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Table of Contents
Related Manuals for Abts Equipment CALF-STAR Mini Flash 2.0
Summary of Contents for Abts Equipment CALF-STAR Mini Flash 2.0
- Page 1 Mini Flash 2.0 Service/User Manual Version 2.1 11/21/2019 Page 1 www.calfstar.com...
- Page 2 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.
- Page 3 Safety Safety Alert Symbol and Signal ords 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 Page 3...
- Page 4 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.
- Page 5 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.
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Page 6: Installation
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 •... - Page 7 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 •...
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Page 8: Requirements For Installation
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 •... - Page 9 1. Air supply connection • 5/32” air connection Connect 110 PSI air supply to back of machine. Water supply connection • Connect hot and cold water supply on back of machine with a garden hose connection. Chemical connection • Connect detergent and acid chemical connection back of machine.
- Page 10 Raw Product Intake RAW product can be filled into the machine by the Auto Fill valve or by the tank cover. The Auto Fill Valve is located on the back of the machine above the tank. 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.
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Page 11: Key Components
Key Components Heating plate cooler Regen plate cooler Product Flow Meter Drain valve Tempering loop Timing loop Product Flowmeter Timing loop Temp Sensor Timing milk pump Balance/Divert tube Page www.calfstar.com... - Page 12 Loop Valve Divert Final product temperature Tank Float Tank Temperature sensor Supply valve Page www.calfstar.com...
- Page 13 Circulation Pump Boiler Fill Float Boiler temperature sensor Electrical boiler heating elements (220V 5500W) Hot water wash Hot water tempering Cold water wash Cold water tempering Page www.calfstar.com...
- Page 14 Air solenoid manifold Acid pump Detergent pump Cover switch/Sensor 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.
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Page 15: Screen Navigation
Screen navigation 1. Main Screen Current Final Current Tank Current Current flow Product temperature Pasteurize rate of product temperature temperature Turn cooling Start on/off Pasteurization Rapid Empty Start the wash will run the pump at full speed emptying the tank Page www.calfstar.com... - Page 16 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 Page www.calfstar.com...
- Page 17 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 hoses and connections must be attached correctly. Adjust product out temperature Page www.calfstar.com...
- Page 18 B. Wash • 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.
- Page 19 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.
- Page 20 D. Agitate Tap the box with the number in it to change the parameter. Page www.calfstar.com...
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Page 21: Temperature Sensor Calibration
E. Temperature sensor calibration To Calibrate Temperature: 1. Disconnect temp sensor from piping system and place it in a vessel of cold water. 2. Wait 2 minutes for the sensor to stabilize. 3. Once the sensor is stable. 4. Take a Temperature reading of the liquid with a thermometer in the vessel then enter the reading into the in the Low column. -
Page 22: Chemical Calibration
F. Chemical calibration To calibrate chemical pumps: Navigate to the Calibration page. Obtain a measuring cup. Disconnect discharge hose from pump and place in a measuring cup. Press desired chemical to be calibrated. Press the Start button. The pump will run for 30 seconds. Enter the amount of chemical that was pumped in to measuring cup into the box. - Page 23 G. Water Flowrate Calibration To calibrate water: Navigate to the Calibration page. Obtain a measuring vessel. Disconnect hose from Balance/Divert tube and place in measuring vessel. Press desired water to be calibrated. Press the Start button. The water will run for 30 seconds. Enter the amount of water that was dispensed in measuring vessel into the box.
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Page 24: Manual Operation
3. Manual operation 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 To access manual operation, the user has to login Page www.calfstar.com... - Page 25 Manual-Cool Press button to activate component Inputs of sensors on on or off the machine. Green circle indicates sensor is working/active. Manual-Heat Press button to activate component on or off Page www.calfstar.com...
- Page 26 Manual-Flow Set the speed/hertz of the timing pump when manually activated. Press button to activate component on or off Manual-Wash Indicates the Press button to amount of time activate component the component is on or off on when activated. Page www.calfstar.com...
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Page 27: Troubleshooting
4. Troubleshooting Problem/Alarm Probable Cause Solution • • Unable to Prime Pump Faulted VFD Check VFD breaker/Read • error code on VFD Faulty timing pump • • Manually run timing pump to Blockage in piping confirm operation system/flowmeter • Activate a hot acid •... -
Page 28: Plc Inputs/Outputs
PLC Inputs/Outputs MINI-FLASH Controller Inputs and Outputs Outputs Inputs Digital Analog Analog Digital DO-0 Heating Element 1 AO-00 VFD 4-20mA AI-0 Boiler Temp I-00 delivery line wash signal DO-01 Heating Element 2&3 AI-1 Tank Temp I-01 Tank Float DO-02 VFD run/stop AI-2 Loop in Temp I-02...