Thank you for purchasing a Dairy
Tech, Inc. DT Platinum 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 & Registration
Receiving your Pasteurizer
Receiving
your Pasteurizer
Important
Safety Instructions
Installation and Operation
Mounting
the Control Panel
Attaching
Optional Leg Kit
Choosing
a location
Connecting
Optional Hoses
Electrical
Requirements
Lid
Assembly/Storage
External Fuse Board
Initial Start-Up of the Unit
System
Operation and Use of Pasteurizer
Cycle
options
Setting
the Clock
Delayed
Start Options
Filling
and Emptying the Milk Pot
Heater
Maintenance
Cleaning
the System
Quality Control and Milk
monitoring
Heater Reservoir Instructions
Trouble Shooting
THIS PASTEURIZER IS INTENDED TO BE USED IN THE
MANNER DESCRIBED IN THIS USE AND CARE GUIDE. IT IS NOT INTENDED TO PASTEURIZE
MILK OR OTHER GOODS 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 Platinum 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 DAIRY TECH 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 the pasteurizer.
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 your local representative or call 1-866-384-2697 and we
will help you to address your needs.
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
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 to 30 months from the date of
purchase, all parts will be covered by a free replacement guarantee. Electric
heating elements are not covered by this warranty as the water supply is the responsibility of the
operator. 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. This warranty covers only the cost of
replacement parts at Dairy Tech, Inc. current pricing. Service is not
covered by this warranty.
Product Registration
If this product was purchased
directly from Dairy Tech in Windsor, CO, it has already been registered and no
further action is required. If the product was purchased by a distributor or
other representative, please call Dairy Tech, Inc. at 866-384-2697 within 10
days to register the product. Failure to do so
may result in a decreased or voided warranty period for
your unit. When calling, please have the serial number which can be found on
the back side of the control housing or back panel.
Receiving your
pasteurizer
Use care when unpacking your
DT Platinum Series pasteurizer. It will have arrived in one box or crate.
Please make a note of any cautionary labels that are used on the carton
suggesting orientation, where to cut with a knife, fragile, etc.
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. Do not turn on the pasteurizer without first purging
the heaters and filling the heater reservoir.
3. Always disconnect the electrical power before
attempting service. Disconnect by grasping the plug, not the cord.
4. 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.
5. Do not reach into the Pasteurizer when the power is on
and the paddle is turning as this can cause serious harm.
6. Hot Surfaces include the brass plumbing fixtures,
electrical fixtures, hoses, heater body, milk cabinet surfaces, draining water
and the milk or colostrum. Touching these surfaces during operation may result
in severe burns.
7. Do not try to change the settings in the pasteurizer
controller without consulting a technical expert at Dairy Tech, Inc.
8. 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.
9. 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 propeller or tank will decrease heating and
cooling efficiency, as well as harbor potentially harmful pathogens.
10. During the heating cycle, always make certain the
Pasteurizer lid is firmly seated on the pot of milk.
11. 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.
12. Do not touch the tank of milk, motor, hoses or brass
fittings while the unit is hot and working.
13. Do not attempt to tilt the machine while it is full. It
is extremely heavy and can cause severe injury to the operator and may cause
failure of the support structures.
14. To prevent severe burns, always allow the milk or
colostrum to cool completely before handling or feeding to calves.
15. 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.
16. The pasteurizer must be installed on a level surface to
evenly distribute weight to all the support structures.
Installation:
Step 1: Mounting the
Control Panel
The pasteurizing unit is
typically shipped with the unit fully assembled. In some instances, mounting of
the control box will be required. Gently remove the controller from the milk pot
Four mounting holes are provided on the lid of the unit. Using the bolts that
are provided, attach the control unit in an upright fashion to the top lid of
the pasteurizer. The electrical connections must also be made by inserting the
male and female sides of the connector together. See Figure 1.
Figure 1
The motor shaft must also be
attached by inserting it through the side entry of the coupler, followed by
right-hand threading of the shaft into
the coupler. The shaft can be gripped at the knurling located midway on the
shaft.
Step 2: ATTACHING THE
LEG KIT
Some water cooled units will
ship with the leg kit removed for shipping. The leg kit can be assembled using
the enclosed hardware kit and instructions, so that the pasteurization unit is
mounted on top of the leg stand. Always be certain to build and position the
unit on a level floor, with the risers placed in the rear. See Figure 2 for
further instructions.
Step 3: Choosing a
Location
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) Cold water is required to be connected to the unit for
water cooled models, but a nearby hot water source is also necessary for proper
cleaning.
c) Floor drains will allow for proper cleaning and rinsing
of the product as well as to clean up milk spills.
d) Power requirements are 115vac 15 amp GFI for the controls
of the DT30W. 240VAC single phase 30 amp supply is required for the heater
connection. For the DT30W-EU the 115vac is supplied internally by a step-down
transformer so that it can be connected to a normal European 220vac outlet.
e) Floor space requirements are approx 36Ó x 36Ó, similar
to a residential dryer or washing machine.
f)
Figure 2.
Avoiding extremely drafty
areas will improve heating efficiency of the unit.
Step 4: Connecting the Hoses for
Water-Cooling
WATER-Cooled Units: This hose with
factory ends supplies all the cold water to cool the product when
pasteurization is finished. It can connect to any low pressure cold water
source including a hose but it MUST BE ON AT ALL TIMES DURING OPERATION. Using
the supplied hose, attach one end where indicated on the back of the unit, with
the other end going to a regular hose bib supply. A pressure reducer is built
into the unit and must be used. The water jacket is intended for systems with 15psi. Install an additional water pressure reducer if
necessary for high pressure systems.
WATER DRAIN: 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 labeled on the
back of the unit if it is not already attached for you. Do not connect the
hose to another hose or to any system that can create back-pressure. This will
cause damage to the cooling jacket and void the warranty.
Once the unit is in operation,
adjust the flow rate of cooling water to be steady but slow so the water can
absorb the most heat without wasting water. High pressure and high flow rates will damage the cooling jacket
of the system.
Step 5: Electrical
Requirements DT30W
The standard electrical cord
emerging from the back of the machine should be plugged directly into a 115vac grounded
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 and
will resume automatically.
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 heater plate is replaced
when necessary by removing the back panel and front panel after disconnecting
all power to the unit. The side supports can be relieved by removing the bolts
and dropping them down to access the heater. Slide out the old heater and
insert the new one making certain that the milk tank sits evenly on the heater
pad. Reconnect supports and wiring.
In addition to the electrical
requirements of the DT30W and DT30W-EU, the 30 gallon system also requires 240vac
for the heater. The 240vac supply for the electric heater emerges from the back
of the equipment. A 6Õ length is supplied for termination into an appropriate
outlet. 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 30 gallon
heater at full capacity will draw 18 amps on a single phase 240 vac system. 30
amp breakers are sufficient in most instances. 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 inserted 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 receptacle, have
a proper outlet installed by a qualified electrician.
DT30W-EU
This European Model is
equipped with a built-in step-down transformer to provide the necessary 115vac
supply for control function. Use the provided Euro style plug to connect to
standard 15amp 220vac supplies. The heater requirements are the same for this
model but will require a direct connection using the stripped wire ends. White
is a common neutral connection. Red and Black are leads 1 & 2 which should
carry 120vac each. Green is a ground to earth.
Step 6: Lid Storage
The lid is packaged with the
unit and can be hung on the side of the pasteurizer by the handle. This
provides a convenient place to store the lid while the unit is being cleaned or
filled. See Figure 4 for proper
lid storage.
Figure 4.
External Fuse Board
The unit is equipped with 7
external fuses on the back of the unit. These fuses protect delicate electronics and also serve as a
troubleshooting guide in cases of system malfunction. The layout of the circuit
breakers is described below in Figure 5 as well as on the unit itself. Refer to
Trouble Shooting for further information.
F1 Main
power supply 115vac 15A Part# E-fuse15
F2 Transformer 1A Part# E-fuse1
F3 Cold
valve/pump 2A Part# E-fuse2
F4 Refrig/Accessory 10A Part# E-fuse10
F5 Ctrl/Refrig 1A Part# E-fuse1
F6 Ctrl/Valve
or pump 1A Part# E-fuse1
F7 Stir
motor 2A Part# E-fuse2
Use of the Pasteurizer
Initial cleaning of the milk
pot may be necessary to remove oil residues from the manufacturing process. Next, simply add milk or colostrum and
replace the lid. You are now ready to choose one of the operational options
listed below.
Try
to avoid excessive splashing or spilling of the product as it is being poured
into the unit. Clean spills with a damp cloth as quickly as possible.
Do
not overfill the pot as the milk will splash out from under the lid while being
stirred.
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 START features are below.
¤The
display will indicate the temperature and stage of cycle. The TIME to complete
pasteurization is displayed when temperature is reached.
¤The
display will indicate END when the chosen cycle is complete.
¯
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 display 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.
¯
REHEAT is used to warm
the milk or colostrum back to a feeding temperature after it has been
pasteurized and cooled or refrigerated. This is not a pasteurization cycle.
¤
The temperature will be
displayed until the set point is reached, at which time the unit will display
ÒENDÓ .
¯
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 error on the display.
¯
If the display indicates
other ÒERRORSÓ, look in the trouble shooting guide for further information.
¯
To power down the unit,
turn off the red toggle switch or unplug the unit from the wall
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. If
power is interrupted, the cycle will resume in the cycle it was in when the
power was interrupted or failed. The unit will attempt to restart even if
manually turned off during a cycle. To reset the unit, hold in the lit LED
button for 4 seconds to return to IDLE. For example, if it continues to return
to the full cycle, holding in the START button for 4 seconds will first pause
and then cancel the cycle and return the unit to IDLE.
SETTING THE CLOCK
¤
Power the unit on so that
ÒIDLEÓ is displayed on the screen of the controller.
¤
Depress the START and REHEAT
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.
DELAYED START
a. Press either the START or HEAT ONLY button so that the
word ÒNOWÓ is displayed.
b. Then press the UP key once or twice to choose Delay1 or
Delay2.
c. By pressing the START key once again, the clock will
appear and the UP and DOWN keys can be used to set the time you wish the cycle
to begin.
d. Once the time is set, press START again and the screen
will again display Òdelay1 or delay2Ó.
e. The unit will now come on at the time you have set.
f. The two settings are to allow for an AM and PM setting
that it will revert to unless a change is made.
Filling and Emptying
the Milk Drum
While some dairies may elect
to have the milk line pump directly into the pasteurizer, most dairies will be
dealing with volumes that can be dumped into the unit from milk cans or
collection buckets. Try to avoid
unnecessary splashing and provide a sturdy step for short employees who may
have trouble comfortably dumping milk into the unit.
To remove the milk: Open the
spigot to fill buckets, bottles or storage bags. DO NOT TILT THE EQUIPMENT TO
GET MILK OUT!. This may cause undue stress on the support system and could
potentially damage the unit or harm the operator. Any residual milk or
colostrum can easily be wiped or brushed from the unit
Maintenance of the DT30W
and DT30W-EU Water Heaters
These units are equipped with
an electric heater that is immersed in a water bath. The water reservoirs are
suspended on the right side of the unit. The water should be changed every 2
months or when dirty. Build up of deposits from water can decrease heat
efficiency and increases the likelihood of premature heater element failure.
Changing the water often will prevent this. Use de-ionized or distilled water
when possible to reduce the amount of sediment and deposits forming on the elements.
The maintenance is simple and inexpensive as the unit requires 4-6 quarts of DISTILLED
WATER from your local grocery store. The following instructions go into more
detail about how to maintain the heater, how to change the water and how to
change a heating element if necessary.
SEE THE ATTACHED INSTRUCTIONS
FOR HEATER MAINTENANCE FOLLOWING
THIS SECTION
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 while pasteurizing.
á
Colostrum can be stored
in the refrigerator for an extended period of time if it is handled cleanly
once it has been pasteurized. Filling freezer bags allows for a disposable
system that makes it easy to keep track of dates and colostrum quality. These
bags also allow the product to be warmed more quickly when they are needed for
the newborn.
á
Do not dip bottles into
the tank for filling as this will likely contaminate the product with bacteria
from the bottom and sides of the bottles.
á
Always wear nitrile or
latex gloves when handling the milk or colostrum to prevent the spread of
pathogens from the skin surface.
CLEANING THE SYSTEM (be
sure the equipment is powered OFF)
¤
Motor shaft, coupler and
propeller (shaft can be unthreaded for cleaning by grasping the coupler with
the slot facing forward and unthread the shaft by grasping the knurling mid
shaft for a better grip.)
¤
Thermocouple well at
bottom of pot
¤
Underside of the
pasteurizer lid
¤
Milk tank and drain
spigot/valve
¤
accessory spigots,
pitchers or hoses
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.
Repair
by an unauthorized service technician will void the warranty.
www.dairytechinc.com
Quality Control and System
Monitoring
The following recommendations
should be carried out when the system is first installed and then on a monthly
schedule to make certain that the pasteurization process is working adequately.
1. Follow all instructions for proper installation by
thoroughly reading the manual.
2. Use quality milk and colostrum in the machine. The
process can be overwhelmed if there are too many bacteria to begin with.
3. Handle the milk cleanly after pasteurization to prevent
recontamination.
4. Utilize the Dairy Tech Milk Test Kit to send a sample
to the independent lab for milk quality testing.
5. Verify display temperatures periodically with a second
thermometer to be sure that the displayed reading matches closely with a
trusted calibrated source.
6. Additional milk test kits are available for order at www.dairytechinc.com
READ THESE INSTRUCTIONS
BEFORE POWERING THE UNIT!
Installation of New Water Tank
nder the pasteurizer for shipping
purposes. It looks like an automotive coolant reservoir and has a
demarcation on it to indicate the filling level.