefully read the instructions (especially the safety
instructions and warnings) and sign to confirm that they have understood
them and will act in accordance with them!

A full set of legible instructions is always kept by the product.

Anyone who has to carry out work on the product can look at the instructions
at any time.

The instructions in the section entitled Basic safety instructions are

observed.

The legal requirements are observed.

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.

The work to be carried out is performed by a sufficiently qualified person!

In this respect, please also read the section on Personnel
Qualification.

3300-9001-520
12-2009

These personnel will be regularly instructed in all relevant matters of safety

at work and protection of the environment and be familiar with the manual,
particularly the safety instructions it contains.

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.

The personal protective equipment required for personnel carrying out

operation, maintenance and repairs is made available and used.

Unauthorised persons (e.g. children) are not allowed in hazardous areas

and do not have access to cleaning agents or disinfectants.
7

Safety
Basic safety instructions

2.2

Explanation of the safety symbols used

Safety symbols draw attention to the importance of the adjacent text.
Safety symbols and signaling word
Danger!
The word Danger together with a symbol signals a danger to peoples
and/ or animals lives and health.
Attention!
The word Attention together with a symbol signals a danger for
product, material or the environment.

2.3

Basic safety instructions

Note!
There are warnings about specific residual dangers in the
corresponding chapters.
Note!
If the work requires special qualifications, these are described in the
corresponding chapters!

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)!

The chapter on Technical data gives the permissible working conditions

(pressure ranges, temperature ranges, airflow quantities etc.) and these
must be observed!

Do not open or dismantle devices (risk of injury)!

Do not remove any protective devices (risk of injury)!

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!

Observe measures on protection against noise!

Do not stand underneath suspended loads.

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.

Protect live and high-voltage components against moisture. Under no

circumstances may water jets or high-pressure cleaners be directed at
these!

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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!

3300-9001-520
12-2009

Participation in corresponding product training is necessary.

In principle, all work on electrical equipment and electrical connection work

should only be performed by trained electricians.

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

Original WestfaliaSurge parts and accessories are specially designed for

WestfaliaSurge components.

We would specifically like to point out that parts or accessories and

installation instructions not provided by WestfaliaSurge are not checked or
released by WestfaliaSurge.

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.

Changes to the product

For safety reasons, do not carry out any unauthorized changes!
WestfaliaSurge must approve any planned changes in writing.
Parts and special equipment which have been obtained elsewhere must be
expressly authorized by WestfaliaSurge, in writing, for use in WestfaliaSurge
components and installations.

10

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Description
Technical Data

3.3

Design of the equipment

The control unit consists of:

3.4

3.5

An electronic card (CPU) with inputs and outputs for the relays.

A temperature sensor (NTC).

Controlling milk temperature

Controlling a second pre-selected temperature

Digital temperature display

Agitation cycles

Cooling start delay

Functions

Technical Data
Electrical data
Power supply

230V / -15% +10% / AC 50/60 Hz

Ambient temperature

-10 ... +60C

Set-point adjustment

+2 ... +30C

Differential gap

+0,7 ... +2,0C

Temperature sensor

NTC (3k / 25C )

Temperature sensors resistance values

TC
3
4
5
6
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8416
8006
7619
7252

TC
7
8
9
10

6905
6576
6266
5971

11

Transport
Information on disposing of packing material

Transport

4.1

Special personnel qualification required for transport

Transport may only be performed by specially qualified personnel in
accordance with the safety instructions.
Also see the section on Personnel qualification.

4.2

Safety instructions for transport

To prevent damage to property and/or life threatening injury to people during
installation the following points must be observed:
Also read the chapter on Safety.
Special transport hazards:
D

4.3

4.4

There is a fire hazard due to the highly inflammable packing material - naked
flames and smoking prohibited!

Dimensions and weight

Packing unit
(content)

dimensions
(mm)

Weight
(kg)

Wooden crate / cardboard box

(automatic rinsing unit, valves,
fasteners)

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

External damage (jolts, knocks, rodents, insects, . . . )

Direct sunlight

Information on disposing of packing material

After unpacking, the packing material is to be handled properly and disposed
of carefully in accordance with the valid local regulations on waste disposal and
utilisation.

12

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Installation
Safety instructions for installation

Installation
If necessary, please contact your nearest authorised technical dealer.

5.1

Special personnel qualification required for installation

Installation may only be carried out by specially qualified personnel in
accordance with the safety instructions.
Also see the section on Personnel qualification.

5.2

Safety instructions for installation

To prevent damage to property and/or life threatening injury to people during
installation the following points must be observed:
D

Before installation, look for any damage caused during transport. Do not use
damaged components!
Also read the chapter on Safety.

Special hazards during installation:

D

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.

Electrostatic processes can cause damage to electronic components.

Attention!
Only touch the edge of the printed circuit board and avoid static
caused for example by clothing.

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Before working on electrical installations or equipment (components,

housings, etc.), they are to be disconnected from the mains.
Any on/off or emergency stop switches are to be fitted with a lock to
immobilise them in the open position and a warning sign is to be put up.

13

Installation
Fitting the control unit

5.3

Fitting the control unit

Electrical connection
Attention!
All electrical installaton work must be carried out, as shown in the
wiring diagrams enclosed, by an approved electrical installation firm in
accordance with VDE requirements and the requirements of the local
power supply companies.

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

3300-9001-520
12-2009

Initial Commissioning
Safety instructions for initial commissioning

5.4

Information on disposing of installation material after installation is finished.

Handle unused installation material properly and dispose in accordance with
current valid local regulations on waste disposal and utilization.

Initial Commissioning

6.1

Special personnel qualification required for initial commissioning

Initial commissioning may only be performed by specially qualified personnel in
accordance with the safety instructions.
All settings that have to be made (e.g. on control units) should always be carried
out by personnel with corresponding training/instruction from WestfaliaSurge.
Also see the section on Personnel qualification.

6.2

Safety instructions for initial commissioning

To prevent damage to property and/or life threatening injury to people during
installation the following points must be observed:
D

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.

Special risks involved in initial commissioning:

D

Incorrectly wired
components.

connections

may

destroy

electrical/electronic

Defective connections can cause the product to start up unexpectedly or

make uncontrolled movements.

Electrostatic processes/interference may endanger electronic components

and also lead to software faults and data loss. Back up data regularly
therefore.
Attention!
Only touch the edge of the printed circuit board and avoid static
caused for example by clothing.

3300-9001-520
12-2009

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)

Setting the set-point temperatures with the

keypad
Checking the supply voltage (d21)
Relay KA1 Stirring while cooling ON
Forced stopping of the compressor if the cooling
time is exceeded
No function
No function
No function
Error code display
TOTAL

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

Limit-value, switch-on temperature

Determine the setting range (higher switch-on
temperature) for the operator.

30,0
(0,7 99,9)

1 (C)

P14

Minimum temperature difference

Determine the minimum temperature difference
between the switch-on and the switch-off
temperature.

0,7
(0,7 2)

0,1 (C)

P15

Milk temperature too low (d19)

Error code (d19) is displayed if the temperature is
below the set value.

0,5
(-5 - +99,9)

0,1 (C)

P16

Milk temperature too high (d20)

Error code (d20) is displayed if the temperature is
above the set value.

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)

3300-9001-520
12-2009

Initial Commissioning
Settings
Increments
(unit)

Code

Function

Default (range)

P20

Minimum voltage (d21)

Cooling stops when the voltage has been below
the limit value for more than 5 seconds (d21
displayed). Cooling continues when normal
voltage has been re-established for at least 30
seconds.

189
(164 - 210)

1 (V)

P21

Maximum voltage (d21)

Cooling stops when the voltage has been above
the limit value for more than 5 seconds (d21
displayed). Cooling continues when normal
voltage has been re-established for at least 30
seconds.

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

Cooling restart pause

Prevents the compressor form starting during the
pause time.

5
(0 30)

1( min)

P30

Default refrigeration time (d13)

Triggers display of fault code d13 if refrigeration
lasts too long (factory set to 210 minutes).

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

Switching time for 2nd temperature range

Change from one set-point to the other (P42) after
this delay.

3300-9001-520
12-2009

0
(0 99)

User setting

1 (min)

1 (h)

17

Operation
Safety instructions for operation

Operation

7.1

Special personnel qualification required for operation

Operation may only be performed by specially qualified personnel in
accordance with the safety instructions.
The operator may only carry out work on the AutoRotor Global 90/70
Automation package if he has been trained, instructed and authorized to do so
by the owner.
Also see the section on Personnel qualification.

7.2

Safety instructions for operation

To prevent damage to property and/or life threatening injury to people during
installation the following points must be observed:
D

Only fit or use the product for its intended purpose.

Before operating, make sure you are adequately familiar with the following:
D

the operating and control elements

the equipment

Operating mode

Carry out the following checks before every start:

D

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

The product may only be started

from the location specified.

No safety equipment may be removed or put out of operation during

operation.
3300-9001-520
12-2009

Operation
Description of the operating elements

7.3

Workplaces for operating personnel

Operation is directly in front of the product.

7.4

Description of the operating elements

The device is operated from the control panel on the front.
Functions are shown on the display
Operating panel

Keys and functions

1

Stop

COOLING mode

Agitation

3300-9001-520
12-2009

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.
3300-9001-520
12-2009

Operation
Operating

7.5

Operating
The A4 control unit has 3 operating modes.
D

Standby

COOLING mode

Agitation

Switching between the modes is only possible in Standby (Display: .). In

stand-by, the system is on but is not giving any commands.
Functions are selected by pressing the keys for at least 0.5 seconds.
Key operation:

7.5.1

short

> 0,5 s

long

>3s

Standby

. . .

All actuators (functions) are off.

Functions in standby mode
D

3300-9001-520
12-2009

Press the cooling button.

(cooling start)
If cooling starts with a time delay, the switch-off
temperature setting flashes on the display
After the start delay, or when the Start button is pressed
(>3 s), cooling begins and the milk temperature is
displayed.
Press the agitation button.
(agitation manual start)
A moving dot on the display.
Pressing the button (> 3s) changes to programming
mode.
(call up setup mode)

Push-b
utton

Display

3.0
0,5s

24.3
3s

.
0,5s

.
p00

3s

21

Operation
Operating

7.5.2

Cooling
D

If cooling starts with a time delay, the switch-off

temperature setting flashes on the display. (>0,5s)

3.0
flashes

24.3

Start cooling by pressing the cooling button. (>3s)

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).

Functions during the start delay

Push-b
utton

Display

3.0
8.0

Temperature range selection (if P42 is set)

D

Press agitation / settings button. (>3s)

Functions during cooling

D

Press stop button. (>0,5s)

(change to standby mode)

Press agitation / settings button. (>0,5s)

The switch-off and restart temperature are displayed.
Example : 3.0C / 4.0C.

0,5s

Press agitation / settings button. (>3s)

Display flashes and can be changed by also pressing
the stop or cooling button. The keypad can be locked to
prevent the set-point values being changed (P01).

3s

7.5.3

. . .
3.0

The change is limited by a minimum value, a maximum

value and a minimum difference of 0.7C.

3.0

flashes

Agitation
Start agitation by pressing the agitation button.

In the case of manual agitation, the dots move on the display.

Functions during agitation

D

22

Press stop button.

(change to standby mode)

Push-b
utton

Display

. . .
3300-9001-520
12-2009

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

Leave programming mode

=ESC

Select parameter
Change parameter value +
3s

Change parameter value 3s

Functions in programming mode

Push-b
utton

Display parameter value

D

Required setting selected.

Setting displayed (code / value alternating)

p00
1.1.
p25
20

Change parameter value

D

Required setting selected.

Display flashes and can be changed by also pressing the

stop or cooling button. The keypad can be locked to
prevent the set-point values being changed (P01).

Exiting programming mode

D

3300-9001-520
12-2009

Press stop button.

Display

20

flashes

3s

. . .

23

Troubleshooting
Safety instructions for troubleshooting

Troubleshooting
If necessary, please contact your nearest authorised technical dealer.

8.1

Special personnel qualification required for troubleshooting

Troubleshooting may only be performed by specially qualified personnel in
accordance with the safety instructions.
Also see the section on Personnel qualification.

8.2

Safety instructions for troubleshooting

To prevent damage to property and/or life threatening injury to people during
installation the following points must be observed:
D

First of all, prevent the product from being restarted accidentally.

Before working on electrical installations or equipment, they must be

disconnected from the mains.
Make the product safe so that it cannot be started accidentally.

Ensure that safe disconnection can be carried out by a second person at any
time.
Also read the chapter on Safety.

Special dangers involved in troubleshooting:

D

If energy sources are switched on unintentionally this may lead to serious

damage to property and/or life-threatening injuries to people and animals.

Electrostatic processes may damage electronic components.

Attention!
Only touch the edge of the printed circuit board and avoid static
caused for example by clothing.

24

3300-9001-520
12-2009

Troubleshooting
Troubleshooting possible faults

8.3

Fault messages and troubleshooting help

The default codes usually enable the origin of the default to be located and
rectified.

d13

Possible cause
time Cooling time is longer than
P30 (210min)

Remedy
D Check compressor.

Milk temperature The

milk
temperature
too low
measured is lower than P15
(0.5C).

Check temperature of
the milk in the tank.

Check the temperature

sensor.

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.

Check the temperature

sensor.

d21

Power supply out The supply voltage has

of limits
been above P21 (257 V) or
below P20 (189 V) for more
than 5 seconds.

Check voltage supply to

the cooling installation.

d22

Restore defaults

Check the parameters.

d19

d20

8.4

Malfunction
Cooling
exceeded

Disturbance
to
the
electronic board affecting
the programme sequence.

Troubleshooting possible faults

Malfunction
Possible cause
The electronic card is not No power supply.
working.

Remedy
D Check

Switches not working.

incorrectly

Check

not Relay KA2 is not switching

or a contact is damaged.

Check

Relay KA1 is not switching

or a contact is damaged.

Check

Relay KA1 is not switching

or a contact is damaged.
Defective safety switch on
the cover. Compressor
auxiliary contact KM1 not
switching.

Check

The compressor
working.

is

Control unit
connected.

The agitator is not working.

3300-9001-520
12-2009

25

Decommissioning
Safety instructions for decommissioning

Decommissioning

9.1

Special personnel qualification required for decommissioning

Decommissioning may only be performed by specially qualified personnel in
accordance with the safety instructions.
Also see the section on Personnel qualification.

9.2

Safety instructions for decommissioning

To prevent damage to property and/or life threatening injury to people during
installation the following points must be observed:
D

Make sure that operating media are disposed of without harming the
environment.
Also read the chapter on Safety.

26

3300-9001-520
12-2009

Spare parts

10

Spare parts

40

3300-9001-520
12-2009

70

30

20

50

60

Pos.

Part no.

Description

20

3300-0857-379

Tank control unit, compl.

(screwed cable gland on
back)

A4 WS +3,5 m - 1x230-50/60

20

3300-0605-926

Tank control unit, compl.

(screwed cable gland on
bottom)

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)

Inch (= 25.4 mm)

mm

Millimeters

cm

Centimeters

Meter

mm2

Square millimeter

mm3

Cubic millimeter

Gram

kg

Kilograms

kPa

Kilopascal

kW

Kilowatt

Amp (current)

Volt (voltage)

Ohm (resistance)

3300-9001-520
12-2009

Appendix
Quick-reference guide

11.2

Quick-reference guide
Push-b
utton

Display

Standby
D

Change to standby mode.

Press stop button.
(change to standby mode)

. . .
0,5s

Cooling
D

Start cooling by pressing the cooling button.

If cooling starts with a time delay, switch-off
temperature flashes on the display.

Select temperature range (if P42 is set)

Press agitation / settings button.

Press the cooling button (> 3s), cooling starts directly.

The milk temperature is displayed when cooling starts.

3.0

flashes

0,5s

3.0
8.0
24.3
3s

Agitation
D

Start agitation by pressing the agitation button.

0,5s

Malfunction

d13
d19
d20
d21
d22

3300-9001-520
12-2009

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

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GEA WestfaliaSurge Japy SAS
Route de Gray, B.P. 18, F-21850 Saint Apollinaire (France)
30

qK HPP EMF P UM TN J UOMQI c~K HPP EMF P UM TN J UOPT

K~J~K

3300-9001-520
12-2009