Allure Melanger 4-0.25-230-50-A User manual

CE and ISO
22000-2007
Certified
OPERATOR'S MANUAL
Melanger 4-0,25-230-50-А
TU 5131-001-02351413-2016
LLC «Allure»
APRIL 2018

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ATTENTION!
• Before starting operating the Machine the Manual should be read by operators,
repairers and others who are responsible for the transportation of the product, its
installation, commissioning, service and maintenance.
• Please read the operating instructions and the safety rules given in this manual.
• Do not start work until fully reading and understanding the material contained
in this manual and other documentation supplied.
• All security recommendations in the manual are obligatory.
• Manual must be kept in accessible place for service personnel.
In addition to the measures referred to in the Manual, the law on the bases of
labour protection and the rules for accident prevention and environmental
protection in accordance with applicable laws should be observed.
Security must be in first priority when using the Melanger.
Manual does not reflect the minor design changes in equipment made by the
manufacturer after the signing of the release of this guide, as well as for accessories
and documentation coming with them. It only means that Melanger is improved to
better meet your requirements.
ATTENTION!
Operating manual applies to the Machine with complete set of all units and does
not take into account the changes reflected in the contract.
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Table of Contents
Applications
3

1. Introduction
This "owner's manual" (the Guide) on the Machine should be seen as an integral part of the
Machine and must be accessible for maintenance personnel.
Purpose of these guidelines is to provide all the information needed for transportation,
commissioning, operation and maintenance of the product. The Manual provides guidelines for
the safe, appropriate and cost-effective operation of the Machine. For the units of the Machine,
for which it is appropriate, the Guide includes instructions for maintenance, replacement and
adjustment. Compliance with these instructions helps avoiding danger, reduce downtime and
repair costs, increase reliability and extend the lifetime of the Machine.
This guide has the sign of attention, with the following meaning:
The sign is put where it is necessary to be especially careful, precisely follow the requirements
and instructions to avoid violations of the technological process and breaking the Machine.
Only a thorough daily implementation of guidelines to ensure the safety, maintenance of the
Machine with care can ensure successful operation!
Failure to comply with the requirements of this manual frees the manufacturer from liability.
Use of Machine for other purposes than specified in this guide, is not permitted. The company
Allure LLC is not responsible for damage caused by non-compliance with instructions and
guidelines outlined in this Manual.
If there are issues that you cannot resolve yourself, consult with the customer service of the
Allure LLC
Any request to perform work by our specialists should have indication to the model of
Machine, serial number and the contract number.
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2. General information
2.1. Designation of the Machine
This guide applies to the Melanger 4-0,25-230-50-А (hereinafter the Melanger), designed for
producing chocolate, masses, fillings from its ingredients.
2.2. Personnel qualification
Installation, commissioning, operation, maintenance and repair is allowed by personnel qualified
and trained to work with Machine . Staff qualification must be proved by proper documents.
The owner or his authorized representative is responsible for training the untrained personnel and
the necessary training of qualified personnel of the rules of safe operation and maintenance of
Machine.
The staff which is being trained should work on the Machine only under the supervision of an
experienced person authorized to provide training.
Staff training to operate the Machine by the Allure LLC company specialist can be done at the
time of commissioning, or on the Allure LLC factory facilities.
We recommend the company, which uses the Machine, To Issue internal instructions, taking into
account the professional expertise of the staff and, in all cases, documenting studying this Manual
and implementation of instruction or training.
• Trained personnel/specialist
• Instruction at the workplace
• Training by the manufacturer
• Specialist
• Instruction at the workplace
• Training by the manufacturer
• Specialist
• Instruction at the workplace
• Training by the manufacturer
Operator
Service-mechanic
Service-electrician
Please make an entry in the registry log of "Registration of staff development and
maintenance verification".
Failing to fill the log can lead to voiding the manufacturer warranty service for Machine.
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2.3. Declaration of conformity
When you design a Melanger, in the selection of materials, parts and Melanger nodes, selecting
components, manufacture of Melanger security Melanger was in conformity with the following European
standards, directives and safety regulations:
• (E)N 954-1 safety of machinery. Details of control systems for safety.
Part 1. The basic principles of design.
• EN1005-2 safety of machinery. The physical characteristics of the person. Part 2. Manual handling of
machinery and component parts of machinery.
• EN1005-3 safety of machinery. The physical characteristics of the person. Part 3. Recommended limits of
efforts for the operation of the machines.
• GOST r 51333-99 (EN 292-1-91, EN 292-2-91).Safety of machinery. Basic concepts, general principles
for design. Terms, technology solutions and specifications.
• GOST r 51334-99 (eN 294-92), safety of machinery. Safety distances for the protection of the upper
extremities from getting into the danger zone.
• GOST r 51335-99 (eNo. 349-93) safety of machinery. Minimum distances to prevent crush parts of the
human body.
• GOST r 51337-99 (eN 563-94), safety of machinery. Temperature of those surfaces. Ergonomics data to
establish limit values for hot surfaces.
• GOST r 51339-99 (eN 811-96), safety of machinery. Safety distances to prevent lower limbs from getting
into the danger zone.
• GOST r 51343-99 (eN 1037-95), safety of machinery. Prevention of unexpected start-up.
• GOST r 51344-99 (eN. 1050-96), safety of machinery. Principles of risk assessment.
• GOST r 51345-99 (eN 1088-95), safety of machinery. Locking device of protective devices-principles of
design and choice.
• GOST r MEK 60204-1-99 (eN 60204-1) safety of machinery. Electrical equipment of machines and
mechanisms. Part 1: General requirements.
• EU directive on machinery (98/37/EG).
• EU directive on electrical equipment designed for use within certain voltage limits (73/23/EEC).
• STATE STANDARD 12.2.003-91. system of labour safety standards. Equipment production. General
safety requirements.
• GOST 2.601-2006 ESKD. Operational documents
• GOST 9.014-78 ESZKS. Temporary corrosion protection products. General requirements.
• GOST 9.032-74 ESZKS. Varnish-and-paint coatings. Groups, technical requirements and symbols.
• GOST 9.105-30 ESZKS. Varnish-and-paint coatings. Classification and basic parameters of a method of
staining.
• GOST 9.402-2004 ESZKS. Varnish-and-paint coatings. Preparation of metal surfaces before painting.
• GOST 12.1.003-83 SSLS Noise. General safety requirements.
• GOST 12.1.012-2004 SSLS. Vibration safety. General requirements.
• GOST 12.1.030-81 SSLS. Electrical Safety. Protective earth. Features.
• STATE STANDARD 12.2.003-91 SSLS. Equipment production. General safety requirements.
• GOST 12.2.062-81 SSLS. Equipment production. Protective fences.
• GOST 12.2.064-81 SSLS. Control of production facilities. General safety requirements.
• STATE STANDARD 12.2.124-90 SSLS. Food equipment. General safety requirements.
• GOST 12.4.040-78 SSLS. Control of production facilities. Mark.
• GOST 15.201-2000 development system and products. Products for industrial purposes. Procedure for
development and production of products for production.
• GOST r 27.403-2009 Reliability in engineering. Test plans to control the probability of non-failure
operation.
• 112-78, GOST meteorological glass Thermometers. Technical conditions.
• GOST 2991-85 Boxes sealed the deal for cargo weighing up to 500 kg. General technical conditions.
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• GOST 5264-30 manual arc welding. Welded connections. The main types, features and dimensions.
• GOST 6359-75 meteorological barographs of aneroid type. Technical conditions.
• GOST 7502-98 Roulettes, tapes measuring metal. Technical conditions.
• GOST 9150-2002 basic norms of interchangeability. Metric thread. Profile.
• GOST 10354-82 polyethylene film. Technical conditions.
• ISO 10374-93 analogue direct-acting electrical indicating and auxiliary parts to them. Part 7. Special
requirements for multi-function instruments.
• GOST 11534-75 manual arc welding. Connections welded under acute and obtuse angles. The main
types, features and dimensions.
• GOST 11708-82 basic rules of interchangeability. Thread. Terms and definitions.
• GOST 12969-67 Decals for cars and appliances. Technical requirements.
• GOST 14192-96 cargo marking.
• GOST 14254-96 degrees of protection provided by enclosures (IP code).
• GOST 15150-69 Cars, machinery and other technical products. Performance for different climatic regions.
Category, operating conditions, storage and transportation in part the impact of climatic factors in the
external environment.
• GOST 17187-81 sound level meters. General technical requirements and test methods.
• GOST 21130-75 electrotechnical products. Earthing Clips and grounding signs. Design and dimensions.
• GOST 23170-78 packaging for mechanical engineering production. General requirements.
• GOST 26582-85 food machinery and equipment. General technical conditions.
• GOST 30150-96 labelling machines. General technical requirements and test methods.
• GOST r 50342-92 thermoelectric converters. General technical conditions.
• GOST r 53228-2008 Scales manual actions. Part 1. Metrological and technical requirements. Tests.
• GOST r 52869-2007 pneumatic drives. The requirement for security.
• GOST r 51317.6.2-2007 electromagnetic compatibility of technical equipment. Immunity to
electromagnetic interference technology applied in industrial areas. Requirements and test methods
• GOST r 51317.6.4-2009 electromagnetic compatibility of technical equipment. Electromagnetic
interference from equipment used in industrial areas. Standards and test methods
• GOST r MEK 60204-1 2007-safety of machinery. Electrical equipment of machines and mechanisms.
Part 1. General requirements
• RD 50-690-89, methodical guidelines. The reliability of the technology. Methods of evaluation of
indicators of reliability by experimental data.
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2.4. Manufacturer's warranty and liability
The manufacturer guarantees the compliancy of Machine with the above standards, directives and
regulations, subject to following the terms of transportation, storage, installation and operation of the
Machine, as set out in this guide.
The warranty period of exploitation for which the manufacturer undertakes to repair or replace the
Machine on manufacturer's fault, is 12 months unless otherwise agreed in the contract.
Beginning of the warranty period is calculated from the day of commissioning of the Machine, but not later
than 3 months from the date of shipment of the Machine from the warehouse of the manufacturer.
The manufacturer is not liable for injuries to persons or damage to property,
if they are the result of:
- non-compliance with the storage rules set out in the Machine Manual;
- accidental or not unintended operation of the Machine;
- improper handling with Machine on maintenance and operation;
- non-compliance to Manual instructions on any of the stages of operation the Machine;
- operation of the Machine with improperly installed, or defective safety devices,
as well as when dismantling or ignoring them;
- changing parameters or design of Machine, not confirmed with the manufacturer;
- increased wear because of the lack of maintenance;
- improper repairs.
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2.5 General appearance and composition of Melanger
General view of Melanger, the location and designation of parts is presented in Fig. 1.
List of components of Melanger is given in a Table 1.
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Figure 1.

2.6. Principle
The construction of the equipment consists of a body 4, a bowl 3. A motor 5 is mounted on the body, rotating
the bowl 3 and two runners 2. The bottom of the bowl and two runners are made of solid dense granite.
Suspension of runners to the upper beam is made through the bar of the clamping device of the millstones.
Pressing granite runners to the granite bottom of the bowl is carried out with the help of springs. The rotation
of the bowl is carried out from the electric motor through a chain drive in the body of the Melanger. When
the bowl is rotated, the components on the granite bottom of the bowl are grinded and mixed with granite
millstones. Stirring and removal from the walls of the cup of chocolate mass is carried out with the help of
blades (scrapers). The control panel 6 is located on the left side of the body.
2.7. Operation
The controls are located on the melange control unit (Figure 2).
The Melanger is controlled by signals coming from the control unit.
- switch 1 is designed to switch on the power supply of the Melanger,
- thermostat 2 shows the current temperature of the loaded mass, and also controls in automatic mode the
maximum temperature set by the operator,
- Button 3 starts the bowl rotation,
- Button 4 stops the bowl rotation (emergency stop button),
- Knob 5 is designed to change the speed of rotation of the bowl,
- indicator 6 is lit when power is available;
- connector 7 of the removable product temperature sensor in the bowl;
- button 4 of the emergency stop of the Melanger;
- network fuse 8.
When the current protection is activated, the Melanger is automatically switched off.
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3. Technical data and specifications
3.1. Technical characteristics of the Melanger
Main parameters and dimensions shall be in accordance with table 3.1.
Table 3.1
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3.2. Conditions for connecting of electrical equipment of the Melanger
The Machine power is supplied by single-phase mains with Earth and the following characteristics:
- voltage 230 V
- frequency of 50/60 Hz;
- power, not less than 0,35 kW.
4. Safety
4.1. General requirements for the safety
The Manual provides the basic safety instructions on handling Machine, including transportation, storage,
operation, maintenance, repair.
Safety at work on the Machine is ensured activities in the design of the Machine in accordance with the
requirements laid down in European standards, norms and guidelines. Despite this, the Machine can be
dangerous in cases of misuse by unqualified personnel or use for other purposes.
The danger situation is possible:
• for the health and life of the operator or third party;
• for the macine and other property.
Any person who maintains moving the Machine, its commissioning, maintenance and repairs, must read and
understand this manual and in particular the section "safety requirements" and strictly implement the
guidelines requirements!
Requirements for security, besides this chapter are contained in the relevant sections of the Manual and
applications delivered.
The following safety instructions must be observed in addition to the General requirements for the safety and
injury prevention.
4.2. Safety measures
4.2.1 The danger warning Signs
In this guide, apply the danger warning signs, have the following meanings.
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Damaged and lost characters must be restored without fail!
4.2.2. Protective and safety devices
Power supply of the Melanger is carried out by an electric line with grounding.
Protection from spontaneous activation of the drive when recovering the suddenly disappeared supply
voltage is provided by the control unit, which establishes zero control signals on its outputs after power
recovery.
The most probable causes of protection operation: jamming, failure or overheating of the engine, deviation
of the electrical network parameters from the norm.
4.2.3. Requirements for service personnel
General requirements for service personnel
Personnel authorized to work with Machine, as well as to commissioning, maintenance and repair the
Machine, is obliged to:
- get health and safety training in accordance with the manufacturer's instructions, developed on the
basis of the operating instructions, standardly applied safety instructions;
- familiarize with the General rules of operation and maintenance of the Machine with safety
instructions contained in this manual;
- familiarize with constructive and technological properties of the Machine and attend a special
instruction on the work of the Machine of this model.
On the Melanger there are signs of warning about the danger, having the following meaning.
Electric danger that threatens the life and health of people, and
can also cause great damage to property. The sign is located on
the side of the control unit Fig. 2-2.
The use of a socket with earthing terminals is mandatory.
Inattention to warning signs and non-compliance with the safety
instructions can lead to serious consequences for the health of the
personnel and material damage!
Responsibilities on maintenance of the Machine should be clearly defined and strictly
adhered, that in the part of ensuring security - the competence of each employee is clearly
defined.
It also means that operation on the Machine in special modes (for example, when setting up)
may only be carried out by specially trained personnel!
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Errors, noises and obvious flaws shall immediately be reported by service personnel to the person in charge
and recorded in the work registry. In the case of danger - Machine should be immediately shut down.
The use of personal protective equipment
When operating the Machine the personnel, as appropriate, should use personal protective equipment:
-dust masks with appropriate filters (when shipping products or materials that emit harmful substances in the
work area that can get into the lungs);
-durable thick gloves to protect hands from mechanical damage during technical maintenance and repairs;
-Sturdy boots with soles to prevent slipping (if slippery fluids are used in production) as well as protecting
the operator legs from injuries (protection from pinching or falling objects);
-special robe, which could not catch hold of parts of Machine. Sleeves should be rolled up only inwards.
Loose clothes, ties, neckwear, jewelry watches, rings, bracelets, etc. are dangerous;
-headdress, closing the hair;
- earplugs (hearing protection from noise) if necessary.
Work on electrical maintenance of Machine must be conducted by two trained
specialists, having Permit to the maintenance of electric equipment with voltage
up to 1000V.
Unauthorized individuals in the service area of the Machine are not allowed.
Before switching on the voltage after installation or repair of electrical equipment
or after a long interruption, ensure correct grounding.
Access to the control unit to unauthorized persons is prohibited.
Areas surrounding the control unit shall not be cluttered or jammed.
Failure to comply with these requirements may result in electrical hazard or its
risk possibility!
Working with disconnected security devices, gives rise to all kinds of mechanical
and electrical dangers.
Dismantling or disabling any security devices is - unacceptable.
If there is dirt or foreign objects, if there is no order in the arrangement of the
workplace tools, devices, movable goods etc. - there is a danger of confusion,
slipping, or being hit by falling heavy objects on lower limbs.
The operator must always maintain the Machine in perfect condition. Keep work area clean.
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4.3. Security measures during transportation and installation of the Machine
Before switching on the Melanger, make sure that its start-up is not dangerous for people near it, remove
foreign objects from the Melanger and from the working area, familiarize yourself with the device, the
operating principle and the Melanger control system.
- check the Machine (damage during transportation);
4.4. Security measures when preparing the Machine
When the input switch is turned on, the white warning light comes on, signaling the
presence of voltage on the melange.
Neglect of this information leads to an increased risk of occurrence of all types of
mechanical and electrical hazards.
If you disable the locks provided for in the electroscheme of the Melanger, all kinds of
mechanical and electrical hazards may appear.
The Melanger should be disconnected from the AC mains supply after completion of
work. Failure to comply with this requirement leads to an increased risk of
electrical hazards.
After pressing button 4 (Fig. 2), the input contacts of the switch and the contacts of the
terminal set remain under hazardous voltage at the control unit. Neglect of this
information leads to an increased risk of occurrence of all kinds of electrical
hazards that threaten the life and health of people.
When using the Melanger in a humid environment on the surfaces of the Melanger,
which normally do not have contact with live parts and which the operator contacts,
dangerous high voltage may appear.
Do not work in dark workplace for higher risk of errors of the operator and the
breakdown of the Machine.
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Observe the recommended operating modes of the Melanger
-training the customer's personnel;
Melanger is not intended for use with combustible and explosive materials.
If flammable or explosive materials are used, there is a risk of fire and / or explosion.
In cases of non-compliance with the recommended modes of operation of the Melanger,
the danger of possible breakage of the Melanger and / or injury to the operator
When using materials that emit harmful substances with concentrations exceeding the permissible limit, we
recommend that you:
- identify the type of hazard;
- conduct a risk assessment that takes place during the Machine processes the product;
- develop a security system for this product;
- provide the necessary accessories, such as devices monitoring, or remove harmful substances, shut-off
devices, quickly triggered before a dangerous product will get into the hands of others, due to the specifics of
a particular production.
- to reduce the concentration of harmful substances in the air of the working area by the exhaust hood system
and use a reliable ventilation in accordance with the characteristics of production and local regulations on
labour protection;
- use of personal protective equipment.
Failure to follow the recommendations of this manual on transportation of hazardous
materials, leads to the risk of contact or inhalation of hazardous gases or dusts (risk
of damage to the skin, eyes, and respiratory tract irritation, as well as diseases of
the internal organs).
Since the list of harmful materials is very wide, this guide does not provide
recommendations for all occasions.
Compliance with these recommendations does not exempt the user from performing
additional security measures due to the specifics of a particular production.
Do not stand on the Machine in carrying out any works.
Failure to do so could result in overturning the Machine, which leads to an increase in
the risk of all mechanical hazards that threaten the lives and health of people, and can
lead to great material damage.
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4.5. The technical design changes
4.6. Machine noise level
In standard operating conditions the Machine operator workplace noise level does not exceed 60 DBA. The
Machine in typical conditions (load the hopper from 60 kg of cocoa beans, the noise level does not exceed
75 DB(a). Uncertainty of measurement of noise conforms to ISO 3746 and 95% probability with confidence
equal to ± 1.96 OR of the measured values, where OR= 3 DBA.
Noise characteristics were measured in accordance with the methodology of ISO 3746-95 and ISO11204-95
in the light of the requirements of BS EN 415-3: 2000.
Any modifications or changes in the Machine unauthorized by the manufacturer are
not allowed for reasons of safety for people and the Machine.
The user can use the spare and wear parts recommended by the manufacturer only.
Otherwise, the manufacturer is not liable for the operability of the Machine.
At adverse operating conditions, when the average noise level for the 8 hour shift
exceeds 80 DBA, one must use safety equipment (ear muffs, ear plugs), and/or reduce
the time in these modes.
The above values of noise level are not necessarily safe for work on the Machine. Despite the existence of a
correlation between emitted and perceived noise, this cannot be used as a reliable option to determine
whether or not you want to take further precautions.
Factors influencing the practical level of perception of the noise emitted include the characteristics of the
working premises, other noise sources, etc. e.g. the number of Machines, and other related processes, as well
as the time during which the operator is exposed to noise. However, the above information will allow the
user to assess the dangers and risks faced by staff.
4.7. The residual risks
The personnel requirements of the above Melanger for this model reduces the residual risks to the level
achieved in the same equipment, adequate security is proven experience of its operation.
However, the personnel must know and remember about the existence of residual risks, because the
fulfilment of the above requirements are not completely obviate the danger.
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5. Scope of supply, marking, packing, storage, unpacking and handling
5.1. Scope of supply
The scope of supply is provided in the packing list, which is composed in accordance with the contract for
the Machine.
5.2. Marking
5.2.1. Each Machine has on its frame side surface, a nameplate attached containing:
• the country of the manufacturer;
• full company of the manufacturer;
• the mark of the manufacturer;
• the address of the manufacturer;
• product model, serial number, year of manufacture;
• power supply, voltage and frequency;
• power;
• weight.
5.2.2. The transport marking on the packaging contains:
Main inscriptions:
• full or conventional name of consignee;
• the name of the destination (the station), and the short name of a transport route (road, if necessary); name
of reloading place (when necessary);
• package number (in the numerator-the pack number in the lot, in the denominator-the number of places).
Additional inscriptions:
• full or conventional name of consignor;
• the name of the item (the station) of road and short name of the sender (if necessary);
• inscriptions of transport organizations.
Information box:
• the dimensions of the package, santimeters;
• NET and gross weight, kg;
• cargo volume, m3.
Manipulation signs:
• «Beware - delicate»;
• «The place of slinging»;
• «Top, do not tilt»;
• «Center of gravity»;
• «do not stack»;
• «No Humitidy».
5.2.3. Additionaly cargo space is indicated by:
• model of the Machine;
• serial number of the Machine.
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5.3. Packaging
Machine comes in a crate or a partial package on a pallet, film wrapped. The type of packing is negotiated
with the buyer and is fixed in the contract on delivery.
All the Machine accessories, spare parts and documentation are packed in boxes, placed in a box for
Machine packing or next to it (on partial packing) and securely fastened.
The manufacturer is not liable for damage of the Machine, occurred during the
transport in package inadequate to normative and technical documentation of the
manufacturer.
When receiving the Machine check the integrity of the packaging. The manufacturer
does not hold liability for the Machine, delivered with damaged factory packaging.
Found damage should be confirmed by the forwarder by a note in the transportation
documents.
5.4. Acceptance
5.5. Storage
Storage of packaged Machine shall be:
-for any climate areas in heated and ventilated warehouses under the following conditions:
-ambient temperature: (+5-+40) °C;
-relative humidity: not more than 80% at 25 °C;
-dew is not allowed;
-the impact of corrosive gases is not permitted.
Storage at temperatures below minus 20° (C) may damage electronic components.
Failure to follow recommended storage mode increases the risk of damaging the
Machine and/or injury to the operator.
Warranty storage period Machine in the factory packaging is 1 year under specified storage conditions.
5.6. Unboxing
When unpacking, it is recommended that you first remove the top board of packing box and then the side
boards. Care should be taken not to damage the Machine by the tools during unpacking.
Before unpacking the Machine should be kept under operating conditions temperature
to align Machine temperature and facilities (usually 24 hours).
When unpacking, verify the completeness of the delivery against the packing list
and/or for possible damage during transportation.
If there are discrepancies, please contact your manufacturer.
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