Abts Equipment CALF-STAR Mini Flash 2.0 Troubleshooting guide

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Mini Flash 2.0
Service/User Manual
Version 2.1
11/21/2019

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1. Introduction
Congratulations on your purchase of a Calf-Star Mini Flash Pasteurizer. This equipment has been
designed and manufactured to meet the needs of a discriminating buyer.
Safe, efficient and trouble-free operation requires that you and anyone else who will be operating
or maintaining the pasteurizer, read and understand this manual.
Use of the equipment outside of the intended use, or without written approval from Calf-Star is
not covered by our performance guarantee, nor will damages caused be covered by our warranty.
Calf-Star cannot be held liable for consequential damages, including, but not limited to, loss of
production, personal injury or property loss.
Installation, setup, operation, maintenance and repairs must be performed by qualified personnel
only.

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2. Safety
Safety Alert Symbol and Signal
Words
You must read, understand and follow the instructions in this manual.
The safety information in this manual is denoted by the safety alert symbol:
This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
The level of risk is indicated by the following signal words:
Installation Hazards

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Operational Hazards
Carefully read all safety messages in this manual and on equipment safety signs. Keep safety
signs in good condition and replace missing or damaged safety signs.
New equipment components and repair parts must include the current safety decal.
Learn how to properly operate equipment. NEVER operate or work around this equipment without
proper instruction, while fatigued or under the influence of alcohol, prescription or non-prescription
medication or if feeling ill.
Keep your equipment in proper working condition.
Know the regulations and laws that apply to you and your industry. This manual is not to replace any
regulations or laws. If you do not understand any part of this manual, contact Calf-Star at 920-866-2485.
Prepare for Emergencies
Be prepared in case of emergencies.
Keep a fire extinguisher and first aid kit close to the machine.
Keep emergency phone numbers close to your phone.
Know your address so emergency services can locate you if an emergency arises.

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Maintenance Hazards
Before performing service, maintenance or adjustments, lockout power source.
Always wear face and/or eye protection, safety shoes, and other protective equipment appropriate
for the job. Follow company stated safety procedures and policies.
Always use Calf-Star replacement parts.
Pressurized Air Hazards
Hazards from Modifying Equipment
Do not alter or modify machine in any way. Altering or modifying may cause your equipment to
be unsafe and may void the manufacturers’ warranty.
Contact Calf-Star before altering or modifying equipment.

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3. Installation
Installation Requirements
•68” x 28” (172cm x 71cm) Foot Print
•380/220 VAC 32/80 Amp Electrical Requirements
•5/32” 110 PSI Air Supply
•Hot Water Supply
•Cold Water Supply
•Acid Chemical Barrel
•Non-Chlorinated Detergent Chemical Barrel
•1.5” (3.8cm) In Floor Drain
Position Machine
1. Position machine on level surface.
2. Position machine near a drain and close to the raw milk supply.
Electrical Connection

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Table of Contents
•Requirements for installation→page 8
•Product discharge connection→page 9
•RAW product intake→page 10
•Key Components→page 11
•Cover switch/sensor→page 14
•Screen Navigation→page 15
•Main Screen→page 15
•Setup→page 16
•Pasteurize/Auto Start→page 17
•Wash→page 18
•Cool→page 19
•Agitate→page 20
•Temperature/Calibration→page 21
•Chemical Calibration→page 22
•Water Calibration→page 23
•Manual Operation→page 24
•Troubleshooting→page 27
•PLC Inputs/Outputs→page 28

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Requirements for Installation
•68” x 28” (172cm x 71cm) footprint
•220/380VAC 80/32 Amp electrical requirements
•5/32” 110 PSI air supply
•Hot water supply
•Cold water supply
•Acid chemical barrel
•NON-chlorinated Detergent chemical barrel
•1.5” (3.8cm) in floor drain
1. Electrical connection
•The Mini-Flash 2.0 requires 80/32Amps of 220/380VAC.
•Wire Line 1 and Line 2 to the terminal blocks on the top of the electrical panel.
•Wire the Ground Wire to the panel mounting bolt.
L1
L2
L3
L1
L2

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1. Air supply connection
•Connect 110 PSI air supply to 5/32” air connection on
back of machine.
2. Water supply connection
•Connect hot and cold water supply on back of machine
with a garden hose connection.
3. Chemical connection
•Connect detergent and acid chemical connection on
back of machine.
Pasteurized product discharge connection
1. Pasteurized product discharge connection is located at the front of the machine.
2. The discharge connection is a ¾” tri-clamp.
When washing discharge
line connect end of line
here.

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10
Raw Product Intake
3. RAW product can be filled into the machine by the Auto Fill valve or by the tank
cover.
4. The Auto Fill Valve is located on the back of the machine above the tank.
5. If using Auto Fill valve control, a +24VDC wash signal is required from delivery device
to the Mini-Flash 2.0 to keep the Auto Fill valve closed when washing the delivery
line. The wash signal wire lands in a terminal block inside the electrical cabinet
labeled wash signal.

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11
Key Components
Heating plate cooler
Regen plate cooler
Drain valve
Tempering loop
Timing loop
Timing milk pump
Balance/Divert tube
Timing loop Temp Sensor
Product Flowmeter
Product Flow Meter

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12
Loop Valve
Divert
Final product temperature
Tank Float
Supply valve
Tank Temperature sensor

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13
Circulation Pump
Boiler Fill Float
Boiler temperature sensor
Electrical boiler heating
elements (220V 5500W)
Cold water tempering
Hot water tempering
Cold water wash
Hot water wash

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14
Cover switch/Sensor
Air solenoid manifold
Acid pump
Detergent pump
The Mini-Flash 2.0 is equipped with a
Cover Switch/Sensor. This switch
utilizes a magnet mounted on the
cover and a sensor mounted in the
compressor cabinet. The purpose of
this feature is to not allow the
agitator to run if the cover is off of
the machine. The agitator will
immediately turn off if the cover is
removed from position. The cooling
compressor will also shut off after a
period of time.

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15
Screen navigation
1. Main Screen
Current flow
rate of product
Current Final
Product
temperature
Current
Pasteurize
temperature
Current Tank
temperature
Start
Pasteurization
Turn cooling
on/off
Start the wash
Rapid Empty
will run the
pump at full
speed emptying
the tank

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2. Setup
To view more setup
settings, the user
has to login
To login in press the log IN/OUT button.
Password =SERVICE222,
*NOTE this menu is intended only for the
proper user. Please keep the password discrete

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A. Pasteurize/Auto Start
The Mini-Flash 2.0 has an Auto Start
Function. This feature will
automatically start pasteurizing at the
desired entered time. *NOTE all
hoses and connections must be
attached correctly.
Adjust product out temperature

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18
B. Wash
This is the amount of time the Supply Tank will
circulate water inside the tank.
This is the amount of time the Divert Tube will
circulate water inside it.
This is the amount of time the Pasteurizer will leave
the drains open.
•Auto wash will Automatically start a wash cycle after
pasteurization. *NOTE additional hardware/setup is
required to use auto wash, Discharge connection must be
placed in proper location.
•Extended line wash will enable a special wash/Flush
sequence. This feature is designed for applications with
an especially long discharge line <100ft/30meter. *NOTE
Additional hardware/ setup is required.
This is the amount of time the delivery line will
circulate water inside it.
This is the amount of time the Pasteurizer will
activate the airblow (only activated with extended
line function)

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C. Cool
Touch box to
change cooling
set point
Touch box to
change cooling
Dead band
This is the amount of time the water will fill during all phases;
this setting dictates how much water the machine will wash
with in each phase. The user can set the water amount by
either time or volume. *Note machine must be calibrated
correctly.
Adjust the amount of chemical in each phase. *Note machine
must be calibrated correctly.
*These time settings shown are factory default
Auto cool will automatically start cooling if
there is product in the tank.

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D. Agitate
Tap the box with the number
in it to change the parameter.