Download MilkMinder 2000 Core Module DX Milk Tank Control System

MilkMinder 2000 Core Module DX Milk Tank Control System
The MilkMinder 2000 Core Module control system is a fully electronics, user programmable cooling and
wash control, for Direct Expansion refrigerated milk tanks.
When fitted in conjunction with the appropriate condensing units, agitators, circulating pumps, chemical
dosing pumps and water valves, MM-2000-CM ensures that milk cooling and tank sanitation will be carried
out to perfection. Powerful operating software permits virtually all functions to be programmed to the exact
requirements of the dairy farmer customer.
The latest technology ensures that MM-2000-CM can work faultlessly, day in day out, even under poor
electrical power situations.
Extensively tested in the UK, Spain, Portugal, France and New Zealand, MM-2000-CM has to be the choice
for milk tank control. This full featured system, including a useful data-logger, is not only the most
technically advanced milk tank control system in production today, but is offered at a price that cannot fail to
impress.
From the world leader in milk tank control technology
Evolving – Inspiring - Innovating – MILKMINDER 2000 TODAY
Arbel Electronics designed and produced the first fully electronics milk tank control system nearly 20 years
ago. Thousands of dairy farms, all over the world, depend on Arbel controls to delivery top quality milk, day
in day out. Milk cooled to the correct temperature and milk tanks cleaned to impeccable standards.
Technology moves on at an alarming pace. Microprocessor power and on-board chip memory storage that
were just a dream five years ago are now available to our designers. We have reached out and embraced
this new technology to offer an outstanding new DX milk tank control system.
MilkMinder 2000 Core Module
Following on from the success of the first MilkMinder systems designed over four years ago, our DX control
systems have been completely re-designed round the fantastic ZWorld Rabbit Core Module microprocessor.
This stunning electronic module is the engine of our new control system.
Why Rabbit Core Module?
Rabbit Core Module has greater computing power than was available on-board to the astronauts in the
Apollo moon spacecraft. This one feature allows designers to give the maximum level of functionality to
control system products. Flash microprocessor, SRAM and Flash memory allow incredible amounts of data
storage, easy of programming and flexibility. Sophisticated on-board electronic watchdogs stay ‘on guard’
24/7/365 to combat the effects of low quality power supplies.
ZWorld the manufacturers of RabbitCM have given a commitment to manufacture for many years ahead – a
key feature in selecting any microprocessor. All our control systems are based on RabbitCM and similar
technology.
The new MilkMinder-CM has been exhaustively bench and farm tested. Farms selected for our field trials
were chosen for their known poor electrical power supplies and history of electronic equipment malfunction.
MM2000-CM offers all the original features of the original system, with some new functions that cannot fail to
please the dairy engineer and dairy farmer.
This manual is provided to assist the dairy engineer from the commencement of installation, to setting up the
system. Technical information is freely available from the manufacturer and suppliers of the product.
Contact details are provided at the end of the manual.
MilkMinder-2000-CM control system is designed specifically for DX milk tanks. It is a stand-alone system
that does NOT require any permanent connection to a computer. This control system will fully manage all
the cooling and tank washing functions, if connected to suitable and appropriate external system devices.
It is possible to carry out a full and functional installation without using a computer. The installation engineer
will however be limited to using the default cooling and wash programs. These defaults have been selected
as being perfectly suitable for an average size tank, working in average conditions. Without a computer, the
engineer can adjust cooling thermostatic settings and calibrate the temperature reading. Using a computer,
preferably a laptop loaded with the MM2000-CM software will open up an interface offering almost infinite
customising facilities. The software is user friendly and provided free to all licensed operators.
Many other manufacturers have attempted to copy and implement our control system functionality.
Invariably, these systems are set up by password access to complex, key switch menu functions that are
tedious to use, difficult to understand and offer limited facilities. By using Arbel custom software, completely
separated from the system, the user and operator is prevented from inputting settings that could result in
malfunction or milk loss. Operating software is made available, free of charge to all authorised installers of
our equipment.
Other manufacturers are still offering rotary cam timers – old washing machine technology! The Arbel
system provides for easy changes to wash and rinse sequence, without any need to plug in, remove or
change plastic pegs on a moving drum.
Many thousands on milk cooling tanks, on dairy farms all over the world, rely on Arbel technology, day in,
day out to consistently cool the milk to collection temperature and ensure that the vat is correctly cleaned
after milk collection. Our systems are the envy of our competitors, highly regarded by our dairy farmer
customers and their service engineers.
Installation of the MM-2000-CM Control System
The MM-2000-CM control is designed specifically for DX refrigerated milk tanks. It can also be used with
tanks cooled by chilled water or low temperature chemical solutions. It can only be used with ice bank tanks
in conjunction with separate ice bank sensing controls. If you wish to use the control on an ice bank milk
tank, consult the manufacturer for details. The MM2000 system can also be used in applications where
other liquids requiring cooling are stored in specialised vats.
MM-20000-CM is manufactured in a high IP rated enclosure. This may be wall or tank mounted. The IP
rating is immediately invalidated when the first hole is drilled in the enclosure for mounting purposes. It is
the responsibility of the installation engineer to seal all holes drilled for mounting or cable conduit entries.
No warranty is offered for units damaged by water ingress. Controls should not be subjected to high
pressure washers, cleaned with aggressive chemical solvents or detergents.
Prior to installation, remove the four corner plastic screws and remove the top lid and attached display circuit
board. Be careful to disconnect the ribbon cable connector between the top lid and lower relay circuit
boards. Do NOT touch any components on the circuit boards. Place the top section in a clean, dry and safe
area while you are working.
The lower enclosure section, together with the power supply/relay board should then be screwed to the
chosen area on the tank or wall. Ensure that the mounting position offers the maximum possible protection
from water and physical damage. In addition it should be in a convenient position for the farm operative and
the milk tanker driver.
Be careful when drilling out the enclosure base that the drill chuck does not damage the circuit board. Do not
allow metal swarf or dust to contaminant the inside of the unit. Drill out all conduit cable entries as required.
These must not be in a position that could allow water to be channelled into the unit. When wall mounting
the system, all conduit entries MUST be through the base, or low down on the side of the enclosure.
Once satisfactory mounted, the electrical installation can be carried out. Electrical wiring should only be
attempted by knowledgeable and qualified electrical engineers. Incorrect installation could result in damage
to the unit and injury to an unskilled installer.
The Power Supply
The MM-2000-CM system is designed to operate on a single-phase supply of 220 to 240 volt a/c. No direct
connection should ever be made to three-phase systems.
A schematic is provided overleaf of the power supply/relay board and the wiring connections.
installation engineer accepts full responsibility for all connections made to the control system.
The
Prior to installation, an electrical power supply survey should be made to ensure that the farm electrical
installation is adequate for the proposed milk tank installation. Do NOT assume that you can automatically
fit a larger size tank with increased capacity condensing unit. Farm power supplies have to conform to
clearly defined standards. If in doubt, consult the electrical power supply provider. On farms where there is
a known serious power supply deficiency, consider using the services of a consultant electrical power
monitoring company.
It is vital that Ground to Neutral voltages are measured. Any reading above 2 volts is unacceptable and
indicates a fault in the farm electrical installation. Ground to Neutral voltages are also know to lower dairy
cow milk production, so it is in the interests of the dairy farmer that this issue is not ignored. Farms with
PME installations require frequent testing to ensure that G to N voltage levels are acceptable.
The MM-2000-CM system can be used with generator systems providing a stable voltage and frequency.
The use of UPS systems should be considered if a power supply problem exists and cannot easily be
remedied. However, it must be clearly understood that the MM-2000-CM system is a device that requires a
satisfactory mains power supply, working within the current EEC LVD and EMI Directives.
WIRING INSTRUCTIONS
Carry out the electrical installation, adhering to the following principles. The unit should be provided with a
mains power supply from a switched, fused power outlet. The connection should be made in 2.5mm cable.
No spur connection off or to any other appliance is permitted. It is normally possible to link the supply feed
to the system on the relay board, to provide power for the internal electronics and the switched outputs. On
installations where electrical conditions are poor or marginal, a separate mains supply, in 2.5mm cable
should be made to the relay terminal.
Motor start contactors MUST be used on the following switched items: 


Condensing Units
Agitator Motors
Water Circulating Pumps.
The following items do not usually require contactor control, but using external switching relays enhances
any system: 


Water valve solenoids
Chemical doing pumps
Dump Valves.
No wiring cables should be allowed to cross directly between the logic and power supply relay boards. Do
not route the temperature sensor cable in the same conduit as mains cable.

Do not over tighten terminal connector screws. Excessive force can break the terminal connector pin
from the solder track. Use insulated, slotted screwdrivers of the correct size that do not damage either
the terminal screw or surrounding plastic insulation.

Use 1.5mm single core cables to connect the external motors, valves etc. Use motor start contactors
where necessary. Do not allow the total relay board output load to exceed 6 amps.

Clip or tie-wrap all cables inside the enclosure neatly. Keep mains wiring away from circuit boards as
much as possible.

Under no circumstances coil any excess cable within the enclosure. Keep cable runs as short as
possible, without putting physical strain on the terminal connector blocks.

Ensure that all cable conduit entries are effectively sealed to prevent water ingress or situated in such a
way that they could act as channels through which water could run into the control unit.
After the wiring is satisfactorily completed, it is permissible to switch on the power supply to determine actual
voltage levels at the supply terminals of the relay circuit board. This should measure at 220 to 240 v a/c
plus or minus 5%. If the reading is outside this range, investigations should be made before proceeding any
further.
The MM-2000-CM control unit is double insulated and does not require any ground connection. If ground
connections are required, these should all be made external to the control unit.
The following diagram clearly shows the wiring connections for MM-2000-CM. The control system should
only be installed by a qualified and competent electrician. There are no serviceable parts inside the control
system and any attempt to modify or repair the system will nullify the warranty.
The farm electrical environment is invariably a challenging one for any electronic equipment. No
manufacturer of electronic equipment can guarantee that his equipment will work faultlessly under any
electrical situation. Installation engineers should have a clear understanding of the effects that low or
fluctuating voltages, high power electrical motors, motor start contactors etc can have on electronic
equipment. Putting this understanding into practice will virtually always eliminate any problems.
ENSURE THAT YOU READ AND UNDERSTAND THE ISSUES REGARDING
CORRECT INSTALLATION OF ELECTRONIC EQUIPMENT
Wiring Diagram for MilkManager 2000-CM
ALL WIRING TO MEET CURRENT ELECTRICAL REGULATIONS
EEC LOW VOLTAGE DIRECTIVE - (LVD 73/23/EEC)
EEC EMC DIRECTIVE - (EMC 89/336/EEC)
1
Level Sensor
Red Blue
2
4 5
3
ALKALI
ACID
COMP 2
E7
HOT
BOOST
ENABLE
COLD
Connector
COMP 1
DUMP
AGIT 2
AGIT 1
Slow Blow
10 Amp
PUMP
Quick Blow
1 Amp
Power Supply-Relay Board
HYPO
Temperature
Sensor
Fuses
N
L NEUTRAL L
Control
Power Relays
L - Live In
220/230 volts AC 50 Hz
6
7
8
9 10
11 12 13
Mains supply 2.5mm cable mandatory. Supply from
principal isolated switch fuse. Warranty invalid if
supply does not meet EEC - LVD and EMC Directives
N- Neutral
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Output to
Output to
Output to
Output to
Output to
Output to
Output to
Output to
Output to
Output to
Output to
Output to
Output to
Boost Pump for Wash Water
Cold Water Solenoid Valve
Hot Water Solenoid Valve
Alkaline Dosing Pump
Acid Dosing Pump
Circulating Pump
Agitator 1
Agitator 2
Dump Valve
Hypo Dosing Pump
Compressor 1
Compressor 2
Economy 7 Relay
Total board loading not to exceed
6 amps. Use external contactors
where necessary.
Temperature Sensor
Correct wiring essential. Reverse
polarity will damage probe
Blue Red -
Thermistor Input
Level Sensor
Requires level sensor device. Contacts close on reaching correct level. No voltage to be applied to these
terminals. Leave terminals open if not using a level device.
It is permissible to link the Live feed to the control system to the Live feed to the power relays in normal
circumstances. Wire separately if power supply is of low quality.
Completion of Installation
Following on from the fixing and electrical wiring of the MM-2000-CM power supply, mounted in the lower
enclosure section, the enclosure top, complete with the display-logic board and keypad assembly can be
connected. At no time should any components on the boards be touched.
Ensure that the electrical power supply is turned OFF
Connect the ribbon cable connector from the top section to the box header connector at the top left-hand
side of the power supply board. Push the connector gently into the socket, making absolutely sure that it is
pushed fully down.
Whilst setting up, it is convenient to replace the upper two plastic enclosure screws, so that the top
assembly can be hinged forward as required.
Memory Retention – Battery Switch
Now activate the battery switch on the top board. This is set in the OFF position when sent out from the
factory. The diagram below shows the position of the battery switch. This must be pushed upwards to the
ON position. Failure to do so will prevent program changes to cooling or wash programs from being
retained in memory in the event of a power fluctuation or failure.
Battery Switch – push up for ON
Now switch on the power supply. You will observe: 

The illumination of the red Connection LED
The activation of the digital temperature display.
If you have not connected the temperature sensor, the display will show a very low minus temperature such
as –69.8 . Check that the temperature sensor is correctly connected.
The temperature display will take up to 10 seconds to display the correct temperature at the sensor head.
This is because the unit takes 10 readings over this time period and displays the average.
The unit is now fully functional and will operate according to default factory cooling and wash settings.
These settings are perfectly satisfactory for most milk cooling tank installations.
The defaults can be changed if required. Minor changes to the cooling parameters can be made without
using a computer. Major changes can be made to both the cooling and washing parameters by using the
custom MM2000 software.
Factory Defaults
As supplied from the factory, MM-2000-CM is ready to carry out useable cooling, washing and rinsing
functions. Many installation engineers will elect to use the default settings. The default cooling settings are
shown below: -
Refer to the Arbel Delphi PDF Document to learn how to communicate with the system using a PC or
laptop to change the cooling parameters.
The Arbel Delphi PDF Document can be downloaded from www.arbelelectronics.co.uk
Some changes can be made to the cooling parameters without a PC. The following page gives further
details.
Changes to the default settings that can be made without a PC
The only changes that can be made without a PC are the following: 



Calibrate the temperature reading.
Adjust the thermostatic cut-in and cut-out points.
Adjust the GMT timer display.
Restore a unit back to the factory default settings.
These adjustments are made using a small switch located at the rear of the display circuit board. See
photograph below.
Rear of Display Circuit Board
Set Switch
With experience, this switch is easily located by feel. Hinge up the top lid slightly and the switch can be felt
towards the back of the assembly, at the extreme lower left corner of the display circuit board.
How to use the SET Switch
The SET switch only works with the unit assembled and the electrical power on. There are no high voltages
on the top displace board. Never touch any component on the power supply board if the electrical supply is
switched on.
Calibrating the Temperature Display
Momentarily depress the SET switch. The display will change to a reading such as P18.7. The
temperature display can now be calibrated. The temperature display should be calibrated in the following
manner. As virtually all milk tanks have the temperature sensor applied to the outside skin of the tank, there
is always a small temperature differential between the true temperature of the milk inside the tank and the
sensor head on the outside. This is normally in the order of 0.3 to 0.5 degrees C. As supplied, the default
temperature on the display will be accurate at 0.0 degrees. It is recommended that an off-set of about +0.4
degrees is used with this type of application. When in calibration mode, simply use the AUTO or
DEEPKOOL buttons on the keypad to scroll the temperature reading higher or lower respectively.
Place the temperature sensor in a jug of water at approximately room temperature for 5 minutes and note
the reading. Now program in a +0.4 degree off-set. For example, if the display showed a reading of P18.7,
use the AUTO button to change this to P19.1. If you go past the setting you are trying to achieve, use the
DEEPKOOL button to lower the temperature display back to the reading you require.
It is permissible to use the temperature reading on the milk collection ticket for fine tuning the calibration. It is
generally accepted that the milk collection tankers have an accurate digital temperature sensor.
Setting the High Cut-In Temperature
This is the temperature at which you require the system to activate the cooling relays and provide
refrigeration.
Momentarily depress again the SET switch. You will see a reading like this : - H 4.0
Once again, use the keypad AUTO and SUPERCOOL switches to set this higher or lower. Do not attempt
to set a differential closer than 0.5 degrees C. If you do and then go onto setting the Low Cut-Out
Temperature, you will not be able to complete the settings until you have restored a minimum differential of
0.5 degrees C.
Setting the Low Cut-Out Temperature
This is the temperature at which you require the system to stop cooling the milk. The cooling relays will
open and refrigeration will cease.
Momentarily depress the SET switch. You will see a reading like this : - L 3.5
Use the keypad AUTO and SUPERCOOL switches to set this higher or lower. Once again, do NOT attempt
to set a differential closer than 0.5 degrees C.
Setting the Internal Clock
The control system clock is set at the factory to give a reading in GMT. To change the clock setting,
momentarily press the SET switch. You will see a display like this: - 10.16
Use the same keypad switches to increase or decrease the time display.
You should note than whenever the system is connected to a PC or laptop computer, the time is
automatically updated during the connection to read the time and date that are set on your computer.
Finalising the Settings
Momentarily depress for the last time the SET switch. The unit will now return to the normal temperature
display. If you accidentally go past this position, just scroll through all your settings back to this display with
single presses of the SET switch. The unit will NOT function if it is left on any parameter change setting.
To Default all Settings
This is an extremely powerful function. Using this function resets the system to the factory default cooling
and washing sequences. It will also clear the data log. To default, simply hold down the SET switch for
several seconds until the display scrolls 888888
Release the SET switch. The unit will now operate according to the factory defaults.
Default wash and Rinse Settings
As supplied from the manufacturer, the MM-2000-CM unit contains an embedded default wash and rinse
sequence. These sequences can always be recovered from the unit if required. The defaults will often be
perfectly satisfactory for the majority of milk tanks.
The wash and rinse sequences can be changed to suit a very wide variety of applications, chemical routines
and vat sizes.
See Arbel Wash Sequence Set-Up Manual