Thank you for purchasing a Dairy
Tech, Inc. DT Series Pasteurizer. Your satisfaction with this product is very
important to us. This guide will help you understand how your pasteurizer
operates, and how to get the most benefit from it for you and your dairy
operation.
Table of Contents:
Introduction
Important
Disclaimers
Table
of Contents
Welcome
to Dairy Tech, Inc.
Product
Warranty
Receiving your Pasteurizer
Receiving
your Pasteurizer
Important
safety instructions
Diagrams
(In back of Packet)
Installation and Operation
Installation
Quick Guide
Mounting
the Control Board
Water
Supply and Connections
Hand
Winch Installation
Electrical
Requirements
Initial
Start-Up of the Unit
System
Operation
Filling
and Emptying the Milk Drum
Delayed
Start Feature/Clock
Service
Energy
and Time saving tips
Troubleshooting
Guide
When
Service is Required
THIS PASTEURIZER IS INTENDED TO BE USED IN THE
MANNER DESCRIBED IN THIS USE AND CARE GUIDE. IT IS NOT INTENDED TO PASTEURIZE
MILK FOR HUMAN CONSUMPTION.
Dairy
Tech, Inc. has provided this use and care guide to assist you in the assembly,
installation, and maintenance of your DT Series Batch Pasteurizer (the
ÒPasteurizerÓ). Serious injury and even death to persons and livestock can
occur from improper installation and use of the Pasteurizer. Serious property
damage can result from improper installation and use of the Pasteurizer.
DAIRY
TECH, INC. RECOMMENDS THAT INSTALLATION OF ANY ELECTRICAL, MECHANICAL, GAS OR
PLUMBING DEVICES REQUIRED FOR THE INSTALLATION, OPERATION AND MAINTENANCE OF
THE DT SERIES PASTEURIZERS BE DONE ONLY BY QUALIFIED INDIVIDUALS.
It
is your responsibility or the responsibility of the electrician, plumber or
other qualified installation expert to obtain all necessary permits and
certifications required by your town, county, state or other jurisdiction
before installation of the Pasteurizer. It is your responsibility to read and
understand the operational requirements of the pasteurizer before using it and
to observe all safety precautions. It is also your responsibility to see that
your personnel are properly trained to operate and maintain the Pasteurizer.
DAIRY TECH, INC. PROVIDES YOU
WITH INSTRUCTIONS AND WARNINGS IN THIS USE AND CARE GUIDE, BUT WE ARE UNABLE TO
COVER ALL POSSIBLE CONDITIONS AND SITUATIONS THAT MAY OCCUR IN YOUR DAIRY
OPERATION. IT MUST BE UNDERSTOOD THAT COMMON SENSE, CAUTION AND CAREFULNESS ARE
FACTORS WHICH CANNOT BE BUILT INTO THE PASTEURIZER. THESE FACTORS MUST BE
SUPPLIED BY THE PERSON(S) INSTALLING, MAINTAINING OR OPERATING THE PASTEURIZER.
Under no circumstances is
Dairy Tech, Inc., its directors, officers, shareholders or employees
responsible for damage to property or injury to persons or livestock resulting
from the improper installation or use of the Pasteurizer. Installation by an
unqualified individual and improper use and improper maintenance may also void
any equipment warranty that Dairy Tech, Inc. offers.
This
use and care guide is based on information and data considered to be accurate;
however, no warranty is expressed or implied regarding the accuracy of the
information or data herein or the results to be obtained from the use of this
data or information.
Please read this
guide carefully and thoroughly before installing and operating this unit.
If you believe the pasteurizer
is operating incorrectly, please refer to the trouble shooting guide included
with these instructions before calling our service department. If you still
have questions, contact a representative at 1-866-DTI-COWS and we will help you
to address your needs. If your pasteurizer was purchased from and installed by
an independent distributor, please contact the service department of that
company for more convenient service.
Did you know?
Dairy Tech, Inc. offers
consultations with an independent Dairy Veterinarian at any time. If you have
questions regarding calf health issues or other veterinary related topics, we
would be glad to organize a conference call for you to discuss these. On site
visits are also available to more thoroughly investigate any problems you may
be encountering with calf health.
For your safety, the
recommendations and information in the manual must be followed to minimize the
risk of serious burns or electrocution, as well as to prevent property damage,
personal injury or death.
We recommend professional
installation by qualified plumbers and electricians familiar with such devices
What to do if you are
burned by the heating coil, hot water, steam or hot milk: Contact a physician or other medical personnel for
expert advice, or go to an emergency treatment facility.
Do not feed pasteurized milk
to calves without first cooling it back down to a minimum of 110¡F (43¡C). Milk
hotter than 110¡ can cause severe burns to the calves.
Product Warranty
This product is warranted to be
free of manufacturing defects for up to30 months from the date of purchase, all
parts will be covered by a free replacement guarantee. This warranty is
intended for equipment in use under normal operating conditions and does not
cover damages incurred by improper use. Determination of covered defects,
damages or repairs is at the discretion of Dairy Tech, Inc. If you purchased this product directly
from Dairy Tech, Inc., your product is covered from the date of your purchase
for the full warranty period. If this product was purchased from a Distributor,
be certain to call Dairy Tech, Inc. at 1-866-DTI-COWS to register within 10
days of purchase from the distributor. Failure to notify will result in the effective
date of purchase being recorded as the date the distributor received the
product into inventory. This warranty covers only the cost of replacement parts
at Dairy Tech, Inc. current pricing. Service is not covered by this warranty.
Receiving your pasteurizer
Use care when unpacking your
DT Series pasteurizer. It will have arrived in two boxes. Please make a note of
any cautionary labels that are used on the carton suggesting orientation, where
to cut with a knife, fragile, etc.
1Õx2Õx4Õ box: Contains the
control board with the heater, controls, pump, valves, etc all pre-assembled.
Carefully slide the unit from the end of the box and move to the location of
the pasteurizer installation.
3Õx3Õx4.5Õ box: The pasteurizing
unit is typically shipped in the correct size drum to complement the system;
however, the DT80, DT100 and DT150 will be shipped in a 55 gallon drum and the
actual pasteurization drum will be shipped separately. Also found in this larger box will be
two small boxes 6Óx10Óx12Ó marked A and B. Other loose items may include the
optional wall mounting bracket if ordered, the adapting collar for larger
systems, and the insulation wrap for around the drums. This white foam
insulation will help to improve the heat efficiency of your pasteurizer and should
not be discarded as packing material.
Box A: winch handle, 900lb
hand winch with bolts, winch mounting bracket, nut for mounting handle to the
winch, 50Õ poly rope, 2 split pulleys, instructions, accessory paperwork,
rubber bands, one-page instructions in English and Spanish, tank adapter and
¾Ó tank spigot.
Box B: Two hoses for connecting the cold water
supply and draining, two hose washers and two screw-clamps.
Important Safety Instructions
Warning:
To reduce the risk of electric
shock, burns, serious injury or death to persons when using the Pasteurizer,
follow these basic precautions:
1. Read all instructions before using the Pasteurizer.
2. Always disconnect the electrical power before
attempting service. Disconnect by grasping the plug, not the cord.
3. Do not allow children to operate or play around the
Pasteurizer. Close observation of children is necessary when the unit is used
with children nearby.
4. Do not reach into the Pasteurizer when the power is on
and the paddle is turning.
5. Hot Surfaces include the brass plumbing fixtures,
electrical fixtures, hoses, heater body, heating coil, draining water and the
milk or colostrum. Touching these surfaces during operation may result in
severe burns.
6. Do not try to change the settings in the pasteurizer
controller without consulting a technical expert at Dairy Tech, Inc.
7. Do not repair or replace any part of the Pasteurizer,
or attempt any servicing unless specifically recommended in the
trouble-shooting portion of this manual. Any modifications made to the unit
beyond these instructions will void all warranties.
8. Always clean the unit immediately after each use,
according to the instructions in the ÒCleaning of your PasteurizerÓ section of
this manual. Build up of residue on the coil or tank will decrease heating and
cooling efficiency, as well as harbor potentially harmful pathogens.
9. During the heating cycle, always make certain the
Pasteurizer is firmly seated and centered on the drum of milk. Do not immerse
the entire black unit into a drum of milk below the level of the top of the
drum.
10. Use the pasteurizer only for its intended purpose. DO
NOT use for milk intended for human consumption as this product has not been
approved for such use.
11. Do not touch the heating coil, hoses or brass fittings
while the unit is hot and working.
12. Never stand under the unit while it is raised in the
air.
13. The Pasteurizer must be electrically grounded. DO NOT
modify the plug that is provided with the Pasteurizer; if it will not fit the
outlet, have an electrician install a proper electrical outlet.
Installation:
Criteria for Selecting
a Location
a) Choose a spot that will be protected from the elements.
Extreme heat will allow milk spoilage and freezing temperatures will damage the
unit.
b) Ceiling height must be adequate to allow the unit to be
raised above the height of the drum. 8Õ ceilings are required for most units.
c) Cold water is required to be connected to the unit, but
hot water is also necessary for proper cleaning.
d) Floor drains will allow for proper cleaning and rinsing
of the product as well as to clean up milk spills.
e) Power requirements are 115vac GFI for the control board
and 220vac 40 amp for the heater.
f) Wall space for the control board is 2Õ x 4Õ.
g) Floor space requirements are approx that of a normal 55
gallon drum.
h) When possible, position larger systems near the milk
line so that it can be diverted directly into the tank while milking the sick
cows or fresh cows.
i) Avoiding extremely drafty areas will improve heating
efficiency of the unit.
Mounting the Control Panel
The control board is supplied
with all of the necessary pumps, valves and heaters pre-assembled for your
convenience. The panel is 2Õ x 4Õ and should be bolted to the wall directly
behind the location of the pasteurizing drum. Use the 8 holes that are provided
in the back of the unit and hardware appropriate for the mounting surface.
Position the panel at a height so that the operator can still reach the key
pad.
Connecting the Hoses
HOT IN: This red hose (or
marked with red tape) comes from the hot side of the electric water heater and
enters the back of the pasteurizer to provide hot water for heating. This must be
attached to the hose barb that is marked red.
HOT OUT: This yellow hose
(marked with yellow tape) returns warm water from the pasteurizer to the top of
the pump and heater to be recirculated. Attach the hose to the barb that is
marked yellow.
COLD IN: This blue hose (or
marked with blue tape) supplies all the cold water to the unit to charge the
system for heating and to cool the product when finished. It can come from any
cold water source including a hose but it MUST BE ON AT ALL TIMES DURING
OPERATION. Using the supplied clamp, attach one end to barb on the side of the
heater marked blue and the other end to the water supply.
COLD OUT: This black hose takes cold water out of
the unit once it has absorbed heat during the cooling cycle. It should be
directed to a drain, cistern, stock tank or other collection system. Using the
supplied clamp, connect one end to the hose barb to the left of the solenoid
valve, with the other end free to flow.
HAND WINCH, PULLEYS,
AND WALL MOUNT BRACKET INSTALLATION
* A wall mounting bracket is
available for scenarios that do not provide an overhead anchoring point for the
pulleys. It must be ordered separately.
Hand Winch: this 900# hand
winch comes with its own separate instructions that should be followed to
prevent injury to the operator. A mounting bracket is included to mount the
winch to the wall. For solid concrete walls, we recommend appropriate mollies
or expansion bolts. For hollow block walls, all-thread bolts are recommended to
penetrate the wall completely.
Mount
the winch at a height that allows for safe and comfortable use, within hands
reach of the unit itself. This allows the operator to guide the unit into the
drum of milk while lowering with the winch.
**MAKE CERTAIN THAT THE
LOCKING MECHANISM ON THE WINCH IS PROPERLY ENGAGED AT ALL TIMES AND REPLACE AT
THE FIRST SIGN OF WEARINGÉNEVER ALLOW THE WINCH HANDLE TO SPIN FREELY WITHOUT
THE HANDS-ON CONTROL OF THE OPERATOR**
Electric winches and hoists
are available. Call Dairy Tech, Inc. for a list of products and vendors.
Pulleys: 2 split pulleys and a
50Õ rope are included for properly attaching the unit to the winch. The pulleys
should be positioned with one directly above the unit into the ceiling, the
other attached to the back or side wall to guide the rope clear of the unit.
The anchor points for the pulleys should be capable of withstanding 200# of
weight.
***THE ROPE SHOULD BE CHECKED
DAILY FOR SIGNS OF WEAR. IT CAN BE CUT AND ADJUSTED AS NEEDED É OR CALL FOR
REPLACEMENT É SUBSTITUTION WILL VOID THE WARRANTY***
To attach the rope, securely
fasten one end to the eyebolt on top of the unit and guide the other end
through the two pulleys to the winch reel. Fasten to the winch according to the
instructions and maintain excess rope length on the reel.
Electrical Hook-Up
Requirements
The standard electrical cord
emerging from the top of the control box should be plugged directly into a 115vac
GFI receptacle on a 15amp breaker. Failure to meet these requirements will void
the warranty and could result in serious damage to the unit, bodily injury or
death. The receptacle should be fitted with a water resistant cover for added
protection.
á
Be certain to use a GFI
receptacle for the 115vac
á
The receptacle should be
sharing minimal usage with other equipment to avoid unexpected outages and
tripping. The Pasteurizer cycle will reset if the power is lost, but cannot
reset if the breaker is tripped.
á
The 115vac breaker should
be 15 amp.
á
DO NOT use an extension
cord to operate the unit other than the one provided.
á
Check your electrical
system to make certain it is properly grounded to avoid the possibility of
electrical shock.
The 220vac supply for the
electric heater emerges through the top of the control box. A 4Õ length is
supplied for termination into a junction box, or this cord may be removed and
wired direct from the panel box by a certified electrician. The gauge of wire
selected for L1 and L2 are very important and will depend on the distance from
the panel box and expected amperage. The heater at full capacity will draw 37
amps on a single phase system. 40 amp breakers are sufficient in most
instances. Some installations may require a 50 amp service, but always consult
a certified electrician.
The Pasteurizer is equipped
with a cord having an equipment grounding conductor and a grounding plug. The
plug must be plugged into an appropriate ground-fault outlet that is installed
and grounded in accordance with all local codes and ordinances. DO NOT modify
the plug provided with the Pasteurizer; if it will not fit the outlet, have a
proper outlet installed by a qualified electrician.
Final Connections:
The last two connections to
make are from the pasteurizer to the control box. The black power cord from the
hood must be routed through the cord grip on the left side of the control
cabinet. There are instructions in the wiring schematic for exact wire
placement, as well as on an instruction sheet included with the pasteurizer.
The thermocouple quick connection is located adjacent to that. The thermocouple
cord has the appearance of a phone cord and plugs into the back of the
pasteurizer on one end, and the left side of the control box on the other end.
Failure to have this
thermocouple cord properly plugged in will result in an Error on the display
and the unit will not operate until the connection is made.
Internal Fuse Board
The unit is equipped with 8 fuses
located inside the control box on the bottom edge of the electrical panel. The
layout of the fuses is defined as follow:
F1 Main
20amp
F2 Transformer 1amp
F3 Pump 2amp
F4 Motor 10amp
F5 cold
ctrl 1amp
F6 Hot
Valve 1amp
F7 Cold
Valve 1amp
F8 cold
ctrl 1amp
Initial Start-up of the
Unit
(Pressurizing the
System)
After making all the proper
plumbing and electrical connections, pressurize the system by turning on the
cold water supply.
(Purging the Air)
Air is purged out of the
system by two means: The pressure relief valve on top of the heater can be
opened to allow water to flow through and force out air pockets trapped in the
system. Likewise, the small red cap on top of the air vent can be opened to
allow air and vapor to escape the system.
Failure to remove all of the
air from the system could result in severe damage to the heating elements in
the heater, and could also prevent the pump from working to circulate the hot
water properly.
Use of the Pasteurizer
The unit is now ready for milk
or colostrum to be added for pasteurization, but first properly clean the drum
and coils to remove oil residues from manufacturing. Simply fill the drum that
was included with your system and lower the pasteurizer completely onto the
drum using the hand winch provided. The drum must be filled to a level that
allows the thermocouple, propeller and heating coil to be immersed in the
product for even heating and process control. If the volume is inadequate,
there will be uneven heating and possible errant temperature readings by the
thermocouple system. Switch to a smaller drum to achieve the desired
conditions. It is also important to not overfill the drum as it will leak over
the sides while stirring once the unit is lowered.
Running the Cycles
¯
Power the unit on by
toggling the red rocker switch; the display should indicate ÒIDLEÓ.
¯
START is used to initiate
a complete heat/cool cycle.
¤Press
twice for immediate start
¤Instructions
for delayed functions follow here.
¤The
display will indicate the temperature, stage of cycle and TIME to complete the
current cycle.
¯
HEAT ONLY is depressed if
only the heating portion of the pasteurization process is desired.
¤
The milk will not cool
down at the end of the timing.
¤
The display will indicate
temperature and time, and ÒENDÓ when complete.
¯
COOL ONLY is depressed
when the milk has already been pasteurized completely, but is not yet cool
enough to feed or handle.
¤
The display will indicate temperature
and then ÒENDÓ when complete.
¯
UP and DOWN keys are used
during programming or alterations to the settings.
¯
AUXILARY / INTERRUPT is
used only for reheating the milk if it needs to be warmed for feeding.
¯
An alarm will beep several times at the
end of a completed cycle, and the display will indicate ÒENDÓ.
¯
If the cycle has not
completed properly within a preset window of time, the alarm will beep
continuously and indicate an ÒERRORÓ in the display.
¯
If the display indicates
other ÒERRORSÓ with associated numbers, refer to the troubleshooting guide for
further assistance.
¯
To power down the unit,
turn off the red toggle switch or unplug the unit from the wall. The unit
should be toggled off after the completion of each cycle, unless set for a
delayed start. If the unit is powered off before completion of a cycle, it
will attempt to resume that cycle when power is restored. To shut down during a
cycle, press the button that was used to initiate the cycle and hold it for 3
seconds. The display will indicate PAUSE, but continue to hold until it
displays ÒIDLEÓ. Now the unit can be powered off.
To STOP Pasteurizer cycle:
Pause by pressing the button used to start the cycle (Start, Heat Only or Cool
Only), or flip the toggle switch off, or unplug the unit from the receptacle.
To restart from the Pause
position, simply press the same button again and the cycle will resume. Only
use the ÒCool OnlyÓ button to restart if you are certain that the product was fully
pasteurized.
DELAYED START
a. Press either the START, HEAT ONLY , COOL ONLY, or AUX button so that the word ÒNOWÓ
is displayed.
b. Then press the UP key to scroll through the options of
Delay1, Delay2 or NOW.
c. Then press the START key once again and the clock will
appear. Use the UP or DOWN button to adjust the time for delay.
d. Once the time is set, press START again and the screen
will again display ÒDelay1Ó or ÒDelay2Ó and will wait for that time to start
the cycle.
e. The unit will now come on at the time you have set.
SETTING THE CLOCK
¤
Power the unit on so that
ÒIDLEÓ is displayed on the screen of the controller.
¤
Depress the START and AUX buttons at the same time and hold for several seconds. The
real time clock will be displayed.
¤
Use the UP or DOWN
buttons to change the time.
¤
Depress the HEAT ONLY
button to accept the changes and return to the ÒIDLEÓ mode.
CLEANING THE SYSTEM (be
sure the equipment is powered OFF)
HINT: Cut the top off of an
old 55 gallon used drum, and then cut the front side out of it so that the unit
can be lowered onto this ÒWash DrumÓ for thorough cleaning without the mess.
¤
stainless steel coil
¤
propeller and shaft
¤
thermocouple probe
¤
underside plate of the
pasteurizing hood
¤
drum
¤
accessory spigots or
hoses
Filling and Emptying
the Milk Drum
There area variety of ways and
means to fill the drum for pasteurization. Ideally, the unit is situated near
the main milk line so that a break can be made to divert the waste milk
directly into the unit. The product can also be bucketed into the drum, or
pumped in from another station with sump pumps or the like.
To remove the milk: A spigot
is included with all systems to install at the bottom, side of the tank. This
can be used to fill buckets or bottles directly. A stainless steel sump pump
can also be used to pump the milk more aggressively onto a calf cart or other
feeding equipment. Larger bore drains are also available for installation into
the side of the tank.
Energy and Time Saving Tips
á
Pasteurize the milk as
quickly as possible after collection to take advantage of the heat already in
the milk to improve energy efficiency. This will also prevent the immediate
heavy growth of bacteria in this fresh product.
á
Avoid placing the unit in
an area of high drafts to prevent convection heat losses from the drums while
pasteurizing.
á
Wrap the drums with the
included ½Ó insulating foam that comes with them. This foam has an insulating
value which can be very helpful in preventing heat loss.
á
To be most efficient,
choose the proper size DT Series Pasteurizer for your operation.
When
Service is Required
If
you purchased the Pasteurizer from an authorized dealer, contact them directly
with inquiries or repair questions. For prompt service, work through the
troubleshooting guide in this manual to give an accurate description of the
problem. Assistance is also available on-line at www.dairytechinc.com.
Repair
by an unauthorized service provider will void the warranty.
Trouble Shooting Guide
DT Series Pasteurizers
*This guide is
intended for use as a troubleshooting directive. All electrical tests and diagnostics
should be performed only by those skilled in the electrical profession*
*All electrical
testing and repairs should be performed by an experienced professional or
technician trained in the electrical trade*
*Serious injury or
death may result from improperly testing or handling this equipment*
*This unit
contains HIGH VOLTAGE electricity that can cause serious harm or death*
a. Check to be certain unit is plugged into 120vac outlet and that there is power at the outlet.
b. Be certain that breakers in panel box or ground fault receptacle are not tripped
i. If the breakers are being tripped, the system is likely being shorted to ground. Look for any blown fuses to indicate trouble areas and consult the fuse layout for more detail. Have the system checked by a certified electrician before operating.
i. If the contactor does not click, check the 115vac leads (brown/white and white/orange wires) on the back top of the contactor to see if it is being signaled by the SS relay. If there is 115vac signal, replace the contactor (Part# E-Contact)
ii. If no 115vac signal to the contactor, check the solid state relay SSR2. There should be a D/C signal though the yellow and orange colored wires to the relay and the LED should be lit when activated. 115vac is supplied to the relay through the black/yellow wire. Once signaled, there should be 115vac out of the black/white wire to the contactor. If not, replace the SSR2 (Part # AE-RelaySS)
iii. No D/C signal to the SSR2. Check the fuses for the control (F5 and F8). Check the orange plug on the back of the control. Call for service as the control output may be damaged and need replaced. (Part# E-Control)
i. Check for power inside the control box at the terminal strips. If there is power to the pump but it is not flowing, the pump may be air-locked (carefully open the pop-off valve on the heater to allow any air out of the system) or the pump may be bound by debris (relieve water pressure and open the body of the pump to check the blades for free movement). If the pump turbine does not spin when powered, replace. (Part# P-Pump.)
ii. No power getting to the pump during a heating cycle: check the fuse in the control panel box marked pump (F4) and replace if necessary. (Part#-AE-Fuse)
iii. No power to the fuse holder during a heating cycle: Check the cube relay CR1. There should be 115vac coming into the top of the CR1 through the black/orange wire at all times. The brown wire brings the 115vac signal from the control to activate the relay to allow 115vac out the bottom of CR1 through the black/red wire to the valve fuse (F6), and through the black/brown wire to the pump fuse (F4). If no power to the brown wire, check the control fuse marked hot (F3). The output of the control may be damaged and need replacement (Part# E-Control). If there is a proper 115vac signal, the relay or relay base may need replaced. (Part# E-relay8 or E-relaybase)
i. Make certain the discharge drain is not blocked, kinked or obstructed with back pressure of any kind
ii. Make certain the cold water supply to the unit is always on É it is common to find that someone has shut the valve not knowing its importance.
iii. Make certain that the user did not initiate a ÒHeat OnlyÓ cycle after which the unit does not cool the milk automatically. Use the ÒStartÓ button to initiate full cycles.
i. Is there power to the valve? If so, and it is not opening, replace the valve. (Part# P-Val2psi)
ii. No power to the valve: Check the fuse marked Cold valve (F7). Replace if necessary and check for power to the fuse from the cube relay CR2 via the blue/white wire. There should be 115vac power supply to the top of the CR2 through the black/orange wire. The 115vac signal from the control comes through the blue wire to open the relay. If the relay is powered, replace the relay or the base of the relay. (Part# E-relay8 or E-relaybase)
iii. If there is no 115vac signal to the relay from the blue wire, check the cold control fuse (F8) or the output from the control may be malfunctioning (Part# E-control)
i. Error 1, Error 2 or Error 3: controller malfunction. Cycle the power off and then back on. IF the error persists, return the controller for replacement. The system may be too cold to operate.
ii. Error 4: calibration error in the controller. Return the controller for recalibration or replacement.
iii. Error 5 and Error 7: temperature sensor input 1 (milk) is incompatible with the controller, has lead wires improperly terminated (leads switched at the terminal) or is measuring a condition below the normal temperature range. Check the lead wires for t/c 1 and check the controller for proper t/c selection and parameters. Check all t/c connections to make certain they are making a good connection. See thermocouple diagnostics below for more information and troubleshooting procedures. Error 6 and Error 8: temperature sensor input 1 (milk) is incompatible with the controller, has lead wires improperly terminated (leads switched at the terminal) or is measuring a condition above the normal temperature range. Check the lead wires for t/c 1 and check the controller for proper t/c selection and parameters. Check all t/c connections to make certain they are making a good connection. See thermocouple diagnostics below for more information and troubleshooting procedures.
iv. Error 9 and Error 11: temperature sensor input 2 (heater) is incompatible with the controller, has lead wires improperly terminated (leads switched at the terminal) or is measuring a condition below the normal temperature range. Check the lead wires for t/c 2 and check the controller for proper t/c selection and parameters. Check all t/c connections to make certain they are making a good connection. The system may be too cold to operate.
v. Error 10 and Error 12: temperature sensor input 2 (heater) is incompatible with the controller, has lead wires improperly terminated (leads switched at the terminal) or is measuring a condition above the normal temperature range. Check the lead wires for t/c 2 and check the controller for proper t/c selection and parameters. Check all t/c connections to make certain they are making a good connection.
vi. Error 13: ambient temperature around the equipment is too high or too low.
vii. Error 14: Real time clock error. Not a fatal error but may need replaced if the clock is not able to be used properly for delayed start function.
i. Fermentation of the milk by bacteria will cause the release of lactic acid and other acidic by-products resulting in a lower pH of the milk. This in turn allows it to separate. The heat of pasteurization will exacerbate this problem. To control this, cool the milk during holding stages or pasteurize the milk sooner after collection to prevent the start of fermentation.
ii. Acidic cleaners are not being rinsed from the system. Rinse properly before each use. Do not use acids to clean the aluminum parts as this can cause severe damage to the tanks and pose a safety risk for the employees.
i. Improper stirring (make certain the propeller is moving during heating, time out and cooling cycles)
ii. Temperatures that are too high (rarely a problem since our units cannot superheat water).
Assessing controller function
*** IMPORTANT WARNING***
DO NOT ALTER SETTINGS IN THE CONTROLLER WITHOUT
CONSULTING A DAIRY TECH REPRESENTATIVE É. ANY UNAUTHORIZED ADJUSTMENTS WILL
VOID THE PRODUCT WARRANTY AND MAY LEAD TO SERIOUS HEALTH CONSEQUENCES FOR THE
CALVES.
To access the controller main
menu for milk/heater temperature settings as well as process timing, follow
these steps:
Instructions for setting the Dairy Tech LP Series
controller functions:
1 2 3
4 5 6
1. Turn power on to the display so that it reads IDLE.
2. Press and hold 3 and 6 for 3 seconds until
straight lines appear across the screen.
3. Press and hold 4 and 5 for 3 seconds to
get into the menu screen .. eType should appear on the screen.
4. Press 1
to go into this menu. DO NOT go into other menus.
5.
Use 3 and 6 to
toggle up and down thru this menu. The code and its numeric value will flash back
and forth between each other. The following 5 parameters are set here:
a. Setpt – pasteurization temperature to reach
b. Coolt – temperature milk will cool to
c. Mntr – maximum temperature of heater
d. tHeat – length of time at Setpt temperature
e. terr -
time allotted for complete cycle before alarm sounds
6.
Press 1 to select a parameter to change; the numeric value
will be displayed.
7.
Press 3 or 6 to raise or
lower the value.
8.
Press 2 to accept the change ... repeat steps 6-8 for any
other changes.
9.
Press 2 repeatedly until you are back to the idle screen and
the changes should have been accepted.
The Pasteurize Profile can
run three different modes, Full Mode, Heat Only Mode, and the Cool Only
Mode. Each of these modes can be
started immediately or set to start at a programmed time. When the initial key is pressed (see
description below) the display reads nOW. If the same initial key is pressed, the
selected mode will start immediately.
At the nOW display, the increment and decrement keys can be used
to select between nOW and dELAy. Initially at the dELAy display, if the same initial key is pressed, 12:00AM time will be displayed. The user may set the starting time by using the increment
and decrement keys to adjust the time.
When the same initial key is pressed, the control will remain in the
Idle State (the display will now read dSTrt), but will
start the appropriate mode of the Pasteurize Profile at the time selected. This delay time will be used only
once. A user must set the delay
time before each delayed start.
Using the Start key (Key A)
as described above will select the Pasteurize Profile in the Full Mode. When the Full Mode starts, the
Pasteurize Profile will execute both the Heat Stage and the Cool Stage (first
the Heat Stage and once it completes, the Cool Stage will begin).
Using the Heat Only key (Key
B) as described above will select the Pasteurize Profile in the Heat Only
Mode. When the Heat Only Mode
starts, the Pasteurize Profile will execute only the Heat Stage.
Using the Cool Only key (Key E) as described above will select the Pasteurize Profile in the Cool Only Mode. When the Cool Only Mode starts, the Pasteurize Profile will execute only the Cool Stage.
Heat Stage
When the Heat Stage is initiated,
the heater (Output 1) is enabled to control heat to the setpoint (setpt parameter in the Equipment Type Submenu), the cooler
(Output 2) will turn continuously off, and the motor (Output 3) will turn
continuously on. Once the heater
temperature sensor (Sensor Input 1) value becomes greater than or equal to the
setpoint (Setpt parameter in the Equipment Type Submenu), an internal
timer is started. The internal
timer will be set to expire in a time interval equal to the theat parameter in the Equipment Type Submenu. Once the internal timer expires and if
the Start key (Key A) was used to start the profile, the Cool Stage will
begin. Else if when the internal timer
expires and the Heat Only key (Key B) was used to start the profile, the
profile will be completed.
When the Cool Stage is
initiated, the heater (Output 1) is disabled from controlling heat, and the
cooler (Output 2) and the motor (Output 3) will turn continuously on. Once the heater temperature sensor
(Sensor Input 1) value becomes less than or equal to the cool setpoint (Coolt parameter in the Equipment Type Submenu), the cooler
(Output 2) and the motor (Output 3) will turn continuously off, and the profile
will be completed.
If the Pasteurize Profile is
in the Full Mode, a single press of the Start key (Key A) will pause the
profile. An additional press of
the Start key (Key A) will resume the profile running. If the Pasteurize Profile is in the
Heat Only Mode, a single press of the Heat Only key (Key B) will pause the
profile. An additional press of
the Heat Only key (Key B) will resume the profile running.
If the Pasteurize Profile is
in the Cool Only Mode, a single press of the Cool Only key (Key E) will pause
the profile. An additional press
of the Cool Only key (Key E) will resume the profile running.
If the Pasteurize Profile is
in the Full Mode, pressing and holding the Start key (Key A) for 3 seconds will
cancel the profile. If the
Pasteurize Profile is in the Heat Only Mode, pressing and holding the Heat Only
key (Key B) for 3 seconds will cancel the profile. If the Pasteurize Profile is in the Cool Only Mode, pressing
and holding the Cool Only key (Key E) for 3 seconds will cancel the profile.
Contact
Dairy Tech, Inc.
Dairy
Tech, Inc.
405
Tuckaway Ct
Windsor,
CO 80550
Phone:
1-866-384-2697
1-970-674-1888
1-970-686-5871
fax
Monday
– Friday
7:00
a.m. – 6:00 p.m., MST
Web: