Allure FM1 User manual

CE and ISO
22000-2007
Certified
OPERATOR'S MANUAL
Melanger 10-0,75-230-50-A
TU 5131-001-02351413-2016
LLC «Allure»
FBR 2017

ALLURE LLC Melanger 10-0, 75-230-50-A
USER MANUAL TU 5131-001-02351413-2016
Identification Data
Type and description Melanger (M-W-VхF-Hz-А) 10-0, 75-230-50-a
Serial number №
Year of manufacture 2017
The name and
address of the manufacturer
ALLURE LLC
107023 Moscow, UL. Elektrozavodskaya, d. 21
Phone [phone]
Fax [phone]
E-mail 79104031110 @ya.ru, [e-mail]
M - Maximum raw material loading, kg;
W– power of main electric drive, kW;
VхF–voltage, three-phase (single-phase);
Hz – frequency, Hz;
A – modification.
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 separator and crusher.
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 the separator with the crusher is improved
to better meet your requirements.
ATTENTION!
Operating manual applies to the separator with Crusher with complete set of all units
and does not take into account the changes reflected in the contract.
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ALLURE LLC Melanger 10-0, 75-230-50-A
USER MANUAL TU 5131-001-02351413-2016
Table of Contents
1. Introduction 4
2. General information 5
2.1. Intended use 5
2.2. Personnel qualification 5
2.3. Declaration of conformity 6
2.4. Manufacturer's warranty and liability 8
2.5. General appearance and composition 9
2.6. Principle of operation 10
2.7. Controls 11
3. Technical data and specifications 11
3.1. Technical characteristics 12
3.2. Electrical connection Conditions 12
4. Safety 12
4.1. General requirements for the safety 12
4.2. Security measures 12
4.2.1. The danger warning Signs 12
4.2.2. Protective and safety devices 13
4.2.3. The demands for personnel 13
4.3. Security measures at transportation and installation 14
4.4. Security measures at preparation for the operation 15
4.5. Safety on operation 15
4.6. The design changes 17
4.7. Noise level 17
4.8. The residual risks 17
5. Scope of supply, marking, packing, storage, unpacking and transportation 18
5.1. Scope of supply 18
5.2. Marking 18
5.3. Package 19
5.4. Acceptance 19
5.5. Storage 19
5.6. Unboxing 19
5.7. Transport 20
6. Installation and initial start-up 22
6.1. Installation location and substructure 22
6.2. The air condition 22
6.3. Installation 22
6.4. Preparation to start-up 23
6.5. The initial start 23
6.6. Emergency shutdown 24
7. Order of operation 24
7.1. General safety instructions for maintenance 24
7.2. Volume of maintenance work 25
7.2.1. Daily maintenance 25
7.2.2. Monthly maintenance 25
8. Spare parts Order, customer service 25
Annexes 25
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ALLURE LLC Melanger 10-0, 75-230-50-A
USER MANUAL TU 5131-001-02351413-2016
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.
An integral part of this guide are the following documents:
Annex 1: electrical equipment
Annex 2: spare parts catalogue
Annex 3: information on acceptance
Technical documentation for components
If there are issues that you cannot resolve yourself, consult with the customer service of the
"ALLURE LLC" company
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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ALLURE LLC Melanger 10-0, 75-230-50-A
USER MANUAL TU 5131-001-02351413-2016
2. General information
2.1. Intended use the Machine
This guide applies to Melanger 10-0, 75-230-50-A (hereinafter referred to as the
Melanger). The equipment is designed for producing chocolate from the raw material and is
used in the confectionary production factories.
.
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.
Operator ·Trained personnel/specialist
·Instruction at the workplace
·Training by the manufacturer
Service-mechanic ·Specialist
·Instruction at the workplace
·Training by the manufacturer
Service
-electrician
·Specialist
·Instruction at the workplace
·Training by the manufacturer
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.
2.3. Declaration of conformity
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ALLURE LLC Melanger 10-0, 75-230-50-A
USER MANUAL TU 5131-001-02351413-2016
While designing the Machine, selection of parts materials and its units, selection of
components, manufacturing the Machine – the conformity with the following European security
standards, directives and safety regulations is ensured:
· (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 (eNo. 1050-96), safety of machinery. Principles of risk assessment.
· GOST r 51345-99 (e# 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 9.105-80 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.
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ALLURE LLC Melanger 10-0, 75-230-50-A
USER MANUAL TU 5131-001-02351413-2016
· GOST r 27.403-2009 Reliability in engineering. Test plans to control the probability of non-
failure operation.
· 112-78, GOST meteorologičeskike glass Thermometers. Technical conditions.
· GOST 2991-85 Boxes sealed the deal for cargo weighing up to 500 kg. General technical
conditions.
· GOST 5264-80 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. Clips earthing 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.
The Director General
ALLURE LLC G.V. Korotkov
2.4. Manufacturer's warranty and liability
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ALLURE LLC Melanger 10-0, 75-230-50-A
USER MANUAL TU 5131-001-02351413-2016
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 the
Machine on manufacturer’s fault, is 6 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 (three) 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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ALLURE LLC Melanger 10-0, 75-230-50-A
USER MANUAL TU 5131-001-02351413-2016
2.5. General appearance and composition of Melanger
General view of Melanger, the placement and designation of parts are presented in Fig. 2-1.
List of components of Melanger is given in table 2.1.
Figure 2-1
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ALLURE LLC Melanger 10-0, 75-230-50-A
USER MANUAL TU 5131-001-02351413-2016
№
p/p
Description Position # on
in Figure 2.1
1 2 3
1 Bowl made of stainless steel, with granite disc mounted on the bottom 1
2 A pair of granite runners with pressure unit 2
3 Main electrical drive, consisting of the motor and the Motor reducer 3
4 Frame 4
5 The control unit 5
6 Grounding of the framework 6
7 The pressing unit 7
8 Tiltable frame 8
Table 2.1 Lists parts Melanger
2.6. Principle
The Machine consists of a load frame-4, tiltable frame 8 and bowl-1 made from food grade
stainless steel. On the bearing frame the main drive-3 is installed, driving the Bowl-1 and two granite
wheel runners- 2. The bottom of the bowl and two runners are made of the hard type of natural granite.
The suspension of the runners is independent. Pressuring the granite runners to granite bottom is done
by pneumatic device 7. Rotation of the bowl is provided by electric motor through a reducer. During
rotation of the bowl, the effect of grinding and mixing of the components on the bottom of the Bowl
granite runners are effected. Mixing and removal of chocolate from the walls of the bowl is achieved
by using the stationary scrapers. Control unit-5 is fixed on frame 4.
2.7. Operator controls
The controls are located on the control unit of Machine (fig. 2-2).
The operation of machine is done via the signals coming from the control unit.
-Toggle switch 1 is used to turn on/off the power of Melanger.
-Regulator 2 shows a current temperature of the product. Also is possible to adjust a maximal
temperature of the product. The Machine will support the adjusted temperature in automatic mode
during the entire work cycle.
- Button 3 is to switch ON/OFF the bowl rotation mode.
- Display 4 shows the value of the rotation frequency of the bowl.
- Knob 5 is designed to set the rotation speed of the bowl.
- Indicator 6 lights up on power supply.
- Joystick 7 is to lift UP and DOWN the granite wheels.
- Connector 9 is for connecting a hose from the compressor.
- Regulator 10 is to adjust the force pressure of granite wheels to bottom of the Melanger bowl.
The value is displayed on the indicator 8.
- Button 11 is designed for EMERGENCY STOP.
When the surge protection goes off, the Melanger automatically shuts down.
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