Milkana

Table of contents

MILKANA SUPERIOR SPECIFICATIONS

KEYPAD AND SWITCHES FUNCTIONS

INSTRUCTIONS FOR USE

1. POWER UP & START UP

2. MILK SAMPLES
3. BASIC MODES FOR USE
4. MILK ANALYSIS WITH MOTORR (SUCTION PUMP)
5. MILK ANALYSIS WITHOUT MOTOR (SUCTION PUMP)
6. CLEANING
7. CALIBRATION
8. CALIBRATION VALUES SAVING

ANALUZER BASIC ASSEMBLIES

ANALYZER DIAGNOSTICS

ERROR MESSAGES ON THE DISPLAY

OTHER PROBLEMS

ASSEMBLIES REPLACING PROCEDURES

1. SAFETY INSTRUCTION
2. MEASURING SYSTEM REPLACEMENT PROCEDURE
3. SUCTION PUMP REPLACEMENT PROCEDURE
4. LCD DISPLAY REPLACEMENT PROCEDURE
5. FRONT PANEL KEYBOARD REPLACEMENT PROCEDURE
6. ANALYZER BOX ASSEMBLY REPLACEMENT PROCEDURE
7. DC POWER SUPPLY FUSE REPLACEMENT PROCEDURE
8. AC POWER SUPPLY FUSE REPLACEMENT PROCEDURE
9. SYRINGE REPLACEMENT PROCEDURE
10. ACCURACY AND REPEATABILITY DEVIATIONS

DATA COLLECTION SYSTEM OPERATION MANUAL

MEASURING SYSTEM CONFIGURATIONS

GUARANTEE CARD

MILKANA SUPERIOR Ultrasonic Milk Analyzer is designed for fast and cost effective analysis of
the fat contents, milk solids non fat (SNF) protein and milk density for both cow and sheep milk
and added water to milk as well.

KEY FEATURES
Simple and lightweight design

+12V DC and 220 V AC Power Supply

Cost Effective

Low power consumption

Very small quantity of milk required

No acid or other chemicals are used

Measuring accuracy adjustment can be done by the user

RS 232 Interface

Data collection – vendor ID, volume-litres and milk parameters for up to 200 vendors (optional
on request)

One year full warranty

Operating Conditions:

Ambient air temperature (15-30) ºC

Milk temperature (15-30) ºC

Relative Humidity (30-80) %

Electrical Parameters:

AC Power Supply voltage (220 V + 10/-15%)

DC Power Supply Voltage 12 V to 14,2 V

Power Consumption 30 W max

Mechanical Parameters:

Dimensions (WxDxH) (130x230x300) mm

Weight <4, 4 kg

Measuring Parameters:

Fat (0,5-9)% accuracy 0.1%

Solid non fat (SNF) (6-12) % accuracy 0.2%

Milk density (1.0260-1.0330) g/cm3 accuracy 0.0005 g/cm3

Protein (2-6)% accuracy 0.2%

Added water to milk (0-60)% accuracy 5%

CONTROL (on the front panel)

1. Select the work mode

2. Skip and search forwards and backwards
3. Confirm the choice
4. Tube (sucker)
5. Plastic support

SWITCHES and OUTLETS (on the rear panel)

1. RS 232 Interface outlet

2. 12 V DC Printer Power supply outlet
3. ON/OFF Switch-for car vehicle use 12 V
4. 12 V DC Power supply outlet
5. POWER switch
6. AC power led

NOTE: For data collection programme system password: milkana

INSTRUCTIONS FOR USE

Place the MILKANA SUPERIOR vertically on a table or any other flat surface.

-220 V/110 V AC Power Supply Voltage

Connect the AC power lead to the mains socket.

Set the Power switch to “ON”

-12V DC Power Supply Voltage

Connect the DC supply lead to 12 V outlet (black is “-“) and to the autonomous DC supply
(for example car battery)

Set the +12 V Power switch to “On”

WARM UP

When the power is on, WARM UP appears on the display.

When the “warm up” stage is over in about 5 minutes.

MILKANA S is shown on the display. The MILKANA SUPERIOR is ready to use.

Do not take into consideration the first sample because it is likely to have a deviation out
of specification.

Warning: the covers of the MILKANA SUPERIOR should never be removed while the power
leads are connected
Warning: under no circumstance should you try to repair the analyzer’s power lead
yourself. In case of power lead damage, contact your dealer to make the repairs.

MILK SAMPLES

Milk samples temperature should be (15-30) ºC

Milk with surface fat film should be heated to (40-45)ºC by means of waterbath. Stir up
and cool it to (29-30) ºC. if the milk temperature is above 38ºC the message HOT SAMPLE
appears on the display. Milk acidity should be higher than pH 6.0

Use the milk sample only once. When the measuring is carried out, thow the sample away.

BASIC MODES FOR USE

Press the MODE button to enter basic modes menu. Basic modes available are as follows:

COW MILK – analysis of cow milk

CLEANING cleaning at the end of working day (Valid in MOTOR ON mode)

MOTOR CHOICE – choice the basic mode

CAL CHANNEL 1- calibration

SYSTEM manufacturer`s mode only

SHEEP MILK analysis of sheep milk

 These modes are available with MILKANA SUPERIOR with suction pump installed only.
Press the search buttons ˄˅ to select desired mode.

MILK ANALYSIS WITH MOTOR (SUCTION PUMP)

Press the MODE button only once. Press the search buttons to select MOTOR CHOICE
mode:
Set with search buttons ˄˅ the desired motor mode – ON . Press OK to confirm it. The
message MOTOR TURNED ON appears on the display. This way the “MOTOR ON”
mode will remain set, even if the power supply is turned off.
Take out the plunger from the syringe. Insert the rubber plug with the plastic tube
instead of plunger.
The analyzer is ready for use in mode with suction pump
Measurement
Steps: Fill the measuring mug with milk sample to be measured. Place the measuring
mug on the plastic support (5) with the tube (aspirator) into the milk sample.
Press MODE and by means of the search buttons select the desired mode:
COW MILK analysis of cow milk
SHEEPMILK analysis of sheep milk
When the poper type of milk is displayed, press OK to start the measurement. Milk
automatically is driven into the measuring camera. The message WORKING appears on
the display while measurement is going on.
 Warning: In case of formation of air bubble in the measuring camera the message
EMPTY CAMERA will appear on the display. Then make a fresh start.
As soon as the measurement is completed the display shows the results for following
milk parameters:

On the upper row:

FAT, SOLIDS NON FAT (SNF), MILK DENSITY
On the bottom row:
ADDED WATER TO MILK, FREEZING VALUE*, PROTEIN
*Freezing Value= Freezing Point (ºC)*(-100)
The milk return automatically into the mug
Throw away the used milk sample
Warning; In case of motor damage the message MOTOR ERROR will appear on the
display. Contact your dealer to make the repairs. Meanwhile you may use the analyzer
In MOTOR OFF mode. (See “Milk analysis without aspirator pump”)

MILK ANALYSIS WITHOUT MOTOR (ASPIRATOR PUMP)

Press the MODE button once. Press the search buttons to select the MOTOR CHOICE
mode. Press OK when the MOTOR CHOICE mode is displayed. Set with search buttons the
desired motor mode –OFF .

Press OK to confirm it. The message MOTOR TURNED OFF appears on the display. This way
the “ MOTOR OFF” mode will remain set, even if the power supply is turned off.

Take out the rubber plug with the plastic tube from the syringe. Insert the plunger instead
of the rubber plug with the plastic tube.

The analyzer is ready for use in mode without suction pump.

Steps: Press MODE and by means of the search buttons select the desired mode:

COW MILK – analysis of cow milk

SHEEP MILK analysis of sheep milk

When the proper type of milk is displayed, fill the measuring mug with milk sample to be
measured. Place the measuring mug on the plastic support (5) with the tube (sucker) into
the milk sample.

Pull up very carefully the plunger. This way milk is driven to the measuring camera.

Warning: Pull up the plunger smoothly to prevent formation of air bubble in the
measuring camera the message EMPTY CAMERA will appear on the display. Then make a
fresh start.

Press OK to start the measurement

The message WORKING appears on the display while measurement is going on.
 As soon as the measurement is completed the display shows the results for following milk
parameters:

On the upper row:

FAT-SOLIDS NON FAT (SNF)-MILK DENSITY

On the bottom row:

ADDED WATER TO MILK –FREEZING VALUE*-PROTEIN

*FREEZING VALUE= FREEZING POINT (ºC)*(-100)

Push down the plunger to pump out milk from the measuring camera into the mug ang
throw the used milk sample away.

CLEANING OUT

Daily procedure

It is necessary to clean the analyzer in the following cases:

1. The interval between two consecutive measurements is more than half an hour;
2. End of working day

Notes: make sure the analyzer is always cleaned properly, otherwise the device sensor will
be contaminated and damaged soon.

Cleaning out with MOTOR (aspirator pump)

Fill the measuring mug with warm, but not boiling and clean water (40-60) ºC. Press the
MODE button once. Press the search buttons to select CLEANING. Confirm with OK. The
display shows message CYCLES 01- number of cleaning cycles to be done. One cleaning
cycle pumps the water in and back five times. Press the search buttons ˄˅ to select the
desired number of cleaning cycles. This number can range from 1 to 99. We recommend
one or two cleaning cycles to be chosen in case a regular cleaning procedure is performed.
When the desired number is displayed, press OK to start the cleaning. When the CLEANING
stage is over CLEANING END is shown on the display. Remove the mug and throw away the
muddy water. Repeat this procedure several times till clean water comes out from the
analyzer.

Cleaning out without MOTOR (aspirator pump)

Fill the measuring mug with warm, but not hot, and clean water (40-60) ºC. Pull up and
down the plunger several times. Remove the mug and throw away the muddy water.
Repeat this procedure several times till clean water comes out from the analyzer.

Weekly procedure

To ensure a good work of the analyzer it is advisory to clean the device at least once a
week following the cleaning out without MOTOR procedure.
 CALIBRATION

The analyzer should be calibrated if the measuring accuracy for one or more milk
parameters is out of the specified limits

Calibration values determination:

FAT

- Determine a milk sample FAT contents by means of a classical method (for example
you can use Gerber method);
- Test the same milk using MILKANA SUPERIOR
- Subtract the Milkana SUPERIOR FAT value form FAT value achieved with classical
method. If the difference value is in the spec limits there is no need of FAT calibration.
Otherwise add this difference value as a FAT calibration value using the procedure
described in “Calibration values Saving”

SOLIDS NON FAT (SNF)

- Determine a milk sample SOLID NON FAT (SNF) by means of a classical method.
- Test the same milk using MILKANA SUPERIOR
- Subtract the MILKANA SUPERIOR SOLIDS NON FAT (SNF) value from SOLIDS NON FAT
(SNF) value achieved with classical method. If the difference value is in the spec limits
there is no need of SOLIDS NON FAT (SNF) calibration. Otherwise add this difference
value as a SOLIDS NON FAT (SNF) calibration value using the procedure described in
“Calibration values saving”
DENSITY
- Determine the milk sample DENSITY by means of a density meter
- Test the same milk using MILKANA SUPERIOR again
- Subtract the MILKANA SUPERIOR DENSITY value from DENSITY value achieved with
classical method. If the difference value is in the spec limits there is no need of milk
DENSITY calibration. Otherwise add this difference value as a milk DENSITY calibration
value using the procedure described in “Calibration values Saving”.

Note: if you will calibrate both SOLIDS NON FAT (SNF) and DENSITY parameters, first
calibrate SOLIDS NON FAT (SNF). Test the same milk using MILKANA SUPERIOR again.
Calibrate the DENSITY only if it is necessary.

PROTEIN

- Determine a milk sample PROTEIN contents by means of a classical method (for

example you can use Kjeldahl method)
- Test the same milk using MILKANA SUPERIOR
- Subtract the analyzer PROTEIN value from PROTEIN value achieved with classical
method. If the difference value is in the spec limits there is no need of PROTEIN
calibration value using the procedure described in “calibration values Saving”

CALIBRATION VALUES SAVING

 - To save a new calibration value press MODE button first
- Press the search buttons ˄˅ to select
CAL CHANNEL 1 mode- calibration of channel 1
- Press OK
- The display shows PASS 1 – first password number prompt
- Set with search buttons ˄˅ the first password number. Press OK to confirm.
- A prompt for the second password number appears on the display -PASS2. Enter the
second password number the in the same way as the first one. Enter the third
password number when a PASS 3 prompt appears on the display.
Notes: In case an incorrect password is entered, a message WRONG PASSWORD
appears on the display. Then make a fresh start.

In case the right password numbers are entered the display will show FAT COW MILK

Press the search button ˄˅ to select the milk parameter to be calibrated:

FAT COW MILK – cow milk fatness calibration

DRY COW MILK –cow milk (SNF) calibration

FAT SHEEP MILK –Sheep milk fatness calibration

DRY SHEEP MILK –sheep milk (SNF) calibration

DEN COW MILK –cow milk density calibration

DEN SHEEP MILK –cow sheep density calibration

PROT COW MILK –cow milk protein calibration

PROT SHEEP MILK –sheep milk protein calibration

Select desired calibration parameter. Confirm it with OK

-The inscription VALUE appears on the display

-Press the buttons to set the calibration value required

-The number can range from -0.99 to +0.99 for fat, protein and solids non fat (SNF) and from -
9.9 to +9.9 for density calibration. This number defines the calibration value. When desired
value is set on the display press the OK button to save it.

-Then the display shows CAL VALUE and a number equal to the total calibration value for this
milk parameter. The total calibration value is an algebraic sum of all calibration values added
for this milk parameter. The calibration value saving is completed.

Note: the total calibration value can range from -0.99% to +0.99% (for fat, protein and solids
non fat (SNF) and -9.9ºA to +9.9ºA (for density). In case a bugger number has been achieved
during a calibration procedure a CAL OUT OF RANGE error message appears on the display.

ERROR MESSAGES ON THE DISPLAY

Some of the problems that may accur will cause an error message to appear on the display.

Warning: sometimes an ERROR MESSAGE maybe due to the shock hazard, power supply
disorder, electromagnetic influence or other incidental reason. In order to avoid any needless
repairs, please repeat the same operation few times to make sure there is a real problem.

ERROR MASSAGE PROBLEM & CAUSES REMEDY

1. MOTOR ERROR 1.1 MOTOR DAMAGE Replace the out of order
Pump with a new one (see
ASSEMBLIES REPLACING
PROCEDURES)
2.1 AIR BUBBLES IN THE Fill again the mug with the
MEASURING SENSOR same milk sample and make
fresh start
2.2 THE ASPIRATOR SYSTEM HAS 1. Check the rubber plug
SOME AIR LEAK position and fix if necessary If
the Rubber Plug satys loose
in the Syringe replace the
Syringe.
2. Test the analyzer in
MOTOR OFF mode.
If no problem occurs in this
2. EMPTY
mode, the Pump is out of
CAMERA
order. Replace the pump
with a new one and put the
analyzer in MOTOR ON mode
(see ASSEMBLIES REPLACING
PROCEDURES)
If the problem still exists see
next cause.
2.3 MEASURING SYSTEM Replace the out of order
CANTAMINATED OR DAMAGE MEASURING SYSTEM with a
new one (see ASSEMBLIES
REPLACING PROCEDURES)
3.1 MILK SAMPLE TEMPERATURE Fill again the mug with
ABOVE THE SPEC. proper temperature milk
sample and make a fresh
start
3.2 MEASURING SYSTEM Replace the out of order
3. HOT SAMPLE CONTAMINATED OR DAMAGE MEASURING SYSTEM with a
new one (Replace the out of
order MEASURING SYSTEM
with a new one (see
ASSEMBLIES REPLACING
PROCEDURES)
4. ERROR 9 4.1 THE POWER SUPPLY VOLTAGE Use proper power supply
IS BELOW SPEC. voltage value
4.2 MEASURING SYSTEM OUT OF Replace the out of order
ORDER MEASURING SYSTEM with a
new one (Replace the out of
order MEASURING SYSTEM
 with a new one (see
ASSEMBLIES REPLACING
PROCEDURES)
5. ERROR 7 5.1 MEASURING SYSTEM OUT OF Replace the out of order
ORDER MEASURING SYSTEM with a
new one (Replace the out of
order MEASURING SYSTEM
with a new one (see
ASSEMBLIES REPLACING
PROCEDURES)
6. WRONG 6.1 INCORRECT PASSWORD Re-enter the password
PASSWORD
7. CAL OUT OF 7.1 ATTEMPT TO ENTER A The total calibration value
RANGE CALIBRATION VALUE OUT OF THE can range from -0.99% to
ALLOWED LIMITS +0.99% (for fatness, protein
and solids non fat (SNF)) and
-9.9ºA to +9.9ºA (for density).
In case a bigger number has
been achieved during a
calibration procedure a CAL
OUT OF RANGE error
message appears on the
display.
If a calibration value out of
allowed limits is really
needed, Measuring system is
out of order and must be
replaced (Replace the out of
order MEASURING SYSTEM
with a new one (see
ASSEMBLIES REPLACING
PROCEDURES)
8. DARK DISPLAY 8.1 THE POWER SUPPLY CORD IS
NOT CONNECTED TO THE MAINS
8.2 THE AC POWER SUPPLY
SWITCH IS NOT TURNED ON.
8.3 THE AC POWER SUPPLY FUSE IS
BURNT
8.4 THE AC POWER SUPPLY
TRANSFORMER IS OUT OF ORDER
8.5 THE MEASURING SYSTEM
BOARD IS OUT OF ORDER (SHORT
CIRCUITED OR BROKEN WIRE)
8.6 THE LCD DISPLAY CABLE IS
BROKEN OR THE DISPLAY IS
DAMAGED.
9. DARK DISPLAY 9.1 THE DC POWER SUPPLY IS TOO Use DC Power Supply with a
WHEN THE LOW correct voltage output only
ANALYZER IS (12 to 14.2) V DC
POWERED
FROM A 12 V Warning: A higher DC
 DC POWER voltage than the specified
SUPPLY can damage the analyzer!
9.2 THE DC POWER SUPPLY CABLE Swap the DC Power Supply
LEADS ARA SWAPPED Cable Leads at the Analyzer
site (at the Back panel DC
Power Supply Socket)
9.3 THE DC POWER SUPPLY FUSE Replace the DC Power Supply
IN BURNT. Fuse with a new one. This
Fuse is located on the
Measuring System PC Board.
A 3 to 4A Fuse should be
used.
10. DISPLAY IS LIT 10.1 FRONT PANEL KEYBOARD IS Connect the Keyboard
BUT THERE IS DISCONNECTED connector to the upper side 6
NO RESPONSE pin connector of the
ON ANY KEY measuring system main PCB.
PRESSED
Warning: connecting the
keyboard connector to the
main PCB pump connector
will permanently damage
measuring system!
10.2 FRONT PANEL KEYBOARD Tighten the screws.
SCREWS ARE NOT TIGHT
10.3 FRONT PANEL KEYBOARD OUT Replace the out of order
OF ORDER FRONT PANEL KEYBOARD
with new one (see
ASSEMBLIES REPLACING
PROCEDURES)
11. STRANGE 11.1 THE MILK SAMPLE IS TOO Please test milk samples with
SYMBOLS ON SOUR (MILK ACIDITY IS acidity higher than pH 6
THE LCD LOWER THAN Ph 6)
INDICATION
INSTEAD OF
MILK SAMPLE`S
RESULTS
Warning: sometimes this
problem may be caused by
a shock hazard, power
supply disorder,
electromagnetic influence
or other incidental reason.
In order to avoid any
needless repairs, please
repeat the same operation
few times to make sure
there is a real problem.
11.2 THE ASPIRATOR SYSTEM HAS 1. Check the rubber Plug
SOME AIR LEAK position and fix if necessary.
If the rubber plug stays loose
in the syringe replace the
syringe.
2. Test the analyzer in
MOTOR OFF mode.
 If no problem occurs in this
mode, the pump is out of
order. Replace the pump
with a new one and put the
analyzer in MOTOR ON mode
(see ASSEMBLIES REPLACING
PROCEDURES)
If the problem still exists see
next causes.
11.3 MEASURING SYSTEM Replace the out of order
CONTAMINATED OR DAMAGE MEASURING SYSTEM with a
new one (see ASSEMBLIES
REPLACING PROCEDURES)
11.4 LCD DAMAGE Replace the out of order LCD
with new one (see
ASSEMBLIES REPLACING
PROCEDURES)
12. NO RS232 12.1 THE RS232 CABLE IS NOT Insert both RS232 cable
COMMUNICATI PROPERLY CONNECTED. connectors properly
ON
12.2 THE CABLE FROM THE RS232 Connect properly the cable to
CONNECTOR IS NOT PROPERLY the measuring system
CONNECTED TO THE MEASURING connector.
SYSTEM.
12.3 SOFTWARE PROBLEM Install (or reinstall) Milk Data
2001 Software. If this does
not help ask for qualified
help.

ASSEMBLIES REPLACING PROCEDURES

Attention!

The assemblies are very sensitive to electrostatic discharge and mechanical shock.

Do not expose the assemblies to the humidity or to excessive heat caused by heating
equipment or direct sunlight.

To guarantee good work of the measuring system always hold them at the edges.

Before to start any replacement, always perform the “Cleaning out” procedure as described in
operating instruction manual.

When replacing any assembly always remember the proper location of all connectors (see
APPENDIX 1 for reference). Mixing the connectors locations will cause permanent damage.

1. SAFETY INSTRUCTION

Warning! When repair Analyzer, basic safety precautions should always be followed including
the following. This is to reduce the risk of fire, electric shock and personal injury!
Always consider these instructions while attempting to repair an analyzer.

1.1 The covers of the analyzer should never be removed while the power leads are
connected.
1.2 Keep the analyzer on a secure place to avoid dropping.
1.3 Never carry an analyzer by the cable or yank it to disconnect it from the receptacle

2. MEASURING SYSTEM REPLACEMENT PROCEDURE

2.1 Set the power switch to OFF

Disconnect the AC power lead from the mains socket.

2.2 Remove the rubber plug and insert the plunger into the syringe as deep as possible in
order to remove any remaining water.
2.3 Remove the side covers of the analyzer
2.4 Disconnect all measuring system board connectors
2.5 Place the analyzer vertically and remove both plastic tubes from the sensor- upper
side first
2.6 Unscrew both screws located at the upper side of the measuring system board and
take out the measuring system.