ELECTRICAL SYSTEM UPGRADE
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- Martin Poole
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1 NEW CONTROLLER & ELECTRICAL SYSTEM UPGRADE FOR DAIRY TECH, INCORPORATED 10, 30 & 60G PASTEURIZERS
2 Parts to Include 2 Wire ties (Nuts) 2 sticky wire mount pads Large Rubber Grommet (for bottom of electric panel) Thermal switch with bolts Alcohol pad JB Weld Thermal Paste 3 yellow female spade terminals for heater wires. 3 yellow ring terminals for the other heater wires to attach to thermal switch
3 READ THIS BEFORE YOU BEGIN This is a 2-day job. After completing Step 1, you must allow the epoxy to cure for a minimum of 24 hours before moving on to Step 2. Following these instructions will allow you to keep using your machine until the epoxy sets up. The remainder of these steps will take approximately 3 hours to complete. Tools Phillips STEP 01: MOUNTING THERMAL OVERLOAD SWITCH BRACKET TO TANK 1/4 A. Unplug the machine from the power source B. Remove back panel by removing Sheet Metal Screws. Supplies C. Clean surface area above the bulkhead of dirt, grease, oil, paint, or loose debris. For best results use a detergent or degreaser to first clean the surface, then roughen surface with file or coarse sandpaper to provide the best repair. Wipe down with rubbing alcohol. D. Use sand paper to roughen back of bracket. This will give the weld compound a surface it can stick to. Skipping this step will result in connection failure an may cause damage to your machine. Alcohol Wipe J-B Weld Cold Weld Compound E. Use a pencil and a straight edge to make a horizontal line.25 above the weld above the top of the bulkhead F. Use a pencil and a straight edge to make a Vertical line that runs up between the 1st and 2nd Heating Element Flanges DairyTechInc.com Toll Free: 866.DTI.COWS ( ) 1
4 G. Bend the supplied aluminum frame at the notches just enough to match the curvature of the tank you are attaching the bracket to. Dry fit the bracket several times before applying the cement. Adjust the bends as needed until the frame sits on the tank side and easily makes contact along the vertical sides and under the heads of the posts. H. Squeeze equal parts from each tube onto a disposable surface and mix thoroughly I. Apply weld compound to the back of the bracket where the wavy lines are shown and to the heads of each threaded post. J. Line up the Bracket Posts with the Vertical line and the bottom of the bracket with the Horizontal line K. Press into position on the tank L. Hold in place with tape while the weld compound hardens. M. Replace back enclosure panel. DO NOT PROCEED TO STEP 2 UNTIL COMPOUND HAS CURED COMPLETELY. Please allow compound to cure for 24 hours before moving on to STEP 2. Failure to follow these directions can result in compound failure which can damage to your equipment. After completing STEP 1, you may continue using your machine as normal until you are ready to move on to STEP 2 2 NEW CONTROLLER & ELECTRICAL SYSTEM UPGRADE
5 STEP 02: REMOVE FAN COVERS AND FAN Tools Phillips 11/32 A. Unplug the machine from the power source B. Remove the stirring prop 4mm 1/4 C. Remove back panel by removing Sheet Metal Screws. D. Remove control top cover by removing Sheet Metal Screws and disconnect the fan E. Remove the fan covers using a Philips Head Screwdriver and/or 4mm Allen Wrench. Clean covers before installing in new system F. Remove the fan from the control top cover with 11/32 wrench and save for later 3 DairyTechInc.com Toll Free: 866.DTI.COWS ( ) 3
6 Tools STEP 03: REMOVE MOTOR ASSEMBLY 11/32 4mm Flat Head A. Remove 4 bolts that secure the motor assembly to the top of the control box (11/32 Wrench) B. Remove 4 bolts that secure the motor assembly to the bottom of the Control box (4mm Wrench) C. Disconnect the wires from the power strip (Small Flathead Screwdriver) D. Remove Motor E. Wipe clean, check chain for proper tension and save for later steps 4 NEW CONTROLLER & ELECTRICAL SYSTEM UPGRADE
7 STEP 04: DISCONNECT THERMOCOUPLE FROM CONTROLLER Tools Phillips 9/ B. Remove the Strain Relief Nut and pull thermocouple assembly out of mounting hole. Thread the Strain Relief Nut back on to assembly and allow it to hang free. (9/16 wrench) 1. Disconnect the PURPLE Thermocouple wire from position 2 (Phillips Screwdriver) 2. Disconnect the RED Thermocouple wire from position 3 (Phillips Screwdriver) STEP 05: DISCONNECT MAIN POWER CORD A. Disconnect the main power cord wires from the terminal blocks, ground lug and contactor in the electrical panel (Flathead Screwdriver) B. Remove strain relief nut from power cord and pull it out of the electrical panel. C. Thread the strain relief nut back onto the power cord and save. DairyTechInc.com Toll Free: 866.DTI.COWS ( ) 5
8 Tools STEP 06: DISCONNECT WIRES Flat Head 4mm A. Disconnect heating elements from the contactor (Flathead Screwdriver) B. Disconnect the two wires to the thermostat at the bottom of the milk tank C. Disconnect the two wires from the water solenoid valve D. Pull the green ground wire through the bottom of the electrical box and leave it for reconnection later STEP 07: REMOVE THE ELECTRICAL PANEL B. Slide the electrical box to the left to release from the bolts in last step and allow the electrical box to hang for the time being A. Loosen the 4 bolts in the inside top of the electrical panel. It is not necessary to remove these 4 bolts. Only loosen each one by a couple threads. (4mm) 6 NEW CONTROLLER & ELECTRICAL SYSTEM UPGRADE
9 STEP 07: REMOVE THE CONTROL BOX Tools 4mm A. Remove control top by removing 4 bolts - 2 on each side of the control top. B. Set the two components to the side. {60G ONLY} On the underside of the control box, there are 6 screws that hold the mounting bracket to the control box. Remove these 6 screws and use them to mount this bracket to the underside of the new control box It is unlikely that any other parts will be necessary for future steps. The WEST control can be returned to Dairy Tech using the FedEx return label provided or call us for a shipping label. Rather than putting these controls into the trash, we can send them to the manufacturer to be refurbished. DairyTechInc.com Toll Free: 866.DTI.COWS ( ) 7
10 Tools STEP 08: NEW CONTROL BOX PREPARATION 3/16 Hex Trench Side Cutters A. Remove from packaging and work on a clean surface B. Use side cutters to remove the black wire tie from the underside of the control box. This was to hold in place during shipping only. FOR 60G UNITS ONLY, attach the mounting bracket to the underside of the control box using the same 6 screws from its removal C. At the pasteurizer, hang the electrical box on the 4 loosened bolts from prior steps. Leave this for now and mount the top control box. D. Next mount only the 2 rear bolts to hold the control box on the pasteurizer. This will allow you to tip the control toward the rear if necessary for better visualization of the motor mounting holes later. E. Now return to the electrical box. Holding tight against side of cabinet, tighten with long 3/16 T handle hex-wrench 8 NEW CONTROLLER & ELECTRICAL SYSTEM UPGRADE
11 STEP 09: NEW CONTROL BOX ASSEMBLY - MOUNTING THE MOTOR Tools A. The motor can either be installed into the new control box while working on a workbench prior to being mounted to the pasteurizer or after the new control box has been mounted to the Pasteurizer Remove Control box lid and set aside. 3/16 Hex Trench B. Place motor with the orange and grey wires on the rear side of the motor. These are for the motor and fan later. C. Use the 8 bolts, nuts, etc to mount the motor as it was removed. (3/16 T handle hex-wrench) D. Now the remaining two bolts can be placed in the control box mounting plate of the 60G. DairyTechInc.com Toll Free: 866.DTI.COWS ( ) 9
12 Tools STEP 10: NEW CONTROL BOX ASSEMBLY - WIRING THE MOTOR Phillips Head 11/32 9/16 A. Connect the black wire to the orange dual wires. Either use the proper male connector as shown or cut both wires, connect with wire nut and tape properly. B. Then connect the red wire from motor to the yellow wire C. Reattach the ground wire at one of the mounting bolts down to the ground lug on the chassis of the control panel floor as shown. (11/32 Wrench) D. Reattach the thermocouple strain relief as shown and pull the wires through to reach the control top. (9/16 Wrench) 5 6 E. Purple wire is attached on the top green phoenix connector at position 5 (positive) Red wire is attached at position 6 (negative) (Phillips Screwdriver) 10 NEW CONTROLLER & ELECTRICAL SYSTEM UPGRADE
13 STEP 11: NEW CONTROL BOX ASSEMBLY - REMOUNT THE FAN & SCREENS Tools A. Clean the old fan filters and mount them to the new control box in the manner that they were previously installed. Fan should blow inward onto the motor side of the control box. Wire Crimper Side Cutters 11/32 4mm Driver B. On inside of Lid Assembly, Line up corner mounting holes on ME-Fan 220V, label side out, with 8-32x1.5 SS Phillips Pan Head Screws. NOTE: Wires must be in the lower left hand corner of the Fan body for this step C. Secure with 8-32 KEPS Lok-Nuts, Tighten with 11/32 wrench Supplies D. Set the Control Box Lid on top of the Control Box E. Attach the two wires using similar means as the motor by using the remaining two orange and grey wires. 4-Way Cable tie holder (1) F. It is advisable to tie down the wires so they are not likely to touch the motor chain or become entrapped when the lid is closed G. Reattach the control top lid. (4mm Driver) DairyTechInc.com Toll Free: 866.DTI.COWS ( ) 11
14 Tools NEW CONTROL BOX ASSEMBLY STEP 01: WIRING THE BOTTOM ELECTRICAL PANEL Do Not Proceed with this step until Weld Compound has cured for at least 24 Hours: Failure to follow these directions can result in compound failure which can damage to your equipment. A. Apply a small amount of Thermal Paste to the back of the Thermal Overload Switch. DO NOT REMOVE the red tape from switch B. Mount Thermal Overload Switch as shown below. NOTE: Position L1 Posts on the BOTTOM, N Posts on the TOP N ON THE TOP Supplies L1 N L3 L2 CE L1 L3 N L2 Thermal Paste L1 ON THE BOTTOM 12 NEW CONTROLLER & ELECTRICAL SYSTEM UPGRADE
15 NEW CONTROL BOX ASSEMBLY STEP 01: WIRING THE BOTTOM ELECTRICAL PANEL Tools A. Insert the included large grommet in the hole bottom left of the electrical box Wire Crimper Side Cutters 11/32 B. Route the large ground wire up through the hole C. Secure the ground wire to the ground lug in the electrical box and attach Supplies D. Each heating element has two wires. Route one from each pair of wires through the same large grommet as shown E. Remove the male spade terminal from each element wire. Large Rubber Grommet 1/4 Female Spade Terminal x 3 F. Replace with a ¼ female spade terminal. G. Connect one to each of the 3 solid state relays inside the electrical box. DairyTechInc.com Toll Free: 866.DTI.COWS ( ) 13
16 NEW CONTROL BOX ASSEMBLY STEP 01: WIRING THE THERMAL OVERLOAD SWITCH A To Water Solenoid Valve E Purple Orange Blue White (NO Terminal) Brown White (RING Terminal) Red 3 Red 2 Red 1 From Inside Electrical Panel D D L3 N N 3 40A 400V L3 B 2 1 L2 L1 CE L2 L1 C Thermal Overload Switch 1 Heating Elements 2 3 To Solid State Relays Inside Electrical Panel 14 NEW CONTROLLER & ELECTRICAL SYSTEM UPGRADE
17 NEW CONTROL BOX ASSEMBLY STEP 01: WIRING THE THERMAL OVERLOAD SWITCH Tools Wire Crimper A: There are two long wires with female connectors (maybe orange and purple). Connect these to the two tab terminals on the water solenoid valve. Tie the wires up as snug as possible after connection is made. Cut one wire of each heating element to a length that can reach posts on the left side of the Thermal Overload Switch. Side Cutters Phillips Head N L3 L2 L After removing the excess wire and male spade terminals, securely crimp a ¼ Ring Terminal onto each cut wire. B: Connect the newly shortened wire from element 1 (left) to the screw marked L1, the wire from element 2 (center) goes to screw 2 and so on. Supplies C: There are 3 large red wires come from L2 inside the electrical panel. These connect to the Right side of the Thermal Overload Switch D: There are two remaining wires with ring terminals on them. (See illustration, p14) 1. The brown wire attaches to the top left position of the thermal switch 2. White wire attaches to the top right position of the thermal switch Wire Nut E: You will notice that there are 3 wires without connections: brown, white and blue in most units. These are in place for a future upgrade that we are working on for a water detection switch to shut down the unit if no water is connected. Please place tape over the ends of these wires and tie them up to prevent damage. Dairy Tech will announce in the future when this feature is made available. Attach clear plastic cover to Thermal Overload Switch posts DairyTechInc.com Toll Free: 866.DTI.COWS ( ) 1/4 Ring Terminal x 3 15
18 Tools NEW CONTROL BOX ASSEMBLY STEP 01: WIRING THE MAIN POWER CORD Flat Head 11/32 A. The cord wires should already be an appropriate length and will need to be inserted as shown in the picture. Black = L1 Right Slot Red = L2 Right Slot White = N Green = Ground Post 16 NEW CONTROLLER & ELECTRICAL SYSTEM UPGRADE
19 NEW CONTROL BOX ASSEMBLY STEP 01: REMOUNT BACK PANEL ENCLOSURE Tools 4mm Driver Replace the back panel DairyTechInc.com Toll Free: 866.DTI.COWS ( ) 17
20 PO Box 250 Severance, CO Toll Free: 866.DTI.COWS ( )
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