Reflectronics, Inc. www.reflectronics.

com CoAguLite Technical Manual

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Technical Manual

CoAguLite

Cutting Time Control Technology for Cheese Making

Revised: 15 October 2000

This Technical Manual was downloaded from the Reflectronics Inc. web site
www.reflectronics.com and is the property of Reflectronics, Inc. Permission to copy
this manual is granted to distributors, users, potential users of the technology, and to
educators.
Reprinting in whole or part for commercial gain is prohibited without the expressed
written permission of Reflectronics, Inc. Reflectronics grants any individual the right to
download and print a single copy as well as updates of this document.

REFLECTronics, Inc.
Reflectronics, Inc.
3009 Montavesta Road
Lexington, KY 40502
(859) 269-9411
info@reflectronics.com
http://www.reflectronics.com

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CoAguLite
MODEL 4A

Cutting Time Control

Technology
for Cheese Making
OPERATING MANUAL

Manufactured by:

Reflectronics, Inc.
3009 Montavesta Road,
Lexington, KY 40502
Phone/Fax 859-269-9411
www.reflectronics.com
info@reflectronics.com

Printed in USA

Part No. 4-07

TM

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The information contained in this manual is believed to be accurate and reliable.

However, REFLECTronics, Inc., assumes no responsibility for its use.
REFLECTRONICS WARRANTS THAT THE PRODUCTS WILL BE FREE FROM
DEFECTS IN MATERIALS AND WORKMANSHIP. SHOULD A PRODUCT FAIL
TO PERFORM AS WARRANTED, THEN REFLECTRONICS LIABILITY SHALL
BE LIMITED TO THE REPAIR OR REPLACEMENT OF THE DEFECTIVE
PRODUCT OR COMPONENT OR THE REFUND OF THE PURCHASE PRICE.
THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, AND ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF
REFLECTRONICS ON ACCOUNT OF THE PRODUCT SOLD HEREUNDER.
IN NO EVENT SHALL REFLECTRONICS BE LIABLE FOR CONSEQUENTIAL
OR SPECIAL DAMAGES.

Reflectronics, Inc. may change the technical specifications at any time. The use
of the CoAguLite sensor for cutting time predictions in cheese manufacture falls
under U.S. Patent 5,172,193.
CoAguLite and FiberView are trademarks of REFLECTronics, Inc.

Reflectronics, Inc.
3009 Montavesta Road
Lexington, KY 40502
Phone/FAX 859-269-9411

Reflectronics, Inc. www.reflectronics.com CoAguLite Technical Manual

Table of Contents

Overview
Technical Specifications
Physical Installation
Calibration
Maintenance
Troubleshooting
Digital Signals
Parts List
Summary of Plant Electrical Connections

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CoAguLite
Cutting Time Control Technology
for Cheese Making

Overview
The CoAguLite Cutting Time Control Technology replicates the
cheesemakers selection of cutting time. The performance consistency of the
technology results from the use of the latest optical technology, a robust sensor
design, and employment of fundamental principles of chemical reaction kinetics.
The system consists of the CoAguLite sensor, prediction algorithm, and
computer. This manual covers an overview of the prediction algorithm and details
of the installation and operation of the CoAguLite sensor.
The CoAguLite sensor measures changes in light backscatter during
enzymatic coagulation of milk. Light from an LED is transferred to the milk
through a fiber and the light reflected from the milk is transmitted through an
adjacent fiber to an optical detector.

PROBE TIP

PARTICLES

FIBER
LIGHT FROM
LED
LIGHT
BACKSCATTER

The reflectance signal carries information about changes in the physical

size and structure of the casein micelles during enzymatic hydrolysis and
coagulation. As the enzymes attack the casein micelles, their physical integrity
breaks, the casein micelle swell, and crosslinking changes the physical state of
the milk resulting in more light being reflected. The time from enzyme addition to
the maximum rate of reflectance change (Tmax) is measured. Tmax was found

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to be a measure of the enzymatic reaction rate. When temperature, pH, added

calcium, or enzyme concentration changes then Tmax also changes. The fact
that Tmax is a measure of the chemical reaction rate of the coagulation process
gives the CoAguLite Cutting Time Control technology its ability to predict the
cutting time with consistency. This results because the ratio of the chemical
reaction rates for protein crosslinking to that for enzymatic hydrolysis is nearly
constant for the conditions normally encountered with milk.

REFLECTANCE PROFILE
REFLECTANCE RATIO

2.0
1.5

Tmax
REFLECTANCE

CUTTING
TIME

1.0
0.5
SLOPE

0.0
0

10

15

20

25

30

TIME AFTER ENZYME ADDITION, min

During coagulation the diffuse reflectance follows a consistent pattern.

The reflectance profile has a latent period during which time enzymatic reactions
predominate with no detectable change in reflectance; a sigmoidal period where
aggregation reactions predominate; and, a crosslinking period where crosslinking
(gelation) proceeds at an ever-decreasing rate.
The time between enzyme addition and the occurrence of the inflection
point (Tmax) is highly correlated with cutting time. The following prediction
equation was developed to predict cutting time (Tcut):
Tcut = BETA * Tmax
The reflectance profile is analyzed after enzyme is added to determine Tmax.
Predicted cutting time is calculated as a constant BETA times Tmax. BETA
typically varies between 1.3 and 2.4 depending on the enzyme used and product
produced. BETA is selected in the plant by the cheesemaker to replicate his
judgment of cutting time. This calibrates the system. An algorithm is available for
correcting the cutting time prediction for changes in milk protein.

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Technical Specifications
The CoAguLite was designed for durability using premium quality
materials. The welding ferrule is fabricated of 316 SS. The plastic probe is
fabricated of high molecular weight plastic and provides thermal isolation for the
optics and electronics. The sensor design is compact, rigid, sanitary, corrosion
resistant, and watertight. The design is also in compliance with the 3A Sanitary
Standard, 46-02.
The CoAguLite sensor measures the light backscatter and linearly
converts the light reflected into a 4-20 mA output signal. The 4-20 mA sensors
offer conventional zero and span output calibration in one compact configuration.

Instrument Cable
Belden 9402 cable is recommended. It contains 2 twisted pairs (Black and
Red; White and Green), individually shielded with drain for each pair, and 20
AWG wires. The sensor is shipped with 8 m (25 ft.) of instrument cable.

Electronic Specifications
Power Supply
Power Loading
Output
Operating Temp.
Probe
Head
Cable Length

Minimum
+10
30
4

Typical
+24
60

Maximum
+27
100
20

Units
VDC
mA
mA

30
30
30

100
60
>100

C
C
m

Electrical Connections
The CoAguLite sensor requires power between 10 and 27 VDC. The
sensor uses a maximum of 100 mA. The instrument cable connections are as
follows: Red (+VDC Input); Black (DC Input Common); Shield (Ground); Green (420 mA Output Common); and White (4-20 mA Output Common).
4-20 mA +
WHITE
4-20 mA COM GREEN
GROUND
COM
BLACK
+VDC
RED

LED SELECTOR
SWITCH

SPAN ADJUSTING
POT (R4)

1 2
J2

SPAN

RED
INDICATING
LED

ZERO

R5

ZERO
ADJUSTING
POT (R5)

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The output signal must be measured using an isolated meter. The following
is a typical wiring schematic for the CoAguLite sensor:
SENSOR

+ VDC

RED

COM

BLACK

10 TO 27 VDC
POWER SUPPLY
100 mA

SHIELD
GROUND
WIRE
OUTPUT ( - ) GREEN

+V

OUTPUT ( + ) WHITE

DC COM

AC SUPPLY
AC SUPPLY

GROUND

METER
AC SUPPLY

DC
COM

AC SUPPLY

GROUND

4-20 mA

LOAD
GROUND

The DC power common (Black wire) is connected on the circuit board to the 4-20
mA common (Green wire) and thus are electrically the same. Thus, the 4-20 mA
load at the meter must be isolated (ungrounded). Otherwise, a ground loop
exists. The DC power supply common is grounded. The instrumentation cable
shield must be grounded.

Verifying Electrical Connections

1. Confirm that 10 to 27 VDC power is being supplied to the sensor (Red
wire is +VDC).
2. Confirm that the cable shield ground is connected.
3. Confirm that the plant instrumentation is ungrounded i.e. isolated.
4. Confirm that the 4-20 mA loop is connected to the plant instrumentation.
5. Apply power and confirm that the Red Indicating LED is on. This
indicates that power is being supplied to the sensor.

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Physical Installation
The installation of the probe in a vat can affect its performance. The
horizontal mounting position is required for cheese vat installations. This reduces
the chance of heavier or lighter materials collecting on the probe tip and
interfering with the signal. The probe must be mounted in a location where
external cooling or heating of the probe or vat wall will not cool the milk around
the probe tip.

TriClamp
A TriClamp mounting (2 ) configuration is available for vats installation.
The ferrule is supplied with the sensor and must be welded into the vat wall.
2 TRI-CLAMP
CONNECTION

PROBE

2
50.8 mm

ENCLOSURE

2.708
[68.8 mm]

FERRULE

VAT WALL

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CoAguLite Calibration
The objective of sensor calibration for milk coagulating applications is to
adjust the output to give sufficient response during coagulation. A general guide
is to adjust the output to 25% of full scale using skim milk (8 mA for a 4 to 20 mA
sensor) or about 45% of full scale (11 mA) for raw whole milk. During coagulation
the reflectance increases up to 50%. The above adjustment allows sufficient
flexibility for occasional products with higher reflectance.
The following section describes calibration of the CoAguLite sensor. In all
cases, the sensor should be operated for a period of one hour prior to calibration
to allow the LED and detector to come into thermal equilibrium.

Quick Sensor Calibration Check

1. Press wetted black rubber firmly over the clean sensor tip to confirm that the
output is near zero.
2. Place index finger over distal tip of sensor. The output should be
approximately 1/3 of full scale. This is a very rough preliminary check of the
sensor but very useful to confirm its operation.

Full Sensor Calibration

Calibration of the 4-20 mA is performed by first selecting an LED light output
level and then adjusting the ZERO and SPAN on the signal amplifier. Typically
the LOW LED setting is sufficient for whole milk coagulation.
A. Selecting LED Output
LED light output level is selected to match the product backscatter
characteristics. The LED output switch is located on the circuit board and has
four positions: OFF, LOW; MED; and HIGH, as shown in the following sketch.
1

J2
OFF

LOW

MED

HIGH

LE D SELECTOR SWITCH

The sensor should be calibrated at the highest light level possible. This
provides for a stronger optical signal that requires less amplification. Try the
HIGH setting and place the probe in your product. If the light level is too high the
output will remain saturated even when the SPAN is minimized (adjustment pot
fully counter clockwise). If this occurs, select the next lower light setting and test
in your product. The ZERO and SPAN adjustment pots have a maximum
adjustment of 25 turns.

B. Calibration Steps
1. Place a current meter at a convenient location to measure the current
output of the sensor. Current output is through the WHITE wire).
2. With the LED at the selected position, press a small piece of black rubber
firmly over the distal tip of the probe.

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3. Adjust the ZERO potentiometer screw (R5) to give 4 mA output current

and verify that the plant instrumentation is reading the proper level.
4. Place the probe into the vat and calibrate when milk covers the probe in
the vat.
a. If the output is below the desired output (Desired output is
approximately 11 mA for whole milk) increase the SPAN by turning
the potentiometer screw clockwise.
b. If the output is too high, turn the potentiometer adjusting screw
counterclockwise until the desired output is achieved. If the SPAN
Adjustment Pot is turned counter clockwise to its maximum (25 turns)
and the output is still over the desired output then a lower LED setting
will be necessary for this product. Select a lower LED light output and
repeat the above calibration steps.
5. Readjust the ZERO for the new gain level (This is usually a very small
adjustment).
6. Replace the screw cap on the enclosure (head). A light quantity of
sanitary lubricant was applied at the factory on the head threads to give
the enclosure head added watertight protection. Add lubricant as
necessary to these threads.
4-20 mA +
WHITE
4-20 mA COM GREEN
GROUND
COM
BLACK
+VDC
RED

LED SELECTOR
SWITCH

SPAN ADJUSTING
POT (R4)

1 2
J2

SPAN

RED
INDICATING
LED

ZERO

R5

ZERO
ADJUSTING
POT (R5)

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Maintenance
The probe distal tip containing the terminating optical fibers is manufactured
from 316 SS. Check the probe distal tip on a periodic basis. The probe should be
removed being very careful not to drop or scuff the probe.
1. Remove any calcium deposits. Use a soft bristled brush and a non-abrasive
soap to clean the probe tip. Use a cotton cloth to wipe the probe tip clean.
2. Confirm that the fibers have not recessed into the distal tip or extended out past
the stainless steel surface. If the fibers have moved then the probe should be
returned for repair of the fiber optic unit.
3. Confirm that the O-Ring in the cone (around the distal tip) is smooth and not
eroded.
4. If the sensor O-Ring (See Parts List) is removed, clean and wipe all lubricant
from the O-Ring grove. Residual lubricant increases the compression required
to press the sensor into the ferrule.
5. Replace the screw cap on the enclosure (head). A light quantity of sanitary
lubricant was applied at the factory on the head threads to give the enclosure
head added watertight protection. Add lubricant as necessary to these
threads.

Troubleshooting
If the sensor is giving an unsatisfactory response, check the following items:
1. Check the distal tip of the probe for calcium buildup and clean if necessary.
2. Check for damage to the distal tip at the end of the probe. If the distal tip is
scratched or damaged, it will result in reduced output. A severely damaged
distal tip must be returned for repair.
3. Remove the screw cap on the enclosure (head) and check for visible signs of
water damage. If water is present, dry the enclosure, and apply a lubricant to
the enclosure threads to aid in waterproofing. If the sensor fails to operate
after drying, return for repair.
4. With enclosure screw cap removed, check terminal connections for proper
seating. Check ground connection. The ground drains the instrumentation
cable. The ground wire should not be contacting the enclosure head or any
other part of the sensor. Check the output connections and power supply
connections for proper seating.
5. Check for a red indicating LED on the circuit board inside the enclosure. A
lighted red LED indicates that the sensor is receiving power. However, the
power voltage should still be checked (BLACK and RED wire) with a voltmeter
to confirm that it is in the range of 10 to 27 VDC at the sensor.
6. Turn the LED selector switch to the HIGH position (See Selecting LED
Output). Place the probe in a dark environment or place wetted black rubber

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over a cleaned distal tip. The output should be near 4 mA. Place the probe in
product or place finger over distal tip. If no response, return for repair. If the
response is more or less than desired, calibrate as described in the Calibration
Section.

The following diagnostic flow chart may help in troubleshooting:

Connect
Sensor
power.

Yes

Disconnect WHITE wire and

measure current between WHITE
wire and terminal post with
probe in dark

No

Yes

Any
Current?

Return to
Manufacturer

No

Check DC power on
terminal connector
Is the voltage +10V
to +27 VDC?

Yes

Return to
manufacturer

Place probe in
product. Current
increases?

Return to
Manufacturer

No

Is Red
indicator light
ON?

Yes

Calibrate
Sensor

No

Check the
power cable
and power
supply

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Digital Signals Required

Input and output digital signals are needed from the plant to make the
CoAguLite Milk Coagulation Sensor System operate automatically.

Input Signals- Two signals are required:

Enzyme Addition signal is used to start the computer program. The
computer must receive a signal when the enzyme is added to the milk. Time
ZERO is when the enzyme physically enters the vat. In some plants the
enzyme is added over a period of 1 to 2 minutes. In such cases the proper time
ZERO is when 50% of the enzyme has been added to the milk. A correction to
time ZERO can be included in the software if necessary
Cutting Motor signal - when the cutting motor is activated it signals that
the coagulation process is complete. This signal is necessary for operation in
both manual and automatic mode. It tells the computer that the coagulation is
complete.

Output Signals- Two signals are required:

Cutting Time signal is used to activate the cutting motor at the predicted
cutting time.
Alarm signal is used to alert the operator of a condition requiring manual
attention

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Parts Lists

ITEM
1
2
3
4
5
6
7
8

DESCRIPTION
COAGULITE SENSOR MODEL 4-A
O-RING
WELDING FERRULE
INSTRUMENT CABLE, 7.5 m ( 25 ft)
PLUG
TRI-CLAMP (13MHHM-2.5)
OPERATING MANUAL

PN
4-01
4-02
4-03
4-04
4-05
4-06
4-07

COAGULITE MODEL 4-A ASSEMBLY

(Includes items 1, 2, 3, 4, 6 and 7)

4-A
PARTSLIST04.DWG

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Summary of Plant Electrical Connections for

4-20 mA sensor

The sensor requires power between 10 and 27 VDC.

The sensor uses a maximum of 100 mA.
The 4-20 mA load at your meter must be isolated (ungrounded). The DC
power common (Black wire) is connected on the sensor circuit board to the 420 mA common (Green wire) and thus are electrically the same. Connecting

the 4-20 mA output wires to a grounded meter will result in a

ground loop, higher noise, and may create a short.

The DC power supply common must be grounded.

The instrument cable connections are as follows:

Red Black Shield Green White -

+VDC Input
DC Input Common
Ground
4-20 mA Output Common; (connected to DC Input Common on board)
4-20 mA Output

The following is a typical wiring schematic for the 4-20 mA sensor:

SENSOR

+ VDC

RED

COM

BLACK

10 TO 27 VDC
POWER SUPPLY
100 mA

SHIELD
GROUND
WIRE
OUTPUT
( - ) GREEN

+V

OUTPUT ( + ) WHITE

DC COM

AC SUPPLY
AC SUPPLY

GROUND
4-20 mA +
4-20 mA COM
GROUND
COM
+VDC

LED SELECTOR
SWITCH

SPAN ADJUSTING
POT (R4)

1 2
J2

SPAN

ZERO

METER

WHITE
GREEN
BLACK
RED

ZERO
ADJUSTING
POT (R5)

METER LOAD
IS ISOLATED
Reflectronics Inc., Lexington, KY 40502

AC SUPPLY

GROUND
LOAD

R5

RED
INDICATING
LED

AC SUPPLY

DC
COM

4-20 mA

GROUND