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
JUne 2015

Calf-Star Milk Jug
2

Calf-Star Milk Jug 3
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 Programming........................................................................................................................ 9
4.5.1 Change Cooling Set Point........................................................................................... 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. Schematics............................................................................................................13

Calf-Star Milk Jug
4
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.

Calf-Star Milk Jug 5
A. Touch Screen
B. Automatic Wash Drain Valve
C. Tank Shutoff Valve
D. Wash System
E. 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
CALF FEEDING SOLUTIONS
CALF-STAR
Custom made for your farming needs!
A
B
D
C
Rear Of Milk Jug

Calf-Star Milk Jug
6
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.

Calf-Star Milk Jug 7
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.

Calf-Star Milk Jug
8
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 hot water supply to water inlet (A). Connect
cold water supply to water inlet (B).
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.
A

Calf-Star Milk Jug 9
4.5 programmIng
4.5.1 CHange CoolIng set poInt
1. From startup page, touch screen to go to main
menu.
2. Touch Setup.
3. Touch Cool Setup.
4. Touch Setpoint.
5. A keypad will popup. Type number and press
return arrow to enter value.
6. Touch Main Page to return to main page.
7. To turn on cooling, while on main page, touch
Cool, then Off/On. Compressor has a 30 second
delay before starting. If wash switch is on, cooling
will not turn on.

Calf-Star Milk Jug
10
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. Touch Off/On button. Go
to Cooling Menu.
Once milk level rises above safety oat, the cooling
will start.
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. Go to Setup.
2. Touch Wash Setup.
3. Touch Detergent Per Wash Cycle. A keypad will
popup. Type in number and touch return button to
enter value.

Calf-Star Milk Jug 11
4. Typically, pump will dispense about 1 ounce every
2 seconds of operation. The amount of water in
detergent cycle will be approximately 10 gal (38 l).
5.4 detergent CalIbratIon
^ WARNING
Skin irritation hazard.
Detergent is potentially hazardous.
Read and follow the handling instructions
and MSDS for the detergent.
It is recommended that this procedure be performed
by a trained professional.
1. Touch Prime Detergent Pump button to make sure
detergent pump is primed.
2. Remove detergent line from output side of
detergent dispense pump. Be sure to wear proper
protection.
3. Hold a cup under the detergent out.
4. Go to Detergent Calibration page. Touch Start
Detergent Calibrate Cycle. Measure amount of
chemical dispensed. Enter amount in Detergent
Dispensed. Touch return arrow to enter the value.
Touch Main Page to return to Main Page.

Calf-Star Milk Jug
12
5.5 WasH CyCle
It is recommended that this procedure be performed
by a trained professional.
1. 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.
2. Make sure tank lid is closed to keep rinse and
wash water from spraying out of the tank. Go to
Wash menu, touch Off/On button.
3. 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. Display
will indicate phase of wash cycle, time of phase
what is currently on (cold, hot, agitator, etc.)
4. Wash cycle times can be changed in factory setup
menu. Factory service code is service22.
5. Use an acid based detergent (one step) for
washing.
6. After each of the three cycles above, water will be
automatically diverted down the wash drain. Once
wash cycle is complete, touch Off/On switch to
turn off.
7. See following chart for complete wash cycle
phases.
8. If using in an automatic calf feeding system, make
sure that milk supply hose is washed during this
wash time.
9. Disconnect wash ferrule from drain valve. Connect
milk hose to drain valve.

Calf-Star Milk Jug 13
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 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
* Time is user adjustable. Times shown are set by Calf Star
6. sCHematICs
APP'D BY:
CUSTOMER:
REVISION DESCRIPTION:DATE: BY
DATE:
TITLE:
CHECKED BY:
NO. OF PAGES:
OF
SCALE:
FRACTIONAL=±1/64
X.XX=±.01
X.XXX=±.005
X.XXXX=±.0002
JOB NO.
TOLERANCES
(UNLESS OTHERWISE SPECIFIED)
DRAWN BY:
NO.
This drawing is protected by U.S. and
International copyright laws and treaties.
The information contained in this drawing
is the sole property of Tri-Phase
Automation and ITech. Any reproduction
or distribution in part or as a whole
without the written permission of
Tri-Phase Automation and/or ITech is
prohibited.
1
2
3
4
5
6
02/07/15
1 6
MILK JUG, UL CONTROL
230VAC, 1PH SCHEMATIC
CALF-STAR
NONE
CS201501-001
ATJ
L1
T1
L2
T2
INCOMING POWER
230VAC, 1Ø, 15A MAX.
DS1-16A MAIN
DISCONNECT
(FSLB16)
1L1 1L2
TB1
1AWG
BLK
1AWG
BLK
L3
TB1 TB1
1AWG
BLK
1AWG
BLK
L1 L2
L1 L2
(EX9C12D11B)
CON1
L1 T1
L3 T3
3L1
2L3
(EX9SN25A14A)
MMS1
L1
L2
L3
T1
T2
T3
3L1
2L3
1L1
1L2
2L2
MTR1
3/4HP
COMPRESSOR
9.1A @ 230VAC
14AWG
BLK
14AWG
BLK
2L2
14AWG
BLK TB1
(48.31.7.024.0500)
R2
11 14
2L1
1L2
MTR2
1/5HP
DETERGENT PUMP
0.8A @ 230VAC
14AWG
BLK
14AWG
BLK TB1
(B1N1D1)
CB2-1A
4L1
4L1
14AWG
BLK
TB1
(48.31.7.024.0500)
R3
11 14
2L1
1L2
MTR3
1/20HP
AGITATOR MOTOR
0.38A @ 230VAC
14AWG
BLK
14AWG
BLK TB1
(B1N1D1)
CB3-1A
5L1
5L1
14AWG
BLK
TB1
(48.31.7.024.0500)
R4
11 14
2L1
1L2
MTR4
1/5HP
WASH PUMP
0.9A @ 230VAC
14AWG
BLK
14AWG
BLK TB1
(B1N1D1)
CB4-1A
6L1
6L1
14AWG
BLK
TB1
(48.31.7.024.0500)
R5
11 14
2L1
1L2
EV5
DRAIN VALVE
14AWG
BLK
14AWG
BLK TB1
(B1N1D1)
CB5-1A
7L17L1
14AWG
BLK
TB1
1
L1
N+V
+V
-V
-V
PWR1
60W, [email protected]
(MDR-60-24)
14AWG
GRN/YEL
2L1
14AWG
BLK
14AWG
BLK 1L2
24VDC
0VDC
18AWG
BLU
18AWG
WHT/BLU
(B1N1D5)
CB1-5A
TB1
1L1 2L1
14AWG
BLK
14AWG
BLK
14AWG
BLK
14AWG
BLK
24VDC POWER
(CONT. ON PAGE 2)
18AWG
BLU
18AWG
WHT/BLU
24VDC
0VDC

Calf-Star Milk Jug
14
APP'D BY:
CUSTOMER:
REVISION DESCRIPTION:DATE: BY
DATE:
TITLE:
CHECKED BY:
NO. OF PAGES:
OF
SCALE:
FRACTIONAL=±1/64
X.XX=±.01
X.XXX=±.005
X.XXXX=±.0002
JOB NO.
TOLERANCES
(UNLESS OTHERWISE SPECIFIED)
DRAWN BY:
NO.
This drawing is protected by U.S. and
International copyright laws and treaties.
The information contained in this drawing
is the sole property of Tri-Phase
Automation and ITech. Any reproduction
or distribution in part or as a whole
without the written permission of
Tri-Phase Automation and/or ITech is
prohibited.
1
2
3
4
5
6
02/07/15
2 6
MILK JUG, UL CONTROL
24VDC SCHEMATIC
CALF-STAR
NONE
CS201501-002
ATJ
15 (I0)
14 (I1)
HMI/PLC
(SM43-J-R20)
13 (I2)
12 (I3)
(O0) 6
10 PNP INPUTS,
2 ANALOG INPUTS, AND
8 RELAY OUTPUTS
24VDC
0VDC
24VDC POWER
(CONT. FROM PAGE 1)
18AWG
BLU
18AWG
WHT/BLU
I0
I1
18AWG
BLU
18AWG
BLU
SPARE RELAY
OUTPUT
HIGH PRESSURE
FAU LT
LOW PRESSURE
FAU LT
SPARE PNP
INPUT
LEVEL
SENSOR
(4-20mA)
TEMPERATURE
SENSOR
(4-20mA)
1 (V+) (0V) 2
OVDC
18AWG
WHT/BLU
24VDC
18AWG
BLU
3 (GND)
18AWG
GRN/YEL
PS2
PS1
I2
18AWG
BLU
TB2
TB2
TB2
11 (I4)
10 (I5)
AI5
TB2
9 (I6)
AI6
20AWG
BLK
TB2TB2
18AWG
RED
TB2
0VDC
24VDC
TB2
TB2
24VDC
24VDC
8 (I7)
7 (I8)
6 (I9)
5 (I10)
4 (I11)
TB2
SH
ANALOG IN CABLE
(3C-20GA SHIELDED)
R2
(48.31.7.024.0050)
A1 A2
O0O0
18AWG
BLU 0VDC
18AWG
WHT/BLU DETERGENT PUMP
CONTROL
(O1) 7
R3
(48.31.7.024.0050)
A1 A2
O1O1
18AWG
BLU 0VDC
18AWG
WHT/BLU AGITATOR MOTOR
CONTROL
(O2) 8
R4
(48.31.7.024.0050)
A1 A2
O2O2
18AWG
BLU 0VDC
18AWG
WHT/BLU WASH PUMP
CONTROL
(O3) 9
R5
(48.31.7.024.0050)
A1 A2
O3O3
18AWG
BLU 0VDC
18AWG
WHT/BLU DRAIN VALVE
CONTROL
(O4) 11
CON1
(EX9C12D11B)
A2+ A1-
O4O4
18AWG
BLU 0VDC
18AWG
WHT/BLU COMPRESSOR
CONTROL
(O5) 12
O5O5
18AWG
BLU 0VDC
18AWG
WHT/BLU HOT WATER
VALVE CONTROL
(O6) 13
O606
18AWG
BLU 0VDC
18AWG
WHT/BLU COLD WATER
VALVE CONTROL
(V+) 10
24VDC
18AWG
BLU
(O7) 14
O7
18AWG
BLU
(V+) 15
24VDC
18AWG
BLU
TB2
TB2
O7
TB2
TB2 TB2
TB2
(IF APPLICABLE)
JUMPER
SETTINGS:
JP4 =B
JP8 =B
JP9 =B
JP10=B
JP12=B
LVS1
SOL2
SOL1
TS1
1
22 (0V)
3
7 (Us+)
8 (GND2)
SC1
(857-800)
(OUT+) 5
(GND1) 6
0VDC
20AWG
RED
20AWG
WHT
AI5
0VDC
24VDC
18AWG
BLU
0VDC
18AWG
WHT/BLU
4-20mA SIGNAL
CONDITIONER
DIPSWITCH 1
SETTINGS:
P6 =ON
DIPSWITCH 2
SETTINGS:
P2 =ON
P3 =ON
P4 =ON
P7 =ON
P9 =ON