CALF-STAR Milk Jug User manual

Calf-Star Milk Jug 1
Calf-Star
4324 N. County Road P.
New Franken,WI 54229
Phone: [phone]
Email: [e-mail]
Website: www.calfstar.com
August 2013

Calf-Star Milk Jug
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Contents
1. Introduction............................................................................................................4
1.1 Introduction .......................................................................................................................... 4
2. Component Identication .....................................................................................5
3. Safety......................................................................................................................6
3.1 Safety Alert Symbol And Signal Words ............................................................................. 6
3.2 Installation Hazards ............................................................................................................. 6
3.3 Operational Hazards ............................................................................................................ 6
3.3.1 Prepare For Emergencies ........................................................................................... 7
3.4 Maintenance Hazards .......................................................................................................... 7
3.5 Pressurized Air Hazards...................................................................................................... 7
3.6 Hazards From Modifying Equipment.................................................................................. 7
4. Installation...............................................................................................................8
4.1 Position Machine.................................................................................................................. 8
4.2 Water Connections .............................................................................................................. 8
4.3 Electrical Connections ........................................................................................................ 8
4.4 Detergent Pump Connection............................................................................................... 8
4.5 Wash Drain Valve ................................................................................................................. 8
4.6 Programming........................................................................................................................ 9
4.6.1 Setting Dixell Control .................................................................................................. 9
5. Operation..............................................................................................................10
5.1 Pre-Operation Check List.................................................................................................. 10
5.2 Cooling................................................................................................................................ 10
5.3 Setting Detergent Pump .................................................................................................... 10
5.4 Check Amount Of Detergent Being Dispensed............................................................... 11
5.5 Wash Cycle ......................................................................................................................... 12
6. PLC Inputs And Outputs.....................................................................................12
6.1 Outputs ............................................................................................................................... 12
6.2 Inputs .................................................................................................................................. 12

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1. IntroduCtIon
1.1 IntroduCtIon
Congratulations on your purchase of a Calf-Star
Milk Jug. This equipment has been designed and
manufactured to meet the needs of a discriminating
buyer.
Safe, efcient and trouble free operation requires
that you and anyone else who will be operating or
maintaining the equipment, 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 qualied personal only.
Modication and tampering and/or the use of
unapproved spare parts will exempt Calf-Star from
any and all responsibility and will void the warranty.

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A. Dixell Controller
B. Wash/Off/Cool Switch
C. Automatic Wash Drain Valve
D. Tank Shutoff Valve
E. Wash System
F. Cold Water Inlet
G. Hot Water Inlet
H. 5 Amp Circuit Breakers, Electronics
I. 10 Amp Circuit Breakers, Compressor
J. Main Power Cord
K. Chemical Pump
Dimensions:
MJ50
34 in (864 mm) Long
34 in (864 mm) Deep
MJ100
61 in (1549 mm) High
34 in (864 mm) Long
34 in (864 mm) Deep
MJ200
83 in (2108 mm) High
34 in (864 mm) Long
34 in (864 mm) Deep
2. Component IdentIfICatIon
55
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F
G
J
H
K
I
CALF FEEDING SOLUTIONS
CALF-STAR
Custom made for your farming needs!
PRODUCT TEMPERATURE
WASH COOL
OFF
A
C
E
B
D
Rear Of Milk Jug

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3. safety
3.1 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:
^DANGER
DANGER - Indicates a hazardous
situation, which, if not avoided, WILL
result in death or serious injury.
^ WARNING
WARNING - Indicates a hazardous
situation, which, if not avoided, could
result in death or serious injury.
^ CAUTION
CAUTION - Indicates a hazardous
situation, which, if not avoided, could
result in minor or moderate injury.
NOTICE
NOTICE - Indicates a situation that could
result in damage to the equipment or
other property.
3.2 InstallatIon Hazards
^ WARNING
Prevent serious injury or death.
Electrical and mechanical installation
must be performed by qualied
technicians.
Installation must conform to all national,
local, and provincial codes and standards.
^ WARNING
Prevent serious injury or death.
Use adequate lifting devices to raise,
move and install machine.
3.3 operatIonal Hazards
^ WARNING
Safely operate equipment.
Allow only properly trained and qualied
personnel to operate this equipment.
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 inuence 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.

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3.3.1 prepare for emergenCIes
Be prepared in case of emergencies.
Keep a re extinguisher and rst 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.
3.4 maIntenanCe Hazards
^ WARNING
Prevent serious injury or death.
Equipment maintenance must be
performed by qualied technicians.
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.
3.5 pressurIzed aIr Hazards
Compressed air can cause serious injury or death.
^ WARNING
Do not use compressed air for any other
purpose than that for which it is provided.
Never direct a stream of compressed air
towards your body or the body of another
person.
Before using, check all components for
damage or wear. Make sure connections
are tight and hoses are in good condition.
3.6 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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4. InstallatIon
^ WARNING
Prevent serious injury or death.
Electrical and mechanical installation
must be performed by qualied
technicians.
Installation must conform to all national,
local, and provincial codes and standards.
4.1 posItIon maCHIne
^ WARNING
Prevent serious injury or death.
Use adequate lifting devices to setup and
install equipment.
Use of inadequate equipment may result
in serious injury or death.
Position machine on level surface. If connecting to
an automatic calf feeding system, mount near inlet of
automatic calf feeder.
4.2 Water ConneCtIons
Note: Water supply must deliver a minimum of 30 psi
(207 kPa) and 5 gpm (19 lpm) of water.
Connect cold water supply to water inlet (A).Connect
hot water supply to water inlet (B).
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A
B
4.3 eleCtrICal ConneCtIons
^ WARNING
Prevent serious injury or death.
Electrical installation must be performed
by qualied technicians.
Installation must conform to all national,
local, and provincial codes and standards.
Electrical installation must be performed by a qualied
electrical technician. Electrical supply must be 220
VAC, 20 amp.
4.4 detergent pump ConneCtIon
Note: Verify the dip tube goes all the way to the
bottom of chemical container.
Connect chemical hose to pump (A). Use an acid
based detergent (one step) for washing.
55
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A
4.5 WasH draIn ValVe
Valve should be mounted near a oor drain to keep
water from pooling during wash cycle.

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4.6 programmIng
4.6.1 settIng dIxell Control
• Verify wash/off/cool switch is in the off position.
• To check setpoint, press set (A) and release.
• To change setpoint, press and hold set (A) for 2
seconds, then release.
• Arrow up or down (B) to change setpoint.
• Wait 10 seconds, normal screen will be displayed.

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5. operatIon
^ WARNING
Safely operate equipment.
Allow only properly trained and qualied
personnel to operate this equipment.
^ WARNING
Do not operate without guards and
shields in place.
^ Do not operate, work on or around this machine
while under the inuence of alcohol, drugs or if
feeling ill.
^ It is your responsibility to operate this equipment
safely. You must be familiar with the equipment
and all safety practices before use.
^ Do not allow untrained or unqualied people to
operate this equipment.
5.1 pre-operatIon CHeCk lIst
Review and understand this manual.
Verify all guards are installed and covers are closed
and latched.
Verify all personnel are clear of machine.
5.2 CoolIng
The Milk Jug is designed to cool milk from 60°F - 70°F
down to 40°F. Adding milk that is warmer than 60-
70°F will result in a slower cooling process
Close shutoff/buttery valve on bottom of tank. Fill
Milk Jug with tempered milk. Move selector switch (A)
to cool.
Once milk level rises above safety oat, the cooling
will start, bringing in freon to expansion plate mounted
on bottom of tank.
The agitator will also start at this time. Once milk
cools to desired set-point, cooling will turn off until the
temperature rises above re-cool threshold.
During the rest time, agitator will still cycle to assure
that milk components stay in suspension.
When milk level falls below safety oat, cooling
system will disengage so milk does not freeze to the
bottom of tank.
5.3 settIng detergent pump
The Milk Jug comes with a Clean In Place (CIP)
system that utilizes a single step wash system. It is
important that you use a One-Step Acid Detergent
product such as BouMatic Brilliance™. To program
the detergent pump:
1. Move selector switch (A) to off position.
2. Open control panel door.
3. Press Start button (B). This will start an internal
timer to set the length of time the detergent pump
will run. Typically, pump will dispense about 1
ounce every 2 seconds of operation. The amount
of water in detergent cycle will be approximately
10 US Gallons.

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4. After proper time has elapsed (20 – 30 seconds
on average), press Stop button (C). This will stop
the timer and end the programming process.
5. Close control panel door.
5.4 CHeCk amount ofdetergent beIng
dIspensed
^ WARNING
Skin irritation hazard.
Detergent is potentially hazardous.
Read and follow the handling instructions
and MSDS for the detergent.
1. Make sure detergent pump is primed.
2. Move selector switch (A) to off position.
3. Remove detergent line from output side of
detergent dispense pump. Be sure to wear proper
protection.
4. Hold a cup under the detergent out.
5. Move selector switch (A) from off to wash position.
6. After about 3 to 5 minutes, detergent cycle will
start and detergent pump will dispense detergent
into the cup.
7. Verify that amount of detergent is adequate for
approximately 10 gallons of water.
8. Dispose of detergent properly.
9. Re-connect outgoing detergent hose to detergent
pump. This concludes test.

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6. plC Inputs and outputs
6.1 outputs
6.1 outputs
0-00 = Detergent Pump
0-01 = Agitator Motor
0-02 = Wash Pump
0-03 = Drain
5.5 WasH CyCle
Remove milk hose from drain valve to empty any
remaining milk left in tank. Once milk is drained,
connect wash ferrule to drain buttery valve.
Make sure tank lid is closed to keep rinse and wash
water from spraying out of the tank. Move selector
switch to wash. The milk jug will go through an
abbreviated wash cycle, cold water rinse, hot water
rinse, hot detergent cycle, then a cold water rinse to
ush tank and cool it down prior to lling of milk.
Use an acid based detergent (one step) for washing.
After each of the three cycles above, water will be
automatically diverted down the wash drain. Once
wash cycle is complete, move selector switch to off.
See chart below for complete wash cycle phases.
If using in an automatic calf feeding system, make
sure that milk supply hose is washed during this wash
time.
Disconnect wash ferrule from drain valve. Connect
milk hose to drain valve. Fill milk jug with milk and
turn the selector switch to cool.
Wash System Cycles
Cold Water
On
Hot Water
On
Drain Valve
Open
Agitator On Wash Pump
On
Chemical
Pump On
Time In
Seconds
Phase 1 X X X X 60
Phase 2 X X X 40
Phase 3 X X X X 120
Phase 4 X X X X Set By Dealer
Phase 5 X X X 120
Phase 6 X X 360
Phase 7 X X X 60
Phase 8 X X X X 60
Phase 9 X X X 120
6.2 Inputs
I-00 = Wash Switch
I-01 = Cool Switch
I-02 = Dixell Controller
I-03 = Start Detergent Switch
I-04 = Stop Detergent Switch
I-05 = High Pressure Cutoff Switch