UNIVERSAL-3000

REFINER / CONCHE
MANUAL

CUSTOMER: P.T. KARINA

Nº ORDEN (ORDER Nº) : 1122

Nº FABRICACION (MACHINE Nº): UNIV-3000-169

YEAR : 2008

Aprobado por / Approved by: E. Balada 06-Mar-2008

I ND E X
1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4

1.1. Safety

1.2. Responsibilities

2. GENERAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7

3. PLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
3.1. Position

3.1.1 Reception of the machine

3.1.1.a Wood packing

3.3.1.b Container

3.2. Connections

3.2.1 Filling and emptying the double jacket of the machine

3.2.2 Electrical connections

4. OPERATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . page 15

4.1. Starting up

4.2. Blade pressure adjustment

4.2.1 Ammeter

4.2.2 Electrovalve and hydraulic circuit

4.3. Conching

4.4. Stop the machine

4.5. Problems

2
I N D E X
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
5.1. Belt tensioning

5.2. Lubrication

5.3. Substitution of the group blade / spring

5.4. Main shaft stuffing box

5.5. Hydraulic group

5.5.1 Hydraulic group sketch

5.5.2 Maintenance

5.6. General maintenance plan

6. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 33
* General assembly

* Hydraulic pressure system

* Internal mechanisms

7. SUB-MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 37
7.1. Reducer

7.2. Fan

8. CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 40

9. ELECTRICAL SCHEMES . . . . . . . . . . . . . . . . . . . . . . . . page 41

3
1. INTRODUCTION

4
This manual describes in detail the functioning and maintenance of this machine.

In order to facilitate future orders for spare parts the lists of assembly are included in the
present manual.

For the proper functioning and long life of the machine point 5.6 "General Maintenance
Plan", must be followed and acted upon.

1.1 SAFETY

The Refiner/Conche UNIVERSAL machines are designed and built according to European
patterns concerning applicable safety, they surpass these essential health and safety
requisites required by the machines Directive 89/392/CEE.

Our Refiner/Conche UNIVERSAL includes the following safety devices:

- Fixed guards for the external moving parts of the machine, charging hoppers and
ventilation ducting.

Operators should pay special attention to the loosing device, the fan and the charging
hopper, as their their manipulation involves a high risk of hands being crushed.

All the safety devices are intergral to the structure of the machine. The modification,
elimination or deterioration due to lack of maintenance of any part of the machine by the user
will increase the risk of accidents. To not maintain the machines safety equipment in good
operating order is in fact a transgression of the Directive about minimal health and safety.

1.2 RESPONSIBILITIES

S.A. MARTIN LLOVERAS will be not directly or indirectly be responsible for any harm
themachine might cause due to misuse by the customer or any third party.

S.A. MARTIN LLOVERAS is not to be responsible for modifications done to the machine
without any previous authorization or supervision by our technicians. Any modification done
by the customer will cancel the guarantee automatically.

S.A. MARTIN LLOVERAS is not responsible for any harm and/or injury that might be
caused by force majeure.

S.A. MARTIN LLOVERAS will not be directly or indirectly responsible for any damage
caused by corrosion on the ferric surfaces of the double jackets of the machines.

We advice to keep the water used under the following conditions:

- soft water (hardness 7÷14ºHf)
- pH neutral
-Salinity (chlorides) < 100 ppm

-Non polluted by organic matter

5
For more information please contact:

S . A . M AR TI N LLO V E R AS

P.O. BOX 71

08221 TERRASSA (BARCELONA)

SPAIN

TELF: (34) 93 783 63 11

FAX: (34) 93 786 39 03

e-mail:headofficell@lloveras.com

e-mail:afsales@lloveras.com (after-sales departement)

Visit our web site: www.lloveras.com

6
2. GENERAL DATA

7
 UNIVERSAL 3000
DIMENSIONS AND POWER

WEIGHT NET WEIGHT 7550 Kgs.

DOUBLE JACKET
500 Lts.
WATER
PRODUCT 3000 Kgs.
TOTAL 11050 Kgs.

DIMENSIONS HEIGHT 2528 mm

LENGHT 3115 mm
WIDTH 1970 mm

TECNICAL DATA
POWER MOTOR 30 Kw
HEATING 9 Kw
HYDRAULIC GROUP 0'5 Kw
TOTAL 39,5 Kw

* THE LEVEL OF A WEIGHTED CONTINUOUS EQUIVALENT ACOUSTIC ENERGY IN

WORK PLACES EXCEEDS 85 dB (A).

to 240 88 A
MOTOR MAXUMUN CONSUMPTION 30 Kw AT: to 400 53 A
to 480 44 A

REFRIGERATING WATER TEMPERATURE 20-25ºc

VOLUME OF FLOW 2000/2500 lts/h

DOUBLE JACKET MAXIMUM PERMITED PRESSURE: 1 bar

* It is very highly advisable to isolate the machine as well as to use ear-plugs when
working beside the machine.

8
3. PLACEMENT

9
3.1 POSITION
The floor where the machine will be located has to be flat, horizontal and able to support
the machine´s weight.

The machine has a load charge of 11050Kgs., when filled with product, this weight
is supported over an area of 2 sq Mt.

To assist with transport and manipulation in a safe manner, the machine is provided
with 4 transport hook points. The transport wire that hooks onto the front cover of the
machine must be longer that the others, in order to balance the machine, as the gravity
center is more or less at the (centre of the) rear cover. The wires must have a minimum
diameter of 18 mm, and should be hooked to the holes using appropriate anchor
shackles.

At the base of the machine, at every corner, are 4 plate covers, that hide 4 holes that
can be used to fit mechanic or hydraulic lifters, in case the machine is to be moved by
some kind of group wheels. If this is the situation, is very important to check the floor
strength, as the whole weight of the machine would be applied to 4 contact points. To
ensure the weight will not damage the floor surface it´s advisable to protect it with steel
plates, along the path the wheels will follow. It is necessary to take adequate
precautions to avoid any accident to personnel, or damage to the machine or factory.

4690
7550
(net weight)

10
3.1.1 Reception of the machine

The machine can be shipped in wood packing or in a container, either open top
or box, according to the facilities of the reception seaport.

3.1.1.a Wood packing

To unload equipment either a forklift or a crane can be used. In both cases, the
wires from the forks must be situated at the places where the marks have been
painted; in order to avoid any accident that could cause serious injures to people,
or damage to goods or the machine itself. Also, when using wheels, they should be
placed close to the marks, under the crate.

When using a crane to remove the machine from the crate, it’s necessary to open
both the upper cover, and a side cover, and hook the machine as described at point
3.1 «Position» If no crane is available, and thus wheels are used, the crate must be
dismantled completely.

When wheels are placed under the base of the machine, assure that their position
will match the reinforcement of the crate base, to not crash it. Please ensure floor
.
surface is as flat as possible., see point 3.1 «Position».

When using wheels, proceed very carefully, in order to avoid any accident to
personnel.

3.1.1.b Container

The machine might come to you in either: open top container or box (closed
container). When the machine comes in an open top, after opening the open top
and the doors, you can proceed exactly as per point 3.1.1.a «Wood packing».

When you receive a box container, discharging the machine from the container will
be a little more difficult.

11
Moving the Refiner from a container

I- Move the machine to the front of the container, by hooking

a cable to the front cover of the machine.

II- Using a lift crane, lift the machine up smoothly, pulling

it out at the same time, till the moment. when the second
c a b l e c a n b e h o o k e d t o t h e r e a r c o v e r h o l es ; A l wa y s
ensure the front cover base of the machine is stable, this
will avoid any possibility of the machine tipping over.

I II - C heck the machi ne to avoi d movementand fi x the

cable.

IV- Having the machine hooked by both points, pull it out

smoothly from the container.

I M P O RTA N T: t h e c a b l e s t h a t f i x t h e ma c h i n e i n t o t he
container during transport, MUSN´T BE USED FOR
UN LO AD IN G PU RP OS ES .

12
13
3.2. CONNECTIONS
3.2.1. Filling and emptying the double jacket of the machine.
The entry of water from the supply system to the machine and the entry of refrigerated
water (if used) must be done through the pipe provided with valve and electro valve. The
valve for total emptying of the machine has to be connected to an open drain. When
water comes out of the overflow pipe this indicates that the double jacket is full.

The overflow pipe has to be connected to a drainage pipe and never is to be closed,
this is to avoid overpressures, as expressed in the point 2 «GENERAL DATA». If the
machine is used in a closed water circuit, the necessary controls must be installed, to
ensure there in no problem with overpressure, as expressed in point 2 «GENERAL
DATA».

NOTE: The water exit valve (pos.3) must be always closed. (exception is when the
water jacket needs to be emptied). Do not reduce the diameter of the emptying pipe.

1- Water pump.

2- Drainage.

3- Emptying.

4- Water net inlet.

5- Cooling water inlet

(with electrovalve).

3.2.2. Electrical connections.

The electrical panel must be connected to the main line, which should have enough
power (see point 2. «GENERAL DATA»). Connect the connection devices and the
connection boxes of the different machines to the electrical panel following and
according to the enclosed electrical sketch (point 9 «ELECTRICAL SCHEMES»).
Once the panel is connected it must be checked that all motors rotate/turn in the correct
direction. If they turn the wrong/opposite direction, it will be enough reversing two
phases; reversed at the pertinent connection device.

NOTE: Probes need to be connected with shielded cable.

14
MI-1867

MI-1867

MI-1867
4. OPERATION INSTRUCTIONS

15
4.1. STARTING UP
Follow those steps carefully to start up the machine.
1. Check the oil level in the reducer. The oil has to reach the visor, if not, fill with the
recommended oil on the reducer plate. Use the plug located under the reducer to
empty oil when required. Check the oil level in the hydraulic group.

2. Check that when starting the machine for the first time THE DIRECTION OF THE
MOTOR IS CORRECT, AS INDICATED IN THE V BELTS COVER, and it is
absolutely forbidden that they turn in the opposite direction of the arrow so, if the
machine is started with the shaft rotating in the wrong direction the machine will be
damaged beyond repair. The direction of the motor should correspond to the
direction of the arrow on the housing.

The safest and best way to check motor direction is to loosen the drive belts and
check the direction manually. Ensure the motor turns in the correct direction.

3. Before starting the machine fill the double jacket with water from the water supply
system (net) by using the water inlet (see point 3.2.1.). Water should be allowed to
pass through the jacket and out through the water outlet. Once the water jacket is
completely full, the electrical heater can be connected.

4. Select the temperatures for the water and the product in the temperature control
device.

Those temperatures have to be set with the corresponding selectors. Once the
temperatures are selected either of two things can happen 1.heating will start if the
actual temperature is below the pre-set temperature or 2. If the actual is above the
pre-set then the system will allow cold water from the suply system (net) to enter in
to the double jacket, to cool down the mass.

NOTE: We recommend 45º C for the water approx. Once temperatures have
been pre-set, heating elements will start.

5. Once the machine has reached the lower set point temperature, the motor can
be started and it can be loaded with the fatty ingredients in a liquid state. If it is not
possible to load fatty ingredients in a liquid state, then those ingredients must be
divided into pieces (the smaller the better) and melted in the refiner, the refiner
should not be started until the fatty masses are completely melted. The heated
water in the double jacket will melt the fatty solids (cocoa butter, vegetable fat,
cocoa liquor, etc).

16
If the machine is to work only one single batch during the day then fatty, small solids
particles should be loaded in the machine the night before, leaving the machine
warm during the night should ensure the following morning the fatty ingredients will
be completely liquid and ready to work. Once all fatty ingredients are liquid, add the
rest of the ingredients (sugar, cocoa powder, milk powder...). The blades must be
loose.

NOTE: In case cocoa nib is to be used, once the nibs have been charged in the
machine, those nibs have to be refined by pressing the blades till they are
completely ground. Once this operation is done, loosen the blades and add the rest
of the ingredients for perfect mixing, before starting the refining process once
again.

6. Once all the ingredients have been loaded and mixed, start pressure to the
blades in order to commence the refining process. When the system is in the
position «pressure on» amperage has to be checked by looking at the ammeter the
consumption values have to be correct according to the working tension table (see
point 2. «GENERAL DATA»).

In case the machine settings are not correct, adjust the pressure of the blades and
settings to the product that is being processed (see point 4.2. «Blade Pressure
Adjustment»).

NOTE: When operating on «automatic» the pressure of the blades will be controlled
by the values pre-set in the ammeter. When operating pressure «manually» the
functions of «pressing» or «loosening» blades will be fully and only the responsibility
of the operator, and the ammeter will only show the real amperage, but the pre-set
minimum and maximum limits of amperage will not operate when working
«manually». Only the safety limits of amperage will work.

The first batch must only be for cleaning purposes to remove any metallic
contamination from the factory manufacturing process. Firstly warm the
machine up to approximately 45ºC over 4/6 hours, load the machine with
400/600
200/300 Kg 200/300kgs
kgs of eatable fat or oil and 100/150 Kg of sugar. It is preferable to
melt the fats prior to loading, however if this is not possible the blocks of fat
should be broken into small pieces. This product has to be rejected to avoid
contamination.

17
 CONNECT
UNIVERSAL WATER
FIRST ELECTRICITY
STARTING

CHECK
MOTORS
DIRECTION
WATER
SET POINT 45º

PRESET
TEMPERATURES

CHOCOLATE
SET POINT 55º
PRESET
AMPERAGE
REFINING
TIME

SELECT TIME

CONCHING STARTING LOAD TIME COUNTER

TIME
START
MAIN
MOTOR

LOAD
FAT
SUGAR

PRESS
TIGHTEN
BUTTON

PRESS PRESS
LOOSEN AUTOMATIC
BUTTON BUTTON

STOP
MAIN
MOTOR

OPEN
EXIT VALVE OR
START CHOCOLATE
PUMP BCH*

*Optional equipment
CLOSE
EXIT VALVE OR
START CHOCOLATE
PUMP BCH*

18
UNIVERSAL MACHINE
WORKING WARM?
PROCEDURE YES

START
MAIN
MOTOR LOAD
FATS

AUTOMATIC
FUNCTION MANUAL
LOAD FUNCTION
SOLIDS

PRESS PRESS
AUTOMATIC TIGHTEN
BUTTON

SWITCH ON OPTIONAL
SWITCH ON
OPTIONAL FAN
FAN

CHECK
CHECK TEMPERATURE AND
TEMPERATURE AMPERAGE

CHECK
CHECK
FINESS
FINESS

SWITCH OFF OPTIONAL

SWITCH OFF
OPTIONAL FAN
FAN

LOAD
LOAD OPTIONAL
OPTIONAL LECITHINE
LECITHINE

STOP PRESS
MAIN LOOSEN
MOTOR BUTTON

OPEN STOP
EXIT VALVE OR MAIN
START CHOCOLATE MOTOR
PUMP BCH*
OPEN
CLOSE EXIT VALVE OR
EXIT VALVE OR START CHOCOLATE
START CHOCOLATE PUMP BCH*
PUMP BCH*
CLOSE
EXIT VALVE OR
*Optional equipment START CHOCOLATE
PUMP BCH*

19
4.2. BLADES PRESSURE ADJUSTMENT
4.2.1 Ammeter
The blade pressure adjustment will determine the maximum performance settings and
the safety setting for the "automatic" operation of the machine.

MOTOR CONSUMPTION VALUES TABLE

Working CONSUMPTION SAFETY

tension values values
Minimum Maximum
a 240 V 83 A 87 A 88 A
Consumption of the
a 400 V 48 A 52 A 53 A
motor of 30 Kw
a 480 V 39 A 43 A 44 A

NOTE: the detector "2" must never be moved. Otherwise can have big
troubles.

TOTALLY LOOSEN BLADES POSITION

20
4.2.2 Electrovalve and hydraulic circuit
In order to regulate the tightening or loosening of the blades through the hydraulic
circuit the flow regulators have to be manipulated. Those flow regulators are
placed in the plate next to the electrovalve (see point "5.5.1 Hydraulic Group
Sketch").

Those flow regulators act over the RETURNS of the respective circuits of
loosening and tightening. If those flow regulators allow the passing of all the flow,
then the movement of the piston would be too fast and the electrical equipment will
not be able to control efficiently the functioning of the machine, this is why the
regulators must be governed in order that the operations are slowed down.

There is a manometer placed over the tightening circuit conduit. This manometer
will show maximum 150 bars during the tightening process.

4.3. CONCHING
Once grinding is completely finished and the end desired fineness is reached an extra
or optional conching process can be done if this is necessary for the mass to improve
its final taste. It is advised to add any flavours at this stage of the operation.

The CONCHING process can be done by starting the UNIVERSAL, always the blades
must be loosened. The «conching» time is always according to different customer’s
criterion, recipes and ingredients.

A humidity-gases extractor/ventilator is situated at the back of the machine if used

during conching it will contribute to improving the final taste of the product.

Once the conching time is ended, according to customer criterion, the whole process
is finished.

21
4.4. STOP THE MACHINE
In order to stop the machine when working under MANUAL operation, the following
rulesmust be followed:

- loosen the blades.

- stop the machine.

Remember not to stop the heating system of the machine.

The heating system must always be checked before starting, as if it has been left off,
there may be cold zones. If the machine has to be stopped for a long time (longer than
a week), the grinding chamber and its mechanisms have to be cleaned before
disconnection. (when changing recipes the same procedure has to be followed).

To change the recipe, you mustproceeded as follows:

400/600kgs
- load the machine with 200/300 Kg of eatable fat or oil.

- start the machine with loose shovels.

- Collect the fat after the cleaning in a container different to the normal storage tank.

NOTE: when working under AUTOMATIC operation, then it is not necessary to do

any previous job to stop the machine.

NOTE: if the machine stops before having done all refining process, blades will loosen
automatically, then it will not be possible to start it up again untill the blades are
completely loose.

22
4.5 PROBLEMS
Find here with a description of some common problems and their possible solutions.

BREAKDOWN CAUSE SOLUTION

There is not current in
The control panel is not working Put the general switch in ON position
the control panel

Maximum tighten of the shovels Hydraulic electrovalve

Replace them for new ones
can not be reached fuses broken down.

Loss of product through the back

Stuffing deficiency Tighten the stuffing box or substitute it.
or front shaft support

Take the broken shovel out of the grinding

Broken shovel
chamber and substitute it. See point 5.3.
Check the water net inlet
Main motor does not start or stop High temperature
Check the electrovalve
Loosen shovels. Check the presence of dirt or
Belt slipping
grease
Main shaft does not turn
Water electrovalves
Replace them for new ones
fuses broken down
Stop machine and decrease maximum value in
Tightening blades is ammeter
Machine does not tighen
on for too much time Stop machine and check that detector pos. 1 is
broken or not in the correct position
Stop machine and decrease maximum value in
Loosening blades is ammeter
Machine does not loosen
on for too long Stop machine and check that detector pos. 2 is
broken or not in the correct position
Check the refrigerating system. Loosen shovels
Temperature fault High temperature
pressure

23
5. MAINTENANCE

24
5.1. BELT TENSIONING.
The motor is fixed to a platform that hangs from four thread bolts and fixed by the
corresponding nuts to each side of the platform. By screwing the nuts tensioning
of the belts is achieved.

If it is necessary to replace the pulley, it should be kept in mind that the tightening
torque is 11,7
11,7 kg/m for the reducer pulley and 3,25 kg/m for the motor pulley.

TAPER BUSHES INSTALLATION INSTRUCTIONS: TO ASSEMBLE

1. Clean and de-grease the bore and taper surfaces of the bush and the tapered
bore of the pulley, insert the bush in the pulley hub and line up the holes (half thread
holes must line up with half straight holes).

2. Lightly oil the grub screws (bush size 1008 to 3030) or the cap screws (bush size
3535 to 5050) and screw them in, do not tighten yet.

3. Clean and de-grease the shaft fit pulley with taper bush on shaft and locate in
desired position.

4. When using a key it should first be fitted in the shaft keyway. There should be a
top clearance between the key and the keyway in the bore.

5. Using a hexagon socket wrench (DIN911) gradually tighten the grub/cap screw
in accordance with the torques as listed in the schedule of screw tightening torque.

6. When the drive has been operating under load for a short period (half to one hour)
check and ensure that the screws remain at the appropriate tightening torque.

7. In order to eliminate the ingress of dirt fill all empty holes with grease.

REMOVAL

1. Slacken all screws. Depending on the size of the bush remove one or two. After
oiling point and thread of grub screws o under head and thread of cap screws insert
them into the jacking off hole in bush.

2. Tighten screw uniformly and alternately until the bush is loose in the hub and pulley
is free on the shaft.

3. Remove pulley bush assembly from shaft.

25
5.2. LUBRICATION.
*For the reducer oil VG-220 with a viscosity of 220 cst at 40ºC must be used.

After the first 500 hours of processing the lubricant must be replaced to clean all
impurities from the first lubrication. After this first change, the lubricant has to be
changed after every 2500 working hours or 6 months.

NOTE: Before starting the machine the lubricant level has to be checked
cause it could have happened that during transportation it might have lost
some of it.

*For the lubrication of the support of the main shaft any kind of lithic grease can be
used.

*The lubrication of the pressure mechanism has to be done through the oiler (pos.
X). The grease to be used will be LITHIC with a yearly periodicity and very small
amount each time.

5.3. SUBSTITUTION OF THE GROUP BLADE/SPRING.

We have provided extra blades and a special key for their substitution.

The precautions in order to avoid the breaking of a blade are:

* DO NOT START THE MACHINE IF THE TEMPERATURE SHOWED IN THE

THERMOMETER IS BELOW 40ºC.

* DO NOT START THE MACHINE WITH THE BLADES TIGHTENED.

* DO NOT INVERT THE RUNNING SENSE OF THE MOTOR.

* DO NOT FEED THE MACHINE WITH BIG BLOCKS OF FAT OR FATTY

INGREDIENTS.

26
Those are the steps to follow in order to replace the blades:

1- Dismount the front hopper (4).

2- Dismount the back hopper (5).

3- Take away the nuts with the key (3).

4- Take away the bolts (2).

5- Substitute the blade (1).

1 2 3

4
5

Proceed to mount the new blade, screwing firmly the nuts and punch between the nut
and the thread of the bolt to assure the blocking of the assembly..

27
5.4. MAIN SHAFT STUFFING BOX
We recommend that before starting the machine to check if there is any chocolate
leackage through the stuffing box. If so it will be necessary to press slightly the stuffing
box by means of the bolts situated at the sides of the stuffing box.

In case the leackage still exists, proceed as follows to change the stuffing.

1- Loosen the stuffing box (pos. Y).

2- Extract the stuffing.

3- Place the new stuffing, the stuffing box and press again the whole assembly.

(pos 25 MI 0215)

(pos Y)

STUFFING

28
5.5 HYDRAULIC GROUP
5.5.1 Hydraulic group sketch

1-Suction filter

2-Moto-pump group

3-Limit pressure valve

4-Electrovalve

5-One way valve

6-Flow regulator

7-Manometer

8-Cylinder

29
5.5.2 Maintenance
The maintenance of the hydraulic unit is only for the oil that it contains. It
mustbe changed ONLY EVERY 1000 HOURS OF OPERATION OF THE
HYDRAULIC UNIT for this reason this maintenance is nearly nonexistent.

If you have arrived to this 1000 hours of operation or for any other reason e.g.
leakage on the hydraulic circuit, to replace the hydraulic oil you have to
proceed as follows:

separate the complete hydraulic unit from it position it is necessary to

dismount the oil tank and then is is possible to get all the oil that it contains,
without spilling it over the reducer and the V-belts.

Then this operation must be done in a mode where by you can empty all the
hydraulic oil.

NOTE: empty completely the hydraulic circuit before refilling the oil tank.

NEVER MIX OILS ! ! !

-once the hydraulic unit was dismounted from its position loose the nut nº 13
and separate the tank nº 1 with it you can empty all the hydraulic oil.

-check the filter nº 7, the gasket nº 14 and the pump gasket nº 15.

-assembling again the tank tightening the nut nº 13 and there removing the
devaporator unit nº 9 refill the tank with 2,5 lts of hydraulic oil type ISO VG-
46; check if there is any leakage of oil from the tank and assemble the unit in
its position.

NOTE: check the connections and the positions of the pipes from the
hydraulic circuit.

30
5.6. GENERAL MAINTENANCE PLAN

first operation
daily 500 1000 2500
order MAINTENANCE LABOR control hours hour hours

Check double jacket is completely filled

1
with water.
2 Lubricate pressure mechanisms bearing.

3 Check the state and number of blades.

4 Change the oil of the reducer.

5 Check belt tensioning and alignment.

Lubricate the bearings of the central shaft
6
support.
Check there is no leackage of chocolate
7
through the stuffing.
Check there is no leackage of oil in the
8
hydraulic circuit
9 Change the oil of the hydraulic circuit

31
 after every
daily 500 1000 2500
order MAINTENANCE LABOR control hours hour hours

Check double jacket is completely filled

1
with water.

2 Lubricate pressure mechanisms bearing.

3 Check the state and number of blades.
4 Change the oil of the reducer.
5 Check belt tensioning and alignment.
Lubricate the bearings of the central
6
shaft support

Check there is no leackage of chocolate

7
through the stuffing.

Check there is no leackage of oil in the

8
hydraulic circuit

9 Change the oil of the hydraulic circuit

32
6. ASSEMBLY

33
 SPARE PARTS ORDER FORM
In case that any spare part is needed, be so kind to fill this form.
S.A. MARTIN LLOVERAS
Ctra. Rubí, 284
APPLICANT COMPANY DATA
P.O. Box 71
08223 TERRASSA (ESPAÑA)
Tels. 34-93 783 63 11
34-93 784 21 22
Fax 34-93 786 39 03
e-mail:headofficell@lloveras.com
e-mail:afsales@lloveras.com

DATA OF THE MACHINE :(look for them at the characteristics plate attached to the
machine).

MACHINE NUMBER :

MANUFACTURE NUMBER : YEAR:

VOLTAGE:

ASSEMBLY Nº POSITION Nº NAME ITEM QUANTITY

EXAMPLE

MI-0205 34 B LA D E IB-6740 1

You can send this sheet properly and full filled by fax or mail.
 GENERAL ASSEMBLY (MI 0211)
POS DENOMINATION
1 Hydraulic mechanism for blades pressure control
2 Main reducer
3 Back hopper
4 Ovreflow
5 Charging hopper
6 Valve for samples
7 Product exit valve
Entrance for water from net and refrigered water by
8
means of solenoid valve
9 Double jacket emptying valve
10 Main motor
11 Water pump
12 Water electric heater

34
 HYDRAULIC PRESSURE SYSTEM AND CENTRAL
SHAFT SUPPORT(M I 0212). V19
POS QTY DENOM INATION ITEM
1 1 Hydraulic group 71MBE 1A 50 A 04 A12
2 1 Reducer TH 25-H3
3 1 Support U 6299 v2
4 1 Main shaft U 6301 v2
5 1 Tension shaft U 6952
6 1 Stuffing box U 6300
7 1 Reducer pulley 50 Hz SPB 500 x 4diam.45
8 1 Motor MH-200 L 40 C.V
9 1 Motor pulley 50 Hz SPB 190 x 4diam.55
9 1 Motor pulley 60 Hz SPB 160 x 4diam.55
10 4 Belts 50 Hz XPB 2410
10 4 Belts 60 Hz XPB 2360
11 4 Tightening device U 6958
12 1 Nut and safety washer KM-10, MB-10
13 1 Bearing support U 6913 v2
14 1 Oil retainer BA 60.80.8
15 1 Cover ring U 6918
16 1 Support U 6955
17 1 Bearing cover U 6911
18 1 Bearing 31310 / DF
19 1 Lubricator 1/4" Gas
20 1 Nut U 6915
21 1 Stuffing box U 6306
22 1 Bearing U 6311
23 2 Oil retainer 55-80-8
24 1 Shaft support U 6307
25 1 Support U 6305
26 1 Conical support U 6304
27 1 Fan HXM-200
1 Hydralic piston DL1F-70-125-50R
2 Temperature control WEST-6500
2 Probe PT-100

35
INTERNAL MECHANISMS (MI 0213) V19
POS QTY DENOMINATION ITEM
1 1 Bolt plate U 7072
2 60 Showel U 6291
4 60 Spring U 7090
5 60 Bolt U 6287
6 1 Ring U 6285
7 60 Countershowel U 7189
8 60 Lifter U 6929
9 1 Conical plate U 6521
10 1 Safety gasket and nut MB 38, KB 38
11 1 Safety gasket and nut MB 12, KB 12
12 1 Tension shaft U 6952
13 1 Stuffing box U 6297 v2
14 1 Support U 7075 v2
15 1 Bearing U 6298
16 1 Main shaft U 6994
17 25 Bars U 6269
18 25 Wall lining U 6268
2 Stuffing 8x8
1 Stuffing 12 x 12

36
7. SUB-MANUAL

37
7.1 REDUCER
Motor reducers (gear boxs) are supplied with their own lubricant oil; only refill in case
of any leakage, with the oil shown on the characteristics plate.

NOTE: Never mix different kind of grease or oil.

When asking for spares, check the following enclosed pages.

38
 SERIES

UK IR SET- UP AND
GEAR REDUCERS MAINTENANCE
INSTRUCTIONS

SET- UP POSITION AND INSTALLATION

This gear reducer has been supplied for a previously agreed set--up position and must be attached firmly to its supporting
structure, taking the relevant measures concerning stiffness and levelling, by attaching it on a flat surface unable to generate
improper forces and stresses.
To transmit power directly from the gear reducer up to the driven machine, it is recommendable to use an elastic coupling.
Machine elements fitted on the shaft shall not be fitted by entering them with a mallet or a hammer, but only fitting them softly under
the pressure exerted by a bolt passed through the hollow shaft or by using the tapped hole arranged on the shaft’s end. Otherwise,
the bearings could be damaged.
The holes of the machine elements to be fitted on the shaft shall have been machined with a tolerance of H7 grade, whilst the
shafts are ground to a k5 grade.
The components of this speed reducer have been subject to strict controls throughout their production process.
Once mounted, this speed reducer has satisfactorily passed, among others, the following controls:
Noise volume, sealing, shaft eccentricity and misalignment, speed, power and finish.

LUBRICATION
Except otherwise specified for the selected working position, these gear reducers have been designed to be splash lubricated
by an oil bath. THEY ARE SUPPLIED WITHOUT LUBRICANT and it is the customer who has to fill in oil up the level, following
the instructions for the maintenance of the reducers.

CLP Lubricants acc. to DIN 51517, part 3

Recommended viscosity

Viscosity (mm 2/s (cSt) at 40 ° C)

Environmental
Lubrication Input speed: n1
temperature ° C
500 at 1000 r.p.m. 1000 at 1500 r.p.m.

--10 to+5 Overpressure, splash lubrication VG 100 VG 100

Overpressure VG 150 VG 150

0 to +40
Splash lubrication VG 320 VG 220

Overpressure VG 320 VG 320

+35 to +60
Splash lubrication VG 460 VG 320

* For input speeds n1 < 500 r.p.m. please ask for advice.
Tolerance admissible for each VG class = ± 10% of the values shown.

RECOMMENDED LUBRICANTS

Viscosity
mm2/s (cSt)
at 40 ° C
Extra Gear BP Energol SPARTAN Mobilgear Shell Omala Oil Engranajes Klüberoil GEM 1 Super Tauro

VG 460 460 GR-- XP 460 EP 460 634 460 460 460 460

VG 320 320 GR-- XP 320 EP 320 632 320 320 320 320

VG 220 220 GR-- XP 220 EP 220 630 220 220 220 220

VG 150 150 GR-- XP 150 EP 150 629 150 150 150 150

VG 100 100 GR-- XP 100 EP 100 627 100 100 100 100
COMMISSIONING AND MAINTENANCE
The hole for filling in the lubricant has been equipped with a breather stopper, existing moreover another plug to empty the lubricant
contained and placed in the bottom part of the housing.
The approximate quantity of lubricant has been shown on the machine plate of the reducer. The optimal level is that corresponding
to the dipstick mark.
After the first 500 working hours, empty the housing by opening the emptying plug and fill in new lubricant up to this has dragged
off all the impurities generated during the running--in period. After this first oil change, change oil every 2500 working hours or
every 6 months. These specifications may vary according to the grade or type of lubricant used, and oil level shall be checked
periodically in order to prevent any type of oil leak.
The lubricant used for running--in the gear reducer can be used again, once it has ben filtered and freed of any impurities.
It is recommended to not surpass the dipstick level, because the addition of more oil not only is not beneficial for the mechanism,
but could even originate an overheating, therefore worsening the thermal efficiency of the gear reducer.

Breather plug
Dipstick Impulsion tube

Level mark Pump

ENG
Suction pipe
Emptying plug Emptying plug

RUNNING
It is recommended to carry out a running--in period consisting in a progressive application of load to the gear reducer before its
difinitive industrial use.
At full load, the stabilized operating temperature of the gear reducer may easily reach 80 to 85 ° C without this influencing
negatively its operation.

GEAR REDUCER WITH PUMP ENCLOSED

Should the gear reducer supplied be equipped with forced lubrication by pump, the following points should be taken into account
before commissioning the machine:

Prime the pump. To this purpose, there is a special stopper in the distribution tubing.
Check periodically that the pump continues primed before carrying out further starts.

GEAR REDUCER COOLING FORCED

Should the gear reducer be equipped with a water cooled oil cooler, the water shall be first filtered to avoid an obstruction in said
cooler.

OBSERVATIONS
It is recommended to periodically stop the plant to check the grade of wear suffered by the gears through the inspection windows.
After dismantling any one of these covers, clean he surfaces from remains of the old joint and refit with sealing paste when it is
to be fitted again.
Any anomaly in the operation of the gear reducer (abnormal noise, excessive temperatures, lubrication failures, lubricant losses)
shall cause an immediate thorough revision of the reducer and the repair or the replacement of the damaged parts.
If a relatively long storage period is envisaged before commissioning the gear reducer, some precautions shall be taken, such
as recovering the internal elements with a protecting product soluble in the lubricating oil; protecting the shafts with a long lasting
anti--oxidation product; and storing the reducer in a dry place, where temperature variations are not significative. Should this be
likely to occur, please ask us for advice.
For better control of lubrication system, we advise about the installation of any element to control the lubricant pass.
7.2 FAN

39
 PLATE MOUNTED AXIAL FLOW FANS
HXM Series
Description Applications
Range of plate mounted axial fans, suitable The HXM range are designed to be installed
for many ventilation applications where the directly into walls or panels and are suitable
extraction of small air volumes at low for use within a wide range of general
pressures are required. ventilation applications.

• Applications include the ventilation of:

– Cafes, bars and small restaurants.
– Commercial premises.
– Small workshops.
HXM

Construction
Mounting Plate mounted to the inlet side of the fan. Both the Manufactured in accordance with IEC 34-1
All HXM Plate Mounted Axial Fans include a motor support and finger guard are protected standard. The following specifications
Plate mounted axial flow fans

one piece bell mouth inlet and mounting plate by a two stage cataforesis primer and tough apply.
manufactured from pressed galvanised steel. beige color polyester paint finish. – Electrical Supply - 230V 50Hz.
This mounting plate assembly is protected by – IP-40 for models 200, 250, 300 and 350,
a two stage cataforesis primer and tough Impeller and IP-20 protection for model 400.
beige polyester paint finish. All models incorporate a five blade impeller – All models incorporate Class B Insulation.
manufactured from galvanised steel sheet – All models incorporate an Auto-Reset
Motor Support and finished with a black epoxy-polyester Thermal Overload Protection device.
The motor and fan impeller are firmly paint. The impellers are factory matched an
supported within the mounting plate by a balanced onto the corresponding motors. All motors are finished in a beige epoxy-
strong steel support frame. The support frame polyester paint coating to complement the
is welded to the mounting plate on models Motor mounting plate and motor supports.
200, 250 and 300; and bolted to the mounting All models incorporate single phase shaded
plate on models 350 & 400. All models pole asynchronous induction motors with All models are supplied with a flexible cable
include a steel finger proof guard as standard squirrel cage rotor in die cast aluminium. for connection to the electrical supply.

Technical characteristics
"

Speed Maximum Maximum Maximum Sound Weight

power current air pressure
absorbed absorbed volume level
Type (r.p.m.) (W) (A) (m3/h) (dB(A)) (kg)

HXM-200 1300 32 0,22 500 36 1,7

HXM-250 1300 46 0,31 900 42 2,5

HXM-300 1300 55 0,40 1400 48 3,1

HXM-350 1300 65 0,50 1800 53 4,4

HXM-400 1300 200 1,60 3000 57 7,3

Dimensions (mm)
"

Ø Ø ø
Type A B C D E F G

HXM-200 222,5 266 9,5 205 85,5 19,5 211

HXM-250 275,5 333 9,5 255 92,5 31,5 261

HXM-300 336,5 400 10,5 305 92,5 35,5 311

HXM-350 390,5 465 10,5 361 105,5 34,5 371

HXM-400 420,5 500 10,5 400 141,0 52,5 414

26
 Performance curves
– Q = Air volume in, m3/hr and m3/s
– Pe = Static pressure in mmWG and Pa.
– Dry air at 20 ºC and 760 mmHg.
– Air flow data in accordance with the following standards: UNE 100-212-89, BS 848, Part 1, AMCA 210-85 and ASHRAE 51-1985.

mmWG mmWG

HXM
Plate mounted axial flow fans
Mounting accessories
"

Back draft Louvre Shutters

Type Plastic Metal

HXM-200 PER - 200 W PER - 250 CN

HXM-250 PER - 250 W PER - 250 CN

HXM-300 PER - 355 W PER - 355 CN

HXM-350 PER - 355 W PER - 355 CN

HXM-400 PER - 400 W PER - 400 CN

Electrical accessories

REB RMB
Electronic, single phase speed Auto transformer, single phase
controller. speed controller.
See Accessories pages for further See Accessories pages for further
details. details.

27
8. CONTROL PANEL

40
 REFINERS SCREENS

Technical
adjustment Select
language
Next screen

Clean screen

Change
automatic/manual
working

Main motor

Manual
Reset screen
alarms

Graphics
screen

Alarms Working time

screen screen
Temperatures screen
 Temperatures screen
Chocolate temperature

Water temperature

Heating
ON/OFF

Fan
Manual screen ON/OFF

Loosen
blades

Chocolate pump
ON/OFF

Tighten
blades
 Loading time:
Starts when we turn on the main motor
until we select the automatic working

Working times
screen

Refining time: Conching time:

Starts when we select the automatic Starts when the refining time is
working until the pre-selected loosening finished until the pre-selected stopping
blades time time

Amperes /time
graphic
 Temperatures/time
graphic

Technical adjustments

Delayed hydraulic
pump time

Maximum time
loosening in
automatic
working, if
programmed Maximum time
amperes are not tightening in
reached the automatic
alarm starts working, if
programmed
amperes are not
reached the alarms
starts

Hydraulic pump
pulses time
loosening/tightening
Minimum intensity
amperes value in
automatic working

Maximum intensity
amperes value in
automatic working

Maximum intensity
amperes which
start the alarm

Select this
button ON if
the machine
has an outlet
chocolate
pump to
enable it
Historical alarms
screen
9. ELECTRICAL SCHEMES

41