Mueller SENTRY II User manual

SENTRY II
WITH AUTO-DOSING ASSEMBLY
INSTALLATION AND OPERATION
MANUAL
PART NO. 8823644
EFFECTIVE 4/1/00
®
THE MILK COOLING SYSTEMS SPECIALISTSTM
®

®
Table of Contents
SENTRY®II WITH AUTO-DOSING ASSEMBLY
INSTALLATION AND OPERATION MANUAL
Section 1.0 - Introduction Page
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Regulatory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Figure 1 - Sentry II Control Cabinet and Milk Cooler Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Section 2.0 - Installation
2.1 Crate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.2 Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Figure 2—Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.3 Site Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.4 Hot Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.5 Water Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.6 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.7 Foundation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Formula 1—Gross Weight of Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure 3—Foundation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.8 Leveling the Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure 4—Leveling the Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.9 Bulk Head Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Figure 5—Agitator Weather Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Figure 6—Basic Bulk Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.10 Milk Room Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 7—Milk Room Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.11 Agitator Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Figure 8—Agitator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.12 Pump Assembly and Electric Drain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Figure 9—Pump Assembly and Electric Drain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.13 Instructions for Mounting the Sentry II Control Box Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.14 Water Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Figure 10—Sentry II Control Box Installation and Water Connections . . . . . . . . . . . . . . . . . . . . . . . .11
2.15 Chemical Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.16 Manway Wash Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Figure 11—Manway Wash Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.17 Spray Dish Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 12—Spray Dish Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 13—Spray Dish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.18 Milk Cooler Vent Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Figure 14—Milk Cooler Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Section 3.0 - Electrical Wiring
3.1 Field Electrical Connections at Milk Cooler’s Rear Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Figure 15—Milk Cooler Electrical Terminal Strip (Rear Junction Box) . . . . . . . . . . . . . . . . . . . . . . . . .16
Part No. 8823644

Section 3.0 - Electrical Wiring - Continued
Figure 16—Electrical Schematic - Wash Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Figure 17—Electrical Schematic - Agitator Motor(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Figure 18—Electrical Schematic - Rear Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Figure 19—Internal Conduit Raceways - Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Figure 20—Electrical Schematic - Field Wiring (enlarged schematic in back of manual) . . . . . . . . . . .19
Figure 21—Electrical Schematic - Factory Wiring (enlarged schematic in back of manual) . . . . . . . . .20
Figure 22—Sentry II Relay and Switch Contact Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.2 PLC Electrical Troubleshooting (Input and Output Data) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Table 1—PLC Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Figure 23—Electrical Schematic - PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Figure 24—Electrical Schematic - Peristaltic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Section 4.0 - Sentry II Temperature Control
4.1 Sentry II Temperature Control and Thermocouple Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.2 Sentry II Thermocouple Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Figure 25—Sentry II Thermocouple Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.3 Sentry II Thermocouple Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Figure 26—Sentry II Thermocouple Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.4 Important Thermocouple Splicing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Figure 27—Sentry II Thermocouple - Temperature Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4.5 Sentry II Temperature Control Calibration Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4.6 Sentry II Temperature Control Lock and Unlock Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Figure 28—Sentry II Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.7 Sentry II Temperature Control Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.8 Sentry II Temperature Control Set Point Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.9 Sentry II Temperature Control Unit of Measure (Fahrenheit or Celsius) . . . . . . . . . . . . . . . . . . . . . . .30
Section 5.0 - Automatic Chemical Dosing
5.1 Initial Start-Up Procedures for Automatic Dosing and Chemical Usage . . . . . . . . . . . . . . . . . . . . . . . .31
5.2 Peristaltic Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
5.3 Chemical Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
5.4 Peristaltic Pump Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Figure 29—Peristaltic Pump Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
5.5 Adjusting Peristaltic Pump Timers for Proper Chemical Concentration . . . . . . . . . . . . . . . . . . . . . . . .33
Figure 30—Peristaltic Pump Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Table 2—Timer Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Table 3A—Peristaltic Pump Timing for Specific Chemical Concentrations (2-240 Seconds) . . . . . . . . .34
Table 3B—Peristaltic Pump Timing for Specific Chemical Concentrations (240-478 Seconds) . . . . . . .35
Table 3C—Peristaltic Pump Timing for Specific Chemical Concentrations (478-726 Seconds) . . . . . . .36
5.6 Determining Water Usage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Figure 31—PLC Fill-Time Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Table 4—Minimum Water Requirements (Per Cycle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.7 Determining Actual Water Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Table 5—Calculated Water Usage (Fill-Time/Supply Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.8 Wash Cycle Timing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Chart 1—Detergent Wash or Complete Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Chart 2—Acid Cycle or Sanitize Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Table of Contents - Continued

Section 6.0 - Sentry II PLC Programming
6.1 Sentry II Programmable Features, Options, and Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.2 Sentry II - MTA to PLC Programming Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
6.3 Sentry II Service Reference Form, Programmable Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Section 7.0 - Operating Instructions
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Figure 32—Sentry II Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
7.2 “Cool-Off-Wash” Rotary-Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
7.3 Cooling Bottoms Units Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
7.4 Cooling All Units Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
7.5 Pre-Start Cooling Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
7.6 Pre-Start Agitator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
7.7 Detergent Cycle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7.8 Acid Cycle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7.9 Sanitize Cycle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7.10 Agitate Sample Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7.11 Alarm Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7.12 Milk Temperature Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
7.13 Cooling Override Switch (Emergency Use Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Section 8.0 - Weights and Dimensions
8.1 English Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
8.2 Metric Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Section 9.0 - Sentry II Replacement Parts
9.1 Sentry II Replacement Parts Drawing, Main Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
9.2 Sentry II Replacement Parts List, Main Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
9.3 Sentry II Replacement Parts Kit, Dosing and Manifold Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
9.4 Sentry II Replacement Parts List, Dosing and Manifold Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
9.5 Sentry II Replacement Parts Kit, Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
9.6 Sentry II Replacement Parts List, Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Section 10.0 - Sentry II Equipment Markings
10.1 Label No. 8822229, Lock Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
10.2 Label No. 8820482, Caution - Disconnect Power and Retain Latch . . . . . . . . . . . . . . . . . . . . . . . . . . .64
10.3 Label No. 8820623, Warning Symbol - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
10.4 Label No. 8805616, Manual - Run Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
10.5 Label No. 8820248, Auto - Automatic Run Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.6 Label No. 8823064, Acid - Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.7 Label No. 8823063, Detergent - Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.8 Label No. 8823065, Sanitize - Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.9 Label No. 8822584, Pump Motor - Wire Marker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.10 Label No. 8802375, Agitator(s) - Wire Marker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.11 Label No. 3791, Hot - Water Valve Marker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.12 Label No. 8823609, Warning - Manifold Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
10.13 Label No. 8823013, Warning - Disconnect Power Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . .66
10.14 Label No. 8801150, Warning - Disconnect Power Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . .66
10.15 Label No. 8822225, CE Data Tag (U.K. Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
10.16 Label No. 8820410, Data Tag (U.K. Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
10.17 Label No. 30612, Notice - Chart Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Table of Contents - Continued

Table of Contents - Continued
Section 10.0 - Sentry II Equipment Markings - Continued
10.18 Label No. 8820454, Dry Nitrogen Holding Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
10.19 Label No. 8805299, Warning - HCFC Class II Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
10.20 Label No. 30737, Bottom Temp-Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
10.21 Label No. 8822972, Transformer Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
10.22 Label No. 8822705, Canadian and U.S. Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
10.23 Label No. 8822948, 24 VAC Component List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
10.24 Label No. 8820409, Mueller Name Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
10.25 Label No. 8822980, Programmable Controller Name Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
10.26 Label No. 8822558, Mueller Milk Cooler Data Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
10.27 Label No. 30890, Mueller Data Tag - Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
10.28 Label No. 8820677, Ground Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
10.29 Label No. 3792, Cold - Water Valve Marker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
10.30 Label No. 30397, Stainless Steel Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
10.31 Label No. 30166, Caution - Vent Must Be Over Milk Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
10.32 Label No. 8820508, Hot - Tube Marker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
10.33 Label No. 8802777, Caution - Do Not Sanitize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
10.34 Label No. 8823146, Terminal Block - 24 VAC - 240 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
10.35 Label No. 8823263, Terminal Block - 24 VAC - 240 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Section 11.0 - Safety
11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
11.2 Manway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Section 12.0 - Disposal
12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
12.2 Chemical Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
12.3 Solid Component Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

SECTION 1.O - INTRODUCTION
1.1 General
The Mueller®Sentry®II refrigeration and cleaning control with auto-dosing feature is custom designed
and manufactured to provide programmable and automated push-button timing of the cleaning,
cooling, and agitation cycles. A large digital temperature display and automatic temperature alarm
system informs the operator of safe milk temperatures.
Durable construction and enhanced control circuitry ensures maximum cooling and energy efficiencies,
superior automation, and long-term reliability.
1.2 Technical Support
This manual provides the basic installation and operating information to ensure safe and optimum
performance of the Sentry II control system. Please contact your local Mueller Sales and Service
Representative if you require additional technical assistance pertaining to installation or operating
procedures.
Manufacturer’s support is available by contacting:
Paul Mueller Company
Dairy Farm Equipment Service Department
P.O. Box 828
Springfield, Missouri 65801
Telephone: [phone] • 1-800-MUELLER (683-5537)
1.3 Regulatory Requirements
It is the responsibility of the purchaser and installer to seek the necessary regulatory pre-approval of
an installation, ensuring that the site and method of installation meets all regulations for the locality.
Local, state, and/or county regulations pertaining to the installation, operation, and service of the
equipment may vary and must be followed accordingly.
Installation and service must be performed by authorized service technicians who have the proper
training and certification to install and service refrigeration and electrical equipment.
Sentry II with Auto-Dosing Assembly Operating Instructions 1Effective April 1, 2000

Figure 1 - Sentry II Control Cabinet and Milk Cooler Components
Sentry II with Auto-Dosing Assembly Operating Instructions 2Effective April 1, 2000
A. Sentry II Control Box
B. Alarm Indicator
C. Detergent Switch/Indicator
D. Acid Switch/Indicator
E. Sanitize Switch/Indicator
F. Sample Agitation Switch/Indicator
G. Cool/Off/Wash Selector Switch
H. Digital Temperature Indicator
I. Cooling Switch/Indicator (Bottom Units)
J. Cooling Switch/Indicator (All Units)
K. Pre-Start Switch/Indicator (Cooling)
L. Pre-Start Switch/Indicator (Agitate)
M. Peristaltic Pump Priming Switch
N. Priming Selector Switch
O. Peristaltic Pump (Sanitize)
P. Peristaltic Pump (Acid)
Q. Peristaltic Pump (Detergent)
R. Chemical Line Priming Disconnect
S. Fill Line Disconnect
T. Pressure Switch (No Water Alarm)
U. Manifold Assembly
V. Water Solenoid Valve (Dual)
W. Electric Drain Valve
X. Wash Pump Assembly

SECTION 2.0 - INSTALLATION
2.1 Crate Removal
CAUTION: Equipment used to move or lift the milk cooler must be rated for the weight of the
milk cooler. Approximate weights are provided in Section 8.
1. Remove any open-type crating and the packaged parts. Do not remove the skids attached to the
milk cooler legs at this time.
2. Inspect the milk cooler and report any damage to the transportation carrier. File a claim
immediately if the milk cooler is damaged.
3. Move the milk cooler into the milk house and position it to meet all regulatory requirements for
the locality.
4. Once in place, the skids can be removed.
2.2 Skid Removal
1. Raise one end of the milk cooler with the floor jack placed beneath the skid’s cross brace. Securely
block the skid to ensure safety and stability while removing the self-tapping screws from the
bottom of each leg.
2. Lower the milk cooler and repeat the procedure on the opposite end.
3. Remove cross-bracing members, leaving the two skids under the milk cooler’s legs.
4. Raise one end of the milk cooler with a floor jack and wooden-cradle block. Pivot the skids away
from the milk cooler. Lower the milk cooler and repeat the procedure for the other end.
Figure 2 - Skid Removal
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Sentry II with Auto-Dosing Assembly Operating Instructions 3Effective April 1, 2000

2.3 Site Requirements
It is the responsibility of the installer and/or purchaser to provide adequate electrical service, water
supply, floor drains, and footer foundations for the installation. Failure to do so can cause non-
warranted structural damage to the milk cooler and/or costly service problems for the user.
2.4 Hot Water Requirements
A water heating device with adequate storage and temperature recovery capacity must be provided to
wash the milk cooler and milking equipment simultaneously. The water heater should be capable of
supplying water temperatures of 160-170°F (71-76.6°C) during the detergent wash cycle.
CAUTION: To prevent non-warranted expansion damage to the milk cooler, the maximum
wash water temperature shall not exceed 170°F (76.6°C). Installation sites that require water
temperatures in excess of 170°F (76.6°C) should install a tempering valve, Mueller Part No.
8820276, to regulate the milk cooler wash water temperature at 170°F (76.6°C) or below.
2.5 Water Supply Pressure
Water supply pressure to the milk coolers wash system must be maintained between 20 and 60 psig.
2.6 Electrical Requirements
The Sentry II Control System requires a 240/50-60/1 power supply, fused at 15 amps maximum. See
Section 3 for detailed wiring schematics.
NOTE: International markets may request optional transformer, Mueller Part No. 8823060, for power
supplies providing 195/50/1.
Electrical installation requirements for the refrigeration units should be obtained from the Installation
and Operation Manual specific to the refrigeration unit(s) being installed.
NOTE: All wiring to be performed in accordance with the National Electrical Code and/or regulatory
agency for the installation locality. All wiring that enters the Sentry II control box must be sealed with
cord grips or liquid-tight conduit connectors.
Sentry II with Auto-Dosing Assembly Operating Instructions 4Effective April 1, 2000
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2.7 Foundation Requirements
IMPORTANT: Due to varying geographical soil conditions, contact a local civil engineer for footer,
concrete, and foundation requirements that will adequately support the weight of the milk cooler
when filled to maximum capacity.
The following information is required to determine the foundation requirements:
1. A drawing showing the layout location of the milk cooler’s legs. See Section 8.
2. A drawing describing the proposed installation layout.
3. Gross weight of the milk cooler when filled to maximum capacity.
Formula 1 - Gross Weight of Milk Cooler
Net Weight (lb)* + (Capacity in US Gallons x 8.6) = Gross Weight (lb)
Net Weight (kg)* + (Capacity in Liters x 1.0305) = Gross Weight (kg)
*Section 8 provides approximate net weights of Mueller milk coolers.
Example: 2,000 gallon Mueller milk cooler filled to maximum capacity.
2,356 lbs. + (2,000 x 8.6) = 19,556 lbs.
1,069 kg. + (7,570 x 1.0305) = 8,870 kg.
IMPORTANT NOTE: Mueller warrants to the original purchaser/user that the Mueller factory calibration
of a Mueller milk cooler will not be affected (i.e. exceed the tolerances prescribed by the National
Institute of Standards and Technology) by distortion or structural change for a period of five (5) years
from the date of installation or sixty-six (66) months from the date of shipment from the Company
factory, whichever occurs first. The Company’s obligation shall be limited to the correction of the
calibration only, and does not cover reimbursement of product loss. This warranty will not apply if
distortion is caused by changes in the floor or foundation on which the milk cooler is installed. Refer
to the Mueller Milk Cooler Warranty Card for complete warranty information.
Figure 3 - Foundation Requirements
Sentry II with Auto-Dosing Assembly Operating Instructions 5Effective April 1, 2000

2.8 Leveling the Milk Cooler
With the assistance of a floor jack and protective wooden-cradle block, level the milk cooler as
described in the following steps:
1. Adjust the inner legs off the floor until the proper pitch is obtained with the four corner legs.
2. Place a carpenter’s level across the brim of the manway opening and level the milk cooler by
adjusting the corner legs with a nylon strap wrench. Legs may be extended by turning the legs
counterclockwise, and retracted by turning the legs clockwise.
3. Using the levels located on the side of the cooler, adjust each end of the milk cooler until the
proper height and pitch is obtained. (The milk cooler should pitch
1
/ 4 " per foot towards the outlet
valve.)
4. Using a certified seraphin, add the exact volume of water indicated for the “Set-Up Reading” on
the calibration chart.
5. Adjust the final pitch of the milk cooler, matching the calibration gauge reading with the “Set-Up
Reading” on the calibration chart.
6. When the front and back corner legs are positioned properly, the inner legs should be extended
firmly against the floor.
7. Ensure that the final location and position complies with all regulations for the installation locality,
including the proper height of the milk outlet and the proper dimensions beneath and around the
milk cooler.
Figure 4 - Leveling the Milk Cooler
Sentry II with Auto-Dosing Assembly Operating Instructions 6Effective April 1, 2000

2.9 Bulk Head Installations
If the milk cooler is bulkheaded through a wall, the wall must be free-standing and not load bearing
against the milk cooler. Mueller offers an optional steel-formed structural support channel that may be
installed in masonry walls to prevent the wall from bearing load on the milk cooler. Contact Mueller’s
Sales Department for availability and pricing.
A weather shield kit, Part No. 93750, is required for agitator(s) that are located exterior of the milk
house wall. See Figures 5 and 8, and Section 2.11 for additional installation instructions.
Figure 5 - Agitator Weather Shield
Figure 6 - Basic Bulk Head Installation
Sentry II with Auto-Dosing Assembly Operating Instructions 7Effective April 1, 2000

2.10 Milk Room Installations
Ensure proper clearances between the milk cooler and other obstacles or equipment as required by the
regulations in your locality. Special attention should be placed on floor drain locations, high-traffic and
working areas, and ease of access for the operators.
The milk cooler parts box includes two stainless steel brackets to secure the water/chemical fill line to
the rear head of the milk cooler, Part Nos. 8823254 (top) and 8823253 (bottom). Each bracket is
supplied with 1.125" rubber grommets, which provides a method to support the water/chemical fill
hose inside of .75" PVC conduit. See Figure 7.
Figure 7 - Milk Room Installations
Sentry II with Auto-Dosing Assembly Operating Instructions 8Effective April 1, 2000

2.11 Agitator Assembly Installation
1. Remove the protective plastic shipping wrap and position the agitator shaft (Item 7) up through
the opening in the top of the milk cooler. Slip the neoprene shield (Item 8) over the end of the
agitator shaft. Be careful not to damage the internal and external finishes of the cooler during this
procedure.
2. Position the spacer sleeves (Item 3) on the studs located on the top of the cooler. Apply Never-
Seez®to the shaft end (Item 7) and threads of the cap screws (Item 1). Slip the agitator shaft
through the agitator drive and secure in place with cap screws (Item 1), lock washers (Item 2), and
spacer sleeves (Item 3).
3. Align the hole in the agitator shaft with the hole in the output shaft of the agitator drive and insert
the roll-pin (Item 5).
4. Place the blue plastic cap (Item 6) over the top of the output shaft after assembly.
5. Thread the 90° liquid-tight conduit fitting (Item 10) through the plastic nut (Item 11) with the flat-
washer flange facing the motor. Slip the cut gasket (Item 12) over the threads and thread the
assembly into the agitator motor. Insert the 3-wire cable through the straight conduit fitting,
conduit, and 90° fitting installed in the motor. Thread the straight liquid-tight conduit fitting into
the full coupling attached to the milk cooler. Connect L1 and L2 as shown in the wiring schematic,
secure the ground wire under the grounding screw in the motor housing. Ensure clockwise
rotation as viewed from the top of the drive.
6. The optional agitator weather shield (Item 13) must be installed on all agitators that are located
exterior of the milk room.
Figure 8 - Agitator Installation
Sentry II with Auto-Dosing Assembly Operating Instructions 9Effective April 1, 2000

2.12 Pump Assembly and Electric Drain Installation
1. Bolt the pump assembly and electric motor to the left front corner of the milk cooler as shown in
Figure 9.
2. Trim the rubber elbow (Item 1) for proper fit and connect between the discharge fitting on the
pump assembly and the wash line in the milk cooler.
3. Install the straight, liquid-tight conduit fitting (Item 2) in the stainless steel cover plate located on
the left side of the milk cooler.
4. Thread the 3-wire cord (marked pump motor) through the conduit fitting and conduit (Item 3).
5. Thread the plastic nut (Item 4) with the flat flange facing the motor onto the 90° liquid-tight fitting
(Item 5).
6. Slip the neoprene gasket (Item 6) over the threads of the 90° liquid-tight fitting and thread the
assembly into the pump motor.
7. Thread the 3-wire cord and conduit into the 90° liquid-tight fitting and secure with the liquid-tight
compression fitting.
8. Wire the motor per the electrical schematic attached to the motor.
9. Install the stainless steel screen (Item 7) in the rubber adapter (Item 8) and clamp the electric drain
valve in position with the two stainless steel hose clamps.
10. Install the cord grip (Item 9) in the stainless steel cover plate located on the left side of the milk
cooler.
11. Thread the cord (marked drain valve) through the cord grip and wire to terminal numbers 1 and 2
at the 24-vac electric drain valve coil.
12. Reattach the stainless steel cover plate and tighten all cord grips and liquid-tight conduit fittings.
Figure 9 - Pump Assembly and Electric Drain Installation
Sentry II with Auto-Dosing Assembly Operating Instructions 10 Effective April 1, 2000

2.13 Instructions for Mounting the Sentry II Control Box Enclosures
1. Install the Sentry II control box in a location where it is easily accessible for the operator and
protected from excessive wash down.
2. Install the peristaltic pump box and manifold box in an area protected from freezing and within
easy access to the chemical storage drums.
NOTE: The maximum length for the chemical supply hose is 28 feet (8 meters).
2.14 Water Line Connections
1. Connect the hot and cold water fill hoses to the water solenoid valves located in the right side of
the manifold box. See Figure 10.
2. Some localities may require the installation of high hazard back-flow preventors in the water
supply plumbing if the installation is connected to chemical supply drums larger than 1 gallon.
Contact your local regulatory agencies for proper direction and compliance.
Figure 10 - Sentry II Control Box Installation and Water Connections
Sentry II with Auto-Dosing Assembly Operating Instructions 11 Effective April 1, 2000

2.15 Chemical Line Connections
1. Locate the chemical supply drums in an area protected from freezing, direct sunlight, and
unauthorized access.
2. Connect the chemical supply hoses between the chemical drums, peristaltic pumps, and manifold
box as follows:
a. Insert the clear-colored chemical supply hose to the bottom of the detergent drum. Route and
connect the opposite end to the inlet of the peristaltic pump marked detergent.
b. Connect a second piece of clear-colored chemical supply hose to the outlet of the detergent
pump. Route and connect the opposite end to the quick-disconnect and check valve located
on the bottom of the manifold box.
c. Repeat the procedure for the acid and sanitize connections, connecting the red hose to acid
and the blue hose to sanitize. See Figure 10.
NOTE: The maximum total length of the chemical supply hoses must not exceed 28 feet (8 meters).
CAUTION: Wear protective clothing and eye protection when handling caustic chemicals!
Always observe the chemical manufacturer’s precautions, warnings, and usage
recommendations! Store all chemicals in a location protected from freezing, unauthorized
access, and direct sunlight.
Sentry II with Auto-Dosing Assembly Operating Instructions 12 Effective April 1, 2000
CAUTION
WEAR EYE PROTECTION,
RUBBER GLOVES, AND
APRONS WHEN HANDLING
CHEMICALS
CORROSIVE POISON
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2.16 Manway Wash Tube Installation
The manway wash tube provides positive wash of the manway opening and cover. The tube is
inserted in the stainless steel nipple in the top of the milk cooler and held in place with a stainless
steel pin. Refer to the drawing in Figure 11 for detailed installation procedures.
Figure 11 - Manway Wash Tube
Sentry II with Auto-Dosing Assembly Operating Instructions 13 Effective April 1, 2000

2.17 Spray Dish Installation
The spray dishes connect to the internal or external CIP wash line with a stainless steel keeper pin.
Check for proper spray dish installation and orientation during the installation and start-up inspection.
The rectangular notch cut across the bottom of the spray dish tube must face the front and rear heads
of the milk cooler and the slot cut in the bottom of the dish must point towards the center of the
agitator shaft. See Figures 12 and 13.
Figure 12 - Spray Dish Orientation
Figure 13 - Spray Dish
Sentry II with Auto-Dosing Assembly Operating Instructions 14 Effective April 1, 2000
Rectangular notch must face front and
rear heads of the milk cooler.
Orient slot towards the center of the
agitator shaft.