Sis Um130-Manual

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Technical Documentation
Universal machine
UM 130
Exemplary illustration. Delivery item can vary!

General Notes 2
HV A.0
Information page
Machine type Universal machine
Type description UM 130
Serial number I09009
Year of manufacture 2009
Manufacturer Stephan Machinery GmbH

Stephanplatz 2
31785 Hameln
Germany
' Service +49 5151 583-0
' Sales +49 5151 583-200
Fitted modifications
Titel | Model number Made modifications | Operator Date
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UM 130
General Notes 3
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Table of contents
1 General Notes 7
1.1 Table of Abbreviations 7
1.2 Definition of Terms 8
1.3 Instructions for orientation 9
1.4 Notes for The Use of This Manual 9
1.5 Notices and Types of Illustrations That Are Used in All Chapters 10
1.6 Used warning symbols 11
2 Safety instructions 12
2.1 Introduction 12
2.1.1 Safety instructions for general machine safety 12
2.1.2 Safety instructions for general production safety 12
2.1.3 Safety instructions for handling and operation 12
2.1.4 Safety instructions for maintenance and care 13
2.1.5 Safety instructions for trouble shooting 13
2.1.6 Notes for specific hazards 14
3 Machine hygiene 15
3.1 Micro-organisms 15
3.1.1 Definition 15
3.1.2 Factors for the multiplication of the micro-organisms 15
3.1.3 Effect of the pH value on the growth of micro-organisms 15
3.2 Production hygiene 16
3.2.1 Likely sources of risk for the production 16
3.3 Cleaning, Disinfection and Sterilisation 16
3.3.1 Basic information on cleaning 17
3.3.2 Basic procedure for cleaning 17
3.3.3 Basic information on cleaning agents 18
3.3.4 Basic information on disinfection 19
3.3.5 Basic information on sterilisation 20
3.4 Effects of the behaviour of the operating personnel 20
3.4.1 Notes on hygiene criteria 20
3.4.2 Impact of non-compliance with hygiene criteria on the production 20
3.5 Effects caused by machine upkeep and maintenance 20
3.5.1 Correct conduct during upkeep and maintenance 20
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4 Technical data and description of performances 21

4.1 Brief Description 21
4.2 Intended application 21
4.2.1 Improper use 21
4.3 Operating and ambient conditions 22
4.4 Machine data 23
4.4.1 Guideline values for the steam connection 23
4.4.2 Vacuum pump 24
4.5 Performance data 24
4.5.1 Energy requirement 24
4.5.2 Electric Data 24
5 Technical Description 25
5.1 Arrangement of assembly groups and operating elements 25
5.2 Technical Description 25
5.2.1 Functional Description 25
5.2.2 Constructional Description 26
5.3 Description of the assembly groups 26
5.3.1 Machine frame 26
5.3.2 Drive 26
5.3.3 Tools 27
5.3.4 Product container 28
5.3.5 Electrical engineering 29
5.3.6 Vacuum system 29
5.3.7 Steam supply 30
5.4 Safety equipment 31
5.4.1 Aeration 32
6 Installing, commissioning and decommissioning 33

6.1 Transport 33
6.2 Installation 33
6.3 Commissioning 33
6.3.1 Functional checks 33
6.4 Storage, utilisation 36
6.4.1 Storage 36
6.4.2 Disposal 36
7 Operation 37
7.1 Arrangement and function of the operating elements 37
7.2 Description of the operating panel 39
7.2.1 Operate the touch elements 39
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7.2.2 Operator menu 39

7.3 Operation 44
7.3.1 Installing / Dismantling working inserts 44
7.3.2 Mechanical and thermic product processing 47
7.3.3 Working under a vacuum 47
7.3.4 Cleaning 48
8 Troubleshooting and fault elimination 49

8.1 Details for STEPHAN Service and customer services 49
8.2 Notes on fault rectification 49
8.3 Faults in the vacuum pump 50
8.4 Faults in the switchgear 51
8.5 Faults in the drive motors 51
9 Servicing and maintenance 53

9.1 Details for services 53
9.2 Safety measures 53
9.3 Servicing and maintenance schedule 53
9.3.1 Daily inspection during operation 53
9.3.2 Weekly Maintenance 54
9.3.3 Semi-Annual Maintenance 55
9.4 Specific maintenance instructions 55
9.4.1 Sharpening the cutter 55
9.4.2 Maintenance of the shaft seal 56
9.4.3 Maintenance of the gear shaft seal 57
9.4.4 Lubricant change of the mixing baffle drive 58
9.4.5 Drive change for the end tipping 59
9.4.6 Linear drive 61
9.4.7 Mounting work on the cover 63
10 Spare Parts 66
10.1 Installation assembly group 66
10.1.1 Installation machine 66
10.2 Machine assembly groups 68
10.2.1 Main drive 68
10.2.2 Shaft seal, main drive 69
10.2.3 Lid opening, assembly group 70
10.2.4 Lid latch 71
10.2.5 Mixing baffle 72
10.2.6 Shaft seal, mixing baffle 73
10.2.7 Bowl, assembly group 74
10.2.8 Machine tool set, hollow edge knife 75
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10.3 Accessories and additional Parts 75
11 Affix 76
11.1 Specific lubrication substances 76
11.1.1 Shaft sealing rings 76
11.1.2 Static seals - O-rings 76
11.1.3 Gear motors 76
11.1.4 Hydraulics 77
11.1.5 Vacuum pump 77
12 Service addresses 78
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1 General Notes
1.1 Table of Abbreviations

Term Definition
EEPROM Electronical Erasable and Programmable Read Only Memory.

Electronical Erasable and Programmable Read Only Memory
Emulsion O/W Oil-in-water emulsion

A mixture of water and oil, however, there is more water present.
See also definition type of emulsion.
Emulsion W/O Water-in-oil emulsion

A mixture of water and oil, however, there is more oil present.
See also definition type of emulsion.
HV Manual version
IP International Protection
The abbreviation IP and a further two digit figure specify the type of protection of an
enclosure.
See also definition type of protection IP 54.
LED Light Emitting Diode

Light Emitting Diode
pabs The absolute pressure is described as p abs. One assumes the absolute pressure as
0 bar. This is also the maximum (theoretic) negative pressure that can be
simultaneously achieved. An atmospheric pressure of 1 bar exists at sea level. All
measuring instruments and values in engineering display the relative pressure. This
relates to atmospheric pressure.
pabs>1bar = Overpressure
pabs>1bar = Negative pressure
pü describes a pressure indication in relation to the ambient pressure.
SRS Sliding ring seal. A seal is used to seal off the machine housing or product container
on the protruding shafts.
SSR Shaft sealing ring. A seal is used to seal off the machine housing or product
container on the protruding shafts.
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1.2 Definition of Terms

Term Definition
Skilled employee Due to their professional training, knowledge and experience as well as their
knowledge of the respective guidelines, a skilled employee is a person that can
evaluate work assigned and individually recognise any possible dangers.
Authorised specialist An authorised specialist is a specialist that has been trained by the manufacturer
or an authorised service dealer or from a company that has been ordered by the
manufacturer.
Instructed person An instructed person is a person that has been instructed of the possible risks
resulting from improper use when carrying out the assigned task and, if necessary
trained for this task as well as the instructing of necessary protective equipment
and protective measures.
Cursor Marks the current position being processed. Shows the position where the input
can be entered on the screen.
Desinfection Killing off of pathogenic germs or other harmful microorganisms using chemical
materials and / or the influence of heat.
Pressure equipment The national German directive based in the EC Directive for pressure equipment
directive 97/23/EG. The directive regulates the technical dimensioning and documentation
of tanks, pipelines, equipping parts with safety function and pressure retaining
parts that are exposed to an allowable overpressure that is more than 0,5 bar.
Emulsion Emulsion designates a finely distributed mixture of two liquids that normally cannot
be mixed with each other. In doing so, one liquid is distributed in the other in small
droplets. The diminution of the droplets is carried out through intensive shearing
and the distribution of both liquids is achieved through intensive rotation.
F Insulation The classification of the insulation classes

H Insulation F ist for the normal version that has a limit excess temperature of 105 °K and a
maximum permissible constant temperature of 155 °C.
H ist for the tropic proof version that has a limit excess temperature of 125 °K and
a maximum permissible constant temperature of 180 °C.
Contamination The contamination of rooms, objects, foodstuffs, ground, air and water by,
amongst others, microorganisms.
Machine safety The term machine safety covers the definition of all measures that prevents
personal injuries. The basis for this are national as well as EC wide valid directives
and laws for protecting the users of technical devices and systems.
Micro-organisms Microorganisms are microscopic small single cell life forms. Micro-organisms are
also referred to as germs.
pH value The pH value designates the acid content of substances. In doing so, the area
between pH0 to pH6 designates acid substances and the area between pH8 to
pH14 designates basic (alkaline) substances. Water that has a pH value of around
pH7 is neutral.
Production safety The term production safety defines measures that are necessary to guarantee
adequate safety for the quality of the product to be produced when producing with
systems and machines. Furthermore, measures for the security of the consumers
of these products are also induded under the terry production safety.
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Term Definition
Protection type IP 54 The protection type of an enclosure is determined through the abbreviation IP
and a two digit figure.
1. Figure (protection against touching and foreign objects)
2. Figure (water protection)
With the protection type used for this machine (IP 54), the 5 means dust protection
where the penetration of dust cannot be fully prevented. The dust, however,
cannot penetrate in such amounts that will prevent a trouble free operation.
The figure 4 means protected against spry water, where the water that is sprayed
agains the enclosure from any direction should not have any dangerous
influences.
Sterilisation The goal of the sterilisation is to kill-off or neutralise all microorganisms that are
capable of reproducing in or on a substance.
Viscosity The term viscosity designates the resistance of liquids, semifluid or pasty masses
against their rotating movement. Generally, viscosity determines the behaviour of
the liquid in pipelines, valves and cylinders.
Cyclone principle The mode of operation of the cyclone principle is that the particulate gas is placed
in a rotating motion and therefore has a centrifugal force effect to the particle.
They are accelerated radial in an outward direction and separated from the flow of
gas that is drawn inwards.
1.3 Instructions for orientation

Front: the main operating side or the usual work location
Rear: the opposite side of the operating side.
Top and bottom: are derived from the main operating position that are also designated as basic
positions. The cover is closed in the basic position and covers the bowl upwards. Further
formulations for „top“ and „bottom“ are derived from the basic position.
1.4 Notes for The Use of This Manual

This manual is structured in functional and task orientated chapters.
There are no repetitious facts that have been previously explained, unless the repetitions are
important for the safety.
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1.5 Notices and Types of Illustrations That Are Used in All Chapters
DANGER Brief description of the hazards
There is a high hazard to life and limb of the user and / or third parties
when the instructions are not followed in detail or the circumstances
described are not followed correctly.
The type of hazard is characterised by a symbol and described in more
detail in the accompanying text.
WARNING Brief description of the hazards
There is a moderate hazard to life and limb of the user and / or third
parties when the instructions are not followed in detail or the
circumstances described are not followed correctly.
The type of hazard is characterised by a specific symbol and described
in more detail in the accompanying text.
CAUTION Brief description of the hazards
There is a low risk of injuries or a hazard of damage to property or to

the production conditions when the instructions are not followed in detail
or the circumstances described are not followed correctly.
The type of hazard is characterised by a specific symbol and described
in more detail in the accompanying text.
IMPORTANT
Brief description of important additional information
NOTICE
Attention is pointed to special conditions or additional important

information is given for the respective subject.
NOTICE Brief description of the additional information
Contains additional information for work assisting features or for

recommendations concerning the respective subject.
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1.6 Used warning symbols

Respective symbols are marked on the UM 130 using symbols when life and limb of the plant /
machine user and / or third parties are threatened or could be threatened when carrying out
activities.
Symbols are also used in these operating instructions to provide notice of hazards that may result
from operating steps or maintenance procedures. In both cases, the symbol provides information
about the type and condition of the hazard.
The following symbols are used:
General dangerous spot
Dangerous working voltage
Risk of hand injuries
Warning of automatic start
Danger of heavy loads
Danger of hazardous materials
Risk of cutting damages
Warning of hot surfaces
Never spray with water
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2 Safety instructions
2.1 Introduction
The following safety instructions are intended to make the use of the machine safer for the
operating and maintenance personnel. This avoids faults beforehand and allows optimal working
process to be carried out.
2.1.1 Safety instructions for general machine safety

With the machine safety, please pay attention to the following points:
• The safety instructions contained in this operating instruction must be observed.

• An optimum safety when operating the machine can only be achieved when the details and
contents of the operating instruction, such as local legal guidelines and in-house safety
guidelines have been read, understood and are observed.
2.1.2 Safety instructions for general production safety

Please pay attention to the following points for production safety:
• An optimum production safety can only be achieved when the details and contents of the
operating instruction, such as local legal guidelines and in-house safety guidelines have
been read, understood and are observed. The hygiene is a decisive factor when relating to
the quality of foodstuffs. Each person involved in the production process have a significant
contribution to the production safety through their careful course of action and the
observance of regulations and guidelines.
• All modifications or retrofitting work to the machine is only permitted after consulting the
manufacturer.
• The use of substances that have not been specified in this operating instruction may lead to
a significant safety risk for users and the machine.
• Unsuitable spare parts and wearing parts may lead to a significant safety risk for users and
the machine Only the use spare parts and wearing parts that are designated by the machine
manufacturer guarantee an optimum safety.
2.1.3 Safety instructions for handling and operation

Pay attention to the following points when operating the machine:
• The machine should only be operated by personnel that have the respective qualifications or
after a training course given by professional staff.
• The safety instructions of this machine should not be deactivated. Safety equipment protects
against accidents and injuries.
• The messages of the display devices must be observed.

• Pressure conditions must be checked and observed. No over-pressure should be at hand in
the product container before opening the cover.
• Reaching in to the bowl can lead to severe injuries caused by machine tools with sharp
edges.
• Tools and parts of the machine that have not been fixed correctly or partially fitted increase
this risk of safety. Rotating knives may loosen and can be a risk.
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• When switching on the machine, no foreign objects are allowed to be located in the machine.
This may cause damage to machine parts.
• The limit values listed in the machine data must be observed and should not be exceeded in
any case.
2.1.4 Safety instructions for maintenance and care

The following points must be observed during maintenance and care work:
• During maintenance work and measures for care, care must be taken that the machine and
the periphery device are switched off and separated from the mains supply.
• Never spray the machine with water, even after this has been separated from the mains
supply. Only clean the machine frame using a cloth moistened with cleaning agent.
• Reaching in to the bowl can lead to severe injuries caused by machine tools with sharp
edges.
• Only use gentle mechanical auxiliary substances, such as a brush and soft scraper that do
not cause damage.
• Do not use intensive corrosive cleaning solvents.
2.1.5 Safety instructions for trouble shooting

Please pay attention to the following points when troubleshooting:
• All inspection and maintenance work should only be carried out by authorised professionals.
• When carrying out maintenance work and fault elimination, care must be taken that the
machine and periphery devices are switched off. The machine must be separated from the
power supply and secured against reactivation when working on the electric system.
• The EMERGENCY STOP switch should only be operated in „Emergency“ situations, such as
for stopping a process or movement that may result in a hazard. (see DIN EN 60204-1 Affix
E) The EMERGENCY STOP switch should not be used as a main switch.
• If the EMERGENCY STOP switch is triggered, all mechanically operated parts of the
machine are stopped for placing the machine in a safe condition.
• The machine is not put back into operation automatically after the EMERGENCY STOP
switch has been released. The machine must be restarted for the new production run.
• Avoid standing in the working area of the bowl and cover.

• Pressure conditions must be checked and observed. No over-pressure should be at hand in
the product container before opening the cover.
• Close the on-site media feed when eliminating faults.

• The local applicable guidelines for accident prevention must be observed during inspection
and maintenance work.
• Observe the fault messages of the machine.

• All safety and protection equipment must be checked for their completeness after eliminating
any faults.
• The instructions for commissioning must be observed and a functional check must be carried
out before the production operation is released.
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2.1.6 Notes for specific hazards

Electrical energy
• Immediately separate the machine from the main switch when disturbances occur with the
electrical energy supply.
• All work on the electrical systems or operating substances should only be carried out by a
certified electrician or by trained personnel under supervision and monitoring of a certified
electrician using the electro-technical regulations.
• All parts of the machine where inspection, maintenance work or fault elimination should be
carried out should be switched volt-free when voltage is not required for this type of work.
This must only be carried out by a certified electrician.
Compressed air
The following must be observed when the machine is equipped with pneumatic equipment:
• All work on compressed air equipment should only be carried out by a technical expert with
respective knowledge
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3 Machine hygiene
3.1 Micro-organisms
3.1.1 Definition
Micro-organisms are defined as microscopically small, usually mono-cellular forms of life. Micro-
organisms are also referred to as germs.
One differentiates between:
• Bacteria
• Fungi (yeasts)
• Viruses.
Typical for micro-organisms is the rapid multiplication by means of cell division. Under certain
conditions bacteria can divide themselves approximately every 20 minutes. This means that by the
division of a single bacteria the number of bacteria can grow to over 8 million in 8 hours
(exponential growth of 2²³).
3.1.2 Factors for the multiplication of the micro-organisms

The following factors are significant for the multiplication of the micro-organisms:
• High level of moisture

• Temperature (20 °C to 60 °C)
• pH value
3.1.3 Effect of the pH value on the growth of micro-organisms
Micro-organisms prefer a very specific environment. Most germs feel particularly good in a slightly
acidic or neutral environment (pH value 4.5 to 7). These conditions are found for example, in milk,
meat, poultry or even fresh fish and many types of vegetables. In contrast, only few bacteria grow
in strongly acidic environments (pH value below 4.5) such as those found in many fruits and juices.
As opposed to this, however, yeasts and fungi develop optimally at pH value of 4.5. This is the
reason that fruits usually decay as a result of mould formation or fermentation.
Micro-organisms react to changes in the pH value (the pH value changes to deterioration of the
conditions for survival) with growth inhibition. One uses this characteristic beneficially to destroy the
micro-organisms by passing through the entire pH range of values during the cleaning process.
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3.2 Production hygiene
3.2.1 Likely sources of risk for the production

Germs can either be present or they can be introduced:
• as a result of improper hygiene of the operating and maintenance personnel

• by the product
• by the packing materials
• by insects
• via rinsing water
• by unhindered entry of external air
• in the supply or exhaust air
• in the supply lines
• in the waste disposal lines (contamination against the flow direction)
• owing to leakage spots (damages caused during operation)
Germs can multiply particularly well:
• in hollow spaces
• in accumulated liquids (condensate)
• on coarse surfaces
• in cracks and cavities of all types
• on or in product residues and miscellaneous impurities
3.3 Cleaning, Disinfection and Sterilisation

The prerequisite for proper and qualitatively high-value production is the absolute cleanliness of the
UM 130 and the production environment. Both at the commencement and termination of the
production, bowls, covers and tools of the UM 130 as well as the production area must be
absolutely clean and free from germs.
The following steps must be carried out for optimal cleaning:
1. Physical cleaning (rinsing with water and removing loosely stuck impurities at the surfaces).
2. Chemical cleaning (removing visible, such as microscopically small residues, fats and proteins
using cleaning agents).
3. Bacteriological cleaning (Disinfection).
4. Sterile cleaning (killing all micro-organisms).
By means of this division in individual steps it is ensured that no contamination takes place as a
result of cleaning agents already used such as sponges, brushes or washing solutions and that
optimal cleaning and sterilisation can be achieved.
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3.3.1 Basic information on cleaning

This cleaning procedure serves to dissolve large and fine impurities even in those spots that are
difficult to reach. To aid the cleaning one can make use of materials such as brushes, scrapers or
sponges provided that they do not damage the surfaces of the machine.
CAUTION Recontamination through contaminated tools and materials
Cleaning with the help of brushes, scrapers or sponges is associated

with the risk of hygiene by possible contamination with germs.
Do not use brushes or scrapers that have already been used before in
the remaining steps.
Use sponges and cleaning cloths only once and replace them
thereafter.
The following points must be observed when cleaning:
• The water used for cleaning must have the quality of drinking water (potable).
• The addition of commercially available rinsing agents reinforces the cleaning effect.
• Rinse out the bowl in flowing water to remove product residues that are stuck loosely. Clean
the production environment using water in accordance with the given conditions.
• Loosen impurities that are stuck persistently using a brush or a scraper.

• Rinse subsequently with hot water (75 °C° to 85 °C or 167 °F to 185 °F).
3.3.2 Basic procedure for cleaning

A high degree of effectiveness is achieved by using specific cleaning agents and the recommended
level of concentration. Manual cleaning using sponges, cleaning cloths and brushes is associated
with hygiene risks owing to possible contamination.
Manual cleaning is generally suitable only for surfaces that do not come into contact with the
product. Exceptions to this are smaller machines and machine parts, which are cleaned in
connection with the use of chemical cleaning agents (sponge cleaning).
• All equipment and rooms must be cleaned after the end of the production process.
• Cleaning agents and disinfection agents may not be used at the same time. The effect of the
disinfection agent is reduced by the cleaning agent under certain circumstances
• Rinse subsequently with hot water (80° to 85 °C / 176 °F to 185 °F).

• Use cleaning cloths only once for manual cleaning and drying (contamination).
The type of impurities is decisive when selecting the cleaning procedure. Cold milk, for example,
can be rinsed off relatively easily from surfaces. In contrast, product residues that have got burnt in
or dried in cannot be removed so easily. Heating the product has a high level of impact on
deposits. The higher the temperature, the higher is the probability that product residues get
deposited. However, high temperatures alone are not responsible for deposits.
A few examples that can lead to deposits:
• Heating speed (Heating is done as fast as possible in order to avoid fires etc.) Local
overheating must be prevented in the process.)
• Flow speed (the slower the product is churned the sooner can deposits be formed)
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• Surface roughness (the rougher the surfaces, the better can deposits get stuck)
• Viscosity (the thicker the product, the faster is the formation of deposits)
Deposits are primarily dependent on the composition of the product. High temperatures or specific
processes can enhance the deposits.
Various impurities of the machine are also subjected to different cleaning procedures. The basic
elements of the cleaning procedure is explained in the following table:
A) Cleaning procedure Can be used with/on
Manual cleaning (cleaning done by hand) Remove coarse and fine impurities, even at
locations difficult to reach. Cleaning is effective
even on rough surfaces. The additional use of
suitable cleaning agents enhances the cleaning
effect.
Machine-aided cleaning (stirring the cleaning liquid Bowl cleaning. Standard – Cleaning procedure for
in the container with the help of a mixing baffle*) cleaning the bowl daily
B) Cleaning activity (in principle) Can be used with/on
Rinse with water Removal of coarse impurities. At water

50 °C to 60 °C / 122 °F to 140 °F* temperatures >50 °C / 140 °F Removal of fatty
substances
Leaching (for heavy deposits) Highly adhesive product residues (soak and
dissolve) Dissolving fats (emulsify and harden the
fatty constituents)
Intermediate rinse with water Removal of cleaning agents and dissolved product
50 °C to 60 °C / 122 °F to 140 °F* residues *
Acid rinsing (for heavy deposits, scales etc.)* Hard product remains and product residues (e.g.
milk stone)
Rinse out with water * Removal of cleaning agents and dissolved product
residues
* depending on the production process
3.3.3 Basic information on cleaning agents

Various impurities in the machine require different cleaning agents. As high a degree of
effectiveness as possible of chemical cleaning is achieved by using specific cleaning agents in their
recommended levels of concentration.
WARNING Substances posing risk to health
Improper concentration of the cleaning agent leads to residues in

foodstuffs and to health hazards for consumers and personnel under
certain circumstances.
Please follow the instructions on safety and usage provided by the
respective manufacturer. Please comply with the specifications
regarding the concentrations and residence times.
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Various impurities of the machine are also subjected to different cleaning agents. Various cleaning
procedures are listed in the following table:
Impurity Group Agent
Proteins Leaches Caustic soda
Fats Soaps Soft soap

Tensides Rinsing agent
Mineral product remains Acids Hydrochloric acid, vinegar,

(e.g. milk stone, scales) tartaric acid
The following points must be observed with chemical cleaning:
• Use chemical cleaning agents only within the specifications provided.

• Remove persistently stuck impurities using a brush.
CAUTION Contamination
Cleaning with brushes, scrapers or sponges is associated with hygiene

risks owing to possible contamination with germs.
Please do not use brushes or scrapers in the following steps that have
already been used before.
Please use sponges and cleaning cloths only once and then replace
them.
3.3.4 Basic information on disinfection

Disinfection is effective only after thorough cleaning has been done. Disinfection agents react with
left-over impurities, which reduce or, in fact, cancel the effect of the disinfecting agent.
WARNING Substances posing risk to health
Improper concentration of the disinfection agent leads to residues in

foodstuffs and to health hazards for consumers and personnel under
certain circumstances.
Please follow the instructions on safety and usage provided by the
respective manufacturer.
In particular, please comply with the specifications regarding the
concentrations and residence times.
The following points must be observed during the disinfection process:
• Cleaning agents and disinfection agents may not be used at the same time. The effect of the
disinfection agent is reduced by the cleaning agent under certain circumstances
• Please comply with the concentration and residence times of the disinfecting agent.
• Rinse off with water only after the required residence time.
• Refrain from drying off the surfaces with cloths as far as possible (contamination).
• The surfaces can be dried quickly by rinsing with hot water.
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3.3.5 Basic information on sterilisation

In contrast to disinfection, sterilisation is more comprehensive, i.e. almost all cells including spores
and viruses are killed, for example, by the effect of heating. A maximum of 1 germ out of 100,000
survives after disinfection. After sterilisation, a maximum of 1 germ in 1 million survives.
It is a standard procedure, which is not a substitute for the other procedures stipulated respectively
as mandatory!
3.4 Effects of the behaviour of the operating personnel
3.4.1 Notes on hygiene criteria

Correct behaviour of the operating personnel is decisive for optimal hygiene.
• Please comply with the hygiene regulations applicable locally.

• Prior to entry, before each new work procedure and naturally also after every visit to the
toilet, please thoroughly wash your hands with soap under flowing water. Please use
disposable cloths for drying your hands.
• Please ensure that your fingernails are short and clean.

• Remove your finger rings and wristwatches prior to commencing work.
• Please wear clean protective gear (head cap, overalls, hand gloves, shoes for interior
rooms).
• Please do not cough or sneeze on the product, its preliminary stages and/or surfaces coming
in direct contact with these substances.
• Please cover wounds on the hands and arms with water-proof plaster.
• All persons must be adequately informed regarding the hygiene criteria and must observe
and comply with them.
3.4.2 Impact of non-compliance with hygiene criteria on the production

Under certain circumstances, harmful micro-organisms can spread across the entire production
batch. Micro-organisms are not visible, and what appears to be clean must not necessarily be
harmless from the health point of view. The risk to health does not lie in the mere presence of a low
number of micro-organisms, but, above all, in the fact that they multiply exponentially under
favourable conditions.
3.5 Effects caused by machine upkeep and maintenance
3.5.1 Correct conduct during upkeep and maintenance

Please ensure that the working environment is clean when undertaking cleaning and maintenance
work. Even impurities that are not present directly on the machine (unclean floors, dust deposits
etc.) can get introduced in the production loop under certain circumstances. Impurities have a
detrimental effect on the production. This is why the machine and its environment must always be
kept clean.
During maintenance, please clean those areas that are kept free for maintenance work, but are
otherwise difficult to reach.
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Technical data and description of performances 21
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4 Technical data and description of performances
4.1 Brief Description
The UM 130 is a universal machine used for manufacturing foodstuffs. They comply with the
newest hygienic guidelines.
All parts that come into contact with the product are made of stainless steel rust free or other
physiologically harmless materials. The process container with working tools driven directly can be
swivelled and are mounted in the machine stand, the tipping of the bowl and cover opening are
carried out electro-mechanically. All periphery devices (vacuum pump, power supply) are
integrated on the machine stand.
4.2 Intended application

The UM 130 is intended for the commercial and industrial production of products. The intended
application includes the specified process, the adherence of the specified specifications as well as
the use of the original accessories provided or that can be ordered separately. Damage caused by
non-intended use will lead to the loss of liabilities and guarantee claims.
4.2.1 Improper use

Improper use is when:
• the modification and / or deactivation of safety equipment such as switches, locking

mechanisms, covers, locking, seals, etc.
• Operating, maintaining and repairing of the UM 130 by non-authorised and non-instructed

persons (see: Definition of skilled professionals).
• Improper or the unintended use of the machine.

• Use of parts that are not original.
• Modifications made to the performance parameters that go beyond the confirmed values.
• Processing of products that have not been agreed.
• Processing of light inflammable and explosive materials.
• Processing of substances that belong to the fluid group 1 (dangerous fluids) acording to
67/548/EEC
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• Operating the machine beyond the inspection and maintenance cycles.

• The insertion of objects that may interfere with the movement of machine parts.
• Permanent operation that lies above the stated performance values. Permanent
overstraining leads to the malfunction of individual components.
• Processing of frozen or hard blocks of raw ingredients that size and / or weight is at leats
above 150 mm and / or 2kg
4.3 Operating and ambient conditions

The dead weight and the vibration reduced run of the machine allow a the machine to be set up
standing free.
The following ambient conditions are necessary for the machine:
• The machine must be installed on a stable floor space.

• The floor space must be level.
• The machine must be installed in closed rooms.
• The premises must be clean.
• The ambient temperature should not lie below 12 ? / 53 °F and should not exceed 35 ? / 95
°F.
• The minimum load rating of the installation location should not be bellow 800 kg/m2.
• The minimum load rating in the area of the equipmet feet should not be bellow 800 kg.
• The installation location suites the machine vibrations, the size of lateral loads can achive
30% of the machine weigh.
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4.4 Machine data

Designation Unit Value
Bowl volume l 120
Batch size - depending on the production (max.) l up to approx. 90
Operating pressure bar unpressurised
Maximum operating temperature °C (°F) 95° (203°)
Main motor speed n/min 300 - 3000
Operating voltage V 400
Mains frequency Hz 50
Allowable operating temperature of the bowl °C (°F) 95° (203°)
Allowable operating temperature (max.) in the °C (°F) 133° (271°)

double jacket
Allowable operating overpressure (max.) in the bar 2

double jacket PSI 29
Recipe water supply pressure bar 3 to 6

PSI 44 to 87
Water demand - recipe water l/min 70
Supply pressure - pneumatic device bar 8 to 10

PSI 116 to 145
Set pressure for cover seal bar 2

PSI 29
Set pressure - pneumatic device bar 6

PSI 87
Total weight of the machine (net.) kg approx. 1190
Dimensions mm (L x W x H)
4.4.1 Guideline values for the steam connection

Steam performance kg/h 290
Preliminary steam pressure bar 6 to 8

PSI 85 to 116
Steam pressure at the steam nozzles bar 2.5 to 3.5

PSI 36 to 50
Steam pressure in the double jacket bar 2

PSI 29
Steam supply line DN 40
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4.4.2 Vacuum pump

Nominal suction capacity m 3/h 26
Vacuum pump total mass kg 20
Teoretically achievable dis charged pressure mbar absolute 33
4.5 Performance data
4.5.1 Energy requirement

Motor kW 30
Mixing baffle kW 1,1
Machine total power kW
Vacuum pump kW 0,75
Water - vacuum pump l/h approx. 240
4.5.2 Electric Data

Supply voltage V / Hz 400/50
Control voltage V 24 AC
Security at 400 V (slow) A
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Technical Description 25
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5 Technical Description
5.1 Arrangement of assembly groups and operating elements
1 Main switch 4 Manometer

2 Operating panel 5 Bowl tilting control system
3 EMERGENCY STOP 6 Drain valve
5.2 Technical Description
5.2.1 Functional Description

The UM 130 is a universal machine particularly for the manufacture of foodstuffs. Processes such
as mixing, chopping, emulsifying or kneading are possible with the help of appropriate tools. During
processing, the product is churned optimally through the tools. The mixing baffle supports churning
of the product by scraping the bowl and the cover clean and putting the product in the centre of the
bowl. The speed of the tools can be adjusted to suit the condition of the product.
Depending on the configuration variant, the UM 130 is fitted with a vacuum system so that it is
possible to handle all those processes that require a vacuum.
The following machine functions are available:
Loading
• Manual via the opened cover.

• Automatic via the dosing valve using vacuum or pumps.
Processes
• Mixing, chopping, cutting, emulsifying, kneading.

• Indirect heating and cooling via the double jacket.
• Venting through the vacuum system.
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Drainage
• Manual via the opened cover by tilting the container.

• Automatically through the drainage valve.
Controlling
• Manually via the control panel of the OP and the film keyboard.
• Automatically using the program control system.
5.2.2 Constructional Description

The UM 130 consists of the machine frame, the drive and the bowl with cover. The extended motor
shaft of the motor protrudes in the bowl and serves as a holder and drive for the working tool. A
mixing baffle adapted to the shape of the bowl is mounted on the cover. All parts of the UM 130
that come into contact with the product are made of stainless steel rust free or other physiologically
harmless materials.
5.3 Description of the assembly groups
5.3.1 Machine frame

The machine frame made of stainless steel holds the drive of the UM 130. The drive can be
swivelled towards the front along with the product container lying above it.
5.3.2 Drive
Motor, shaft, shaft bearing, working shaft, clamping connection and clear view screen make up the
drive unit of the UM 130. The drive is mounted on the container at some distant. Therefore, the
shaft is sealed off twice. Once on the motor and once on the product container. As a result, the
outflowing liquid does not penetrate into the motor when leaking through the container seal. The
low wear standard three-phase motor has a safety device against the overheating. The centrifugal
disc protects against the impurities and seals off the motor with a labyrinth seal towards the gap.
The gear drive motor mounted on the cover for the mixing baffle is a robust and low-maintenance
drive system. It is provided with filling of grease and connected such that it is ready for operation.
The cover of the product container can be opened only when the mixing baffle is driven to a
particular position. A position switch in the cover checks the position of the mixing baffle and
ensures that it is maintained at the correct position when switching off the gear drive motor. When
the mixing baffle drive is switched off the brake gets activated at the same time and holds on to the
mixing baffle.
Position sensing for the mixing baffle
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Position of the mixing wing when opening the cover
Mixing wing position when equipped with the lifting and tilting device
5.3.3 Tools
WARNING Risk of injury when working with the tools owing to their sharp
cutting edges
There is a risk of injury when working with the tools owing to their sharp
cutting edges.
Please handle the tools with care and do not touch the cutting edges of
the tools.
The shape and size of the tools has been adapted optimally to the shape of the bowl. Depending
on the tool, various processes can be carried out and the product can be processed optimally. The
product can be chopped, cut, mixed, emulsified or kneaded.
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CAUTION Risk of damage
If the tools are not installed properly in the machine or if they have been
assembled incorrectly, then this leads to considerable damage to the
bowl and the tool itself.
Please ensure that the tools are installed properly in the machine.
Please also always assemble the tools correctly.
The working inserts are particularly made from high-resistant, stainless steel and polished for the
production in the field of pharmaceutics. Their shape and size are optimally adapted to the motor
power, bowl shape and performed working operations.
Due to their higher hardness the knives are not so long-lasting as all other container parts.
Therefore, in case of not using, first of all after cleaning they should be taken out the machine,
dried and kept dry.
5.3.4 Product container

The product container consists of the bowl and cover. The detailed description is given in the
following sections.
Bowl
The bowl holds the product and can be closed with the cover. The main tool drive motor is mounted
under the cointainer at a small distance. Its schaft end protrudes through the vessel bottom into the
product chamber and serves as a holder for the working tools.
The vessel has been produced according to the regulations for pressure devices. The cover
together with the bowl are locked by a lock ring. The seal between the bowel and the cover is
carried out using a seal made of special silicone rubber. In this condition, the vessel is vacuum and
pressure tight up to the stated pressure data. (Machine data [? 23] )
NOTICE Safety switch
The machine can only be engaged when the cover is completely locked
as the safety switch fitted to the bowel below the hinge of the cover
blocks all processing functions when the cover is open.
NOTICE Zero speed monitoring!
The cover can only be opened after the motor shaft is standing still. This
safety equipment is not allowed to be removed.
Cover
The cover locks the bowl. A silicone seal in the cover seals the bowl in a pressure-tight manner. A
safety mechanism prevents the machine from being switched on when the cover is open. A safety
switch scans the cover to check whether it is in the open or closed condition.
The cover is equipped as follows:
• Mixing baffle
• Energy and agent tree
• Automatic cover opening
• Process connection and loading
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IMPORTANT
Cover safety interlock
NOTICE
The cover and its latches can be opened only when the drives stand
still, the product temperature is below 95 °C, the product vessel is
unpressurised and the mixing baffle is in the right position.
Mixing baffle
The shape of the mixing baffle is adjusted with respect to the wall of the bowl. The mixing baffle
supports churning of the product by scraping the bowl and the cover clean and putting the product
in the centre of the bowl.
The mixing baffle is drived by a special motor.
Before opening the cover the mixing baffle must be brought to a particular position. This Position is
automatically achieved in a normal operating mode. Right after the cover is closed, it cannot be
immediately opened. First, the mixing baffle must be once switched on.
5.3.5 Electrical engineering
NOTICE Description of assembly groups of the electrical system
Partially, the assembly groups falling under the category of electrical

systems have been described in other parts of this documentation in
accordance with their function.
The electrical equipment conforms to the VDE guidelines 0133 and IEC 60204-1. The switching
cabinet and the machine are pre-wired and ready for connection and conform to protection class IP
54.
The mains connection to the switching cabinet must be laid and connected by a locally certified
electrician in accordance with the circuit diagrams. The installation of the motor, control and
pneumatic lines is included in the scope of supply of the UM 130.
CAUTION Do not clean using splash water
The machine has moisture sensitive assembly parts. Splashing water

on the motor or switching cabinet or washing them with rinsing solution
is not allowed.
Controlling
The regulation and monitoring of the equipment are carried out by an electric control system with
an integrated operator panel. The manual operating is carried out using the keys on the operator
panel.
5.3.6 Vacuum system

The UM 130 is fitted with a vacuum system. The vacuum system prevents or reduces air inlets in
the product and counters oxidation of the product.
The vacuum system consists of the vacuum pump, the connection on the product container lid and
the vacuum hose to connect the pump to the lid.
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NOTICE Reduced suction capacity
Under-pressure in the intake line and higher temperatures reduce the

suction capacity just as counter-pressure at the output of the vacuum
pump (pabs > 1.1 bar)
CAUTION Do not allow the pump to operate when it is dry
The missing working liquid leads to damages on the vaccum pump.

Provide always the sufficient quantity of the working liquid for the pump.
Do not allow the pump to operate when it is dry.
The vacuum equipment prevents or reduces the oxidation and air pockets in the product and
enables a flash cooling of the product.
The vacuum device with the aeration valve and vacuum valve as well as the vacuum controller with
pressure transducer are vacuum equipment components.
The vacuum control system switches off the vacuum pump after the preselected pressure is
achieved. If the selected pressure goes beyond 50 mbar, the vacuum pump switches on again.
The vacuum pump generates the vacuum through a rotating liquid ring. The liquid ring sucks in the
gas, thickens it and discharges it through the pressure branch. At the same time some liquid is
carried along. This liquid loss must be continuosly replenished.
The input water (free of foreign substances) temperature as that of a working liquid should be from
5 ° C to 15 ° C (41 ° F to 59 ° F).
The originatig compression heat is drained out and the sliding seal ring is lubricated by the working
liquid.
5.3.7 Steam supply
a Double jacket water and steam (up to 2 bar over-pressure)
WARNING Risk of bursting
A safety pressure relief valve prevents non-permissible high pressure

build-up in the double jacket. This safety valve is set to the permissible
pressure ex-factory (see machine data). Steam escaping from the
safety valve must be led away without restriction.
Do not close the safety valve.
The bowl is fitted with a pressure-tight double jacket (P ü=max. 2 bar (28,4 PSI)) for indirect heating
or cooling. Depending on the version, the heating substance is steam that is delivered from the
steam transfer station or the customer side steam processing.
The steam condenses on the walls of the bowl and transfers its heat energy to the product across
the bowl. The condensation that is generated is automatically drained through a continually working
condensate drain.
Cold tap water or water from the cooling tower can be used as the cooling agent. The control of
water / steam and double jacket discharge takes place via the operating panel, OP.
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1 Compressed air 4 Quick discharge

2 Steam 5 Cooling water drain
3 Cooling water 6 Condensate
5.4 Safety equipment

Security against Security provided by
Exceeding of the permitted Safety valve

pressure in the vessel
Rotating working tool when the An electronic motor monitoring system carries out the standstill
cover is open monitoring.
Opening of dosing or drain cock Manometer

in case of over-pressure in the Pressure switch
container
(with container pressure pue>0 bar the dosing and drain cocks are
automatically locked.
Over-pressure in the double Safety valve

jacket
Opening of dosing or drain cock Temperature sensor with two measuring resistors
in case the temperature > 95 °C Resistor 1 in the safety circuit „Fixed value controller“ (at a
(200 °F) in the container temperature > 95 °C (200 °F) in the container the dosing and drain
cocks are locked automatically.)
Resis tor 2 in the PLC (switching off the heating equipment when the
target value is exceeded)
Switching on processing End switch at the bowl hinge; scanning of „Cover closed“
functions when the cover is open
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5.4.1 Aeration
The lift check valve mounted on the cover has been adjusted ex-factory in such a manner that the
permissible pressure (“Machine data [? 23] “) in the interior of the bowl may not be exceeded.
WARNING Risk of bursting
Damage or impurities in the lift check valve can lead to the risk of a
bursting.
Operate the machine only with an lift check valve that has been properly
fitted and is clean and intact. Take care that at the output of the lift
check valve there is always an unhampered discharge. The output line
must not be closed or narrowed. Do not install any additional discharge
lines on the lift check valve.
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6 Installing, commissioning and decommissioning
6.1 Transport
WARNING Use a suitable means of transport
The machine has considerable weight.

In order to prevent accidents when working and risk to health when
transporting the machine, please use aids such as carrying straps,
transport rollers or platform carriages.
During transport of the UM 130 please pay attention to the following points:
• Lift the UM 130 only at the machine frame.

• Do not use the bowl to lift it.
• Do not use any handles to lift it.
• Do not use the mixing baffle to lift it.
• Tighten the conveyor belts in such a manner that the bowl and the cover are not loaded.
6.2 Installation
Place the UM 130 on a hard and level surface. Separate mounting of the UM 130 is not necessary.
IMPORTANT
Installation must be carried out only by specialists
NOTICE
All measures required for the installation and initial commissioning must
be carried out only by technically qualified and certified personnel. This
applies especially to all electrical work.
Please pay attention to the following points:
• Please read the Operating Instructions, particularly the Chapter Safety Instructions [? 12] .
• Remove any foreign objects from the bowl.
• Before connecting the machine to the mains supply please check that the electrical values
are suitable for operation of the machine.
• Connect the power supply line.
6.3 Commissioning
6.3.1 Functional checks

The basic functions of the UM 130 have already been checked at the factory prior to delivery.
However, under certain circumstances it is possible that the machine may have got damaged in
transit during its transport. In order to detect these well in time, the UM 130 should be subjected to
functional checks. Moreover, the functional checks subsequent to commissioning provide
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information regarding the effects of the power and medium supplies on-site. The functional checks
cover also other faults arising on account of local conditions and functional limitations well in time.
When carrying out the functional checks the sequence listed must be complied with and executed
right up to the last step. Only in this manner can the functional checks be completed successfully.
a Preparing for functional checks

Before the UM 130 is subjected to the respective functional checks, the notes and instructions on
handling given below must be followed.
• Please read and follow the Operating Instructions, specially the chapter Safety Instructions
[? 12] and the section on Commissioning of this chapter.
• Please ensure that the connections of the supply lines are secure and proper. Check the
water supply lines to ensure that there are no leakages.
WARNING Risk of damage
Remove all loose parts from the bowl!

Loose parts can possibly pose risks both for human beings and the
machine when it is switched on.
• Remove any foreign objects from the bowl.

• Place the tool over the motor shaft (Operating: Mounting / Dismounting of attachments and
inserts) [? 44] and close the cover.
b Direction of rotation check

The direction of rotation has been already checked during the trial run before the delivery of the UM
130. The machine must be connected to the mains with the following phase sequence L1-L2-L3
(clockwise rotation). If after re-commissioning a drive it has another direction of rotation as given in
the table below, then the polarity of the mains supply phases must be changed.
DANGER Dangerous working voltage
If it is necessary to change the polarity of the mains supply, this must be

carried out only by electrical technicians.
Electric shocks hazard.
Electric works must be carried out only by skilled electrical technicians.
The connections to the motor must be changed only when after replacing a motor, gear drive or a
pump the direction of rotation needs to be corrected in accordance with the following table.
To check the direction of rotation, remove the working insert from the motor shaft, close the cover
and lock it. Allow the individual drives to run only for a very short time. The direction of rotation in
the following table is always specified viewing the machine from above.
Drive Where to check? Direction of rotation Arrow up
Main motor Clear view screen below the base of Clockwise rotation Bearing bracket
the bowl
Gear drive Below the connecting flange Anti-clockwise rotation Fan hatch
motor
Vacuum pump Fan wheel at the motor Clockwise rotation Fan hatch
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c Test run
In order to ensure that no damage has occurred during the transport and installation of the UM 130
a test run should be conducted immediately after the UM 130 has been installed.
Open the ventilation valve and check on the manometer whether the machine is
unpressurised.
Open the cover.
Tighten the cutter with the supplied spanner.
Fill the bowl up to 2/3 with warm water (about 50 °C/122 °F).
Close and lock the cover.
Close the ventilation valve.
Select the vacuum level of 400 mbar on the OP operation unit in the manual mode, pabs
= 400 mbar = 60% vacuum.
Switch on the vacuum pump. Read the vacuum level on the OP display. The vacuum
pump switches automatically off, after the prescribed vacuum level has been reached.
Switch on the mixing baffle for mixing.
Switch on the main motor and allow it to run for 5 minutes. The vacuum check is
successful if the vacuum with the machine running falls less than 50 mbar within 5
minutes.
Open the ventilation valve in order to compensate the pressure in the machine.
Check on the manometer whether the pressure in the machine is adjusted to the
ambient pressure. Open the cover.
Tilt the container and empty it.
d Functional check for extracting a vacuum

Before providing the vacuum check, make sure that the UM 130 is connected correctly and the
tools are inserted appropriately.(Mounting / Dismounting of working inserts) [? 44] .
CAUTION Emerging product
Due to high pressure differences the product can emerge when the
product container is opended. Before opening the cover the pressure in
the product container must be adjoined to the ambient pressure through
the ventilation cock.
Do not open the machine, if an overpressure or negative pressure
prevails there.
If the UM 130 was ordered without a vacuum pump, then a vacuum pump must first be
connected to the UM 130.
Fill the bowl up to ¾ with warm water (about 50 °C/122 °F).
Close and lock the cover.
Select the vacuum level of 400 mbar on the OP operation unit in the manual mode.
(pabs = 400 mbar = 60% vacuum)
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Read the vacuum level on the OP display. The vacuum pump switches automatically off,
after the pre-selected vacuum level has been reached.
Switch on the mixing baffle for mixing.
Switch on the main motor. Allow the machine to run for 5 minutes. The vacuum check is
successful if the vacuum with the machine running falls less than 50 mbar within 5
minutes.
Switch off the main motor and mixing baffle drive.
Open the ventilation valve in order to compensate the pressure in the machine.
Empty the machine.
e End functional checks

At the end of the checks remove all tools and other equipment objects not belonging to the
machine. Wipe the outer surfaces of the UM 130 dry.
6.4 Storage, utilisation
6.4.1 Storage
In order to maintain the functionality of the UM 130 the following points must be observed during
storage:
• Store the machine in a closed room.

• When possible, the premises must be clean and dry.
• The storage temperature should not lie below 0 °C / 32 °F and should not exceed 50 °C /
122 °F .
• Protect the machine against dust using suitable packing material.

• Liquids in lines and container lead to bursting of the lines under frosty conditions
• For longer storage periods, place a collection container under the machine in order to collect
any liquid medium being discharged.
• If the machine is stored for a short period in an open space, it must be placed on a solid and
level base and protected from the impact of atmospheric conditions.
6.4.2 Disposal
During the course of disposal, various materials and substances must be separated from each
other. Information regarding the disposal of hazardous substances is to be taken from the relevant
data sheets of the respective manufacturers. During disposal substances may be discharged,
which can be hazardous for human beings. Safety tips and legal requirements pertaining to
substances that could be a source of risk for human beings, the environment and the machine are
also provided in the data sheets of the respective manufacturer.
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7 Operation
7.1 Arrangement and function of the operating elements

The UM 130 is operated with the help of the touch-screen panel OP 177 B. The operating condition
of the machine can be observed via the screen of the operating device. One can influence the
process flow directly simply by touching the buttons and input fields.
Key Description Function
Scroll key Scrolls to the next image or to the other functions
Reset key Reset a program that has terminated in the stop

status
Copy Copies the current program. For this purpose enter a

new program number (target).
Copy program step Copies the current program step and inserts it.
Delete program step Deletes the current program step.
Save Saves the program
Delete operation messages Deletes the operation messages.
Delete alarm messages Deletes the alarm messages.
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Key Description Function
Operation messages buffer Display of the operation messages.
Fault messages buffer Display of the fault messages
Current operation messages Display of the current operation messages.
Current fault messages Display of the current fault messages.
Time synchronisation Synchronisation of time and date.
Display Selection of the display.
Programme Program selection.
Report picture Display of report picture
System Display of system functions
Motor Main motor RPM 1
Vacuum Switches the vacuum pump On or Off
Automatic start-up Starts the automatic operation
Mixing baffle drive Switches the mixing baffle drive on or off
Acknowledge Confirm input
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7.2 Description of the operating panel
7.2.1 Operate the touch elements

Touch elements are touch-sensitive operating elements on the screen of the touch panel such as,
for example, buttons, input fields and message windows. The operation does not basically differ
from that of pressing conventional keys. The touch elements are operated by touching them with
the finger.
CAUTION Damage to the plastic surface
Do not use any sharp or pointed objects to operate the touch screen.
The surface gets damaged by using pointed or sharp objects.
Use only the finger to operate the touch panel.
WARNING Triggering of unintended functions
If more than one touch element is touched simultaneously then

unintended functions can get triggered.
When operating the touch panel please take care to ensure that always
only one point on the screen is touched.
Do not touch multiple touch elements simultaneously.
7.2.2 Operator menu

Num eric keyboard
The touch device automatically displays a numeric screen
keypad for entering numeric values as soon as you touch an
entry field.
<ESC> Deletes the entire entry and closes the keypad
<BSP> Deletes the decimal place in front of the cursor
<+/-> no function
<;> no function
The cursor can be moved with the <arrow keys> .
Enter numeric values via the entry buttons of the screen
keypad. If a value is already in the field, then it will be deleted
when entering the first character.
Once you start the entry you cannot leave the field until you
either confirm or cancel the entry.
Characters entered are right justified. When entering a new
character all previously entered characters are shifted one
position to the left.
Invalid characters are rejected and an error message is
displayed. If the maximum possible number of characters is
exceeded, then the last entered character will be overwritten.
With <ENTER> you confirm the entered value, with <ESC>
you cancel the entry. In each case the window closes.
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Alpha-numeric keyboard
The touch device automatically displays an alpha-numeric
screen keyboard for entering alpha-numeric values.
Operable keys of the screen keyboard are spatially
emphasized, non-operable keys are displayed as simple
surfaces.
When concluding the entry the keyboard disappears
automatically.
Start screen
This screen appears after switch-on.
Via the keys F9 to F14, it is possible to branch into the screens
listed below.
F 9 = Display
F10 = Programme
F11 = Controller
F13 = Messages
F14 = System
Display
Select the mode of operation on the top left:
STOP
manual
automatic
CIP
White fields are display fields (e.g. actual values) yellow fileds
are variables, i.e. you can enter the target values in these
fields. By the means of the key <Temp.VMC> you activate the
temeprature hold device for direct or indirect heating.
By the means of the key <Vacuum> you activate the mode
switching off the vacuum pump by falling or rising temperature
(See additionally arrow icon on the key)
The arrow icon scrollt to the next image.
Programme
The program number and the desired number of batches are
specified in this image.
If the program selected has been assigned a name / title, then
this is shown in the display line.
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Program input
The program and step numbers to be edited are input here.
The input of numbers is confirmed with ENTER.
The step time and the target values are entered here. The
input is confirmed with ENTER.
The arrow key scrolls to the next image.
A step time of „0“ is interpreted as the program end.
Here you select the switching function of the current

programme step by scrolling and select in a scroll bar.
Here you select the next switching function of the current

programme step.
After the step has been saved pressing <Diskette key> the
message „Step is saved“ appears on the display. The step
number is automatically increased by 1.
As described above the further programme steps will be
entered.
The <Diskette key> saves the programme step.
The arrow icon scrollt to the next image.
Messages
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System
The keys 1, 2, 4 - 9 can be pressed directly. The keys 3, 11
and 12 require entering the password.
Key 1 = jump back to start image
Key 2 = Chose language
Key 3 = Password request
Key 4 = Options
Key 5/9 = Contrast
Key 6 = Touch calibration
Key 7 = Cleaning image
Key 8 = Weighing
Key 10 = LED Check
The key 11 = Synchronisation of time and date
Key 12 = End run-time
Clean touch panel.
Options
Different option values can be specified here.
The blue fields require entering the password. As soon as the
access key has been entered, these fields get yellow.
Password processing.
The following levels have been programmed:
>9< End run-time
Password editor
>8< Change regulator parameters
Delete messages
Synchronise time / date
>5< Change parameter options
>1< Program editor.
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Operation 43
HV A.0
Synchronisation of time and date
Delete programme.
Copy programme.
Delete Step.
Insert Step.
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Operation 44
HV A.0
Operation message buffer
Fault messages buffer
7.3 Operation
7.3.1 Installing / Dismantling working inserts
cutting edges
cutting edges.
the tools.
WARNING Insert the working tools properly
Working tools that are not inserted and installed correctly can lead to
considerable damage of the machine and the tools. The bevelled
polished area of the knife must always point to the base of the
container.
The wing nut must always be tightened.
NOTICE Use only sharp cutters
Cutters that have become blunt can affect the working process
disadvantageously. Thus, the product would not be cut properly and
thus, under certain circumstances, changes its structure and
appearance.
Assembling and mounting the cutter insert:
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The sequenced described must be maintained when assembling the cutter insert. The bevelled
polished area of the knife must be positioned to the base of the bowl so that the required material
agitation is achieved.
The knife point of the knife (1) must be installed horizontally or inclined to the base of the bowl (2).
After the cutter insert has been assembled, this is tightened to the hexagon bolt using the fastening
nut in a clockwise direction using the special spanner that is provided.
NOTICE Sequence of the slanted rings
The slanted rings (3) determine the inclination of the knife. They have
been numbered consecutively from the bottom to the top.
Cutter insert
When assembling the cutter insert make sure that the bevelled polished area of the knife is
positioned to the base of the bowl so that the required material agitation is achieved. The knife
point of the knife must be horizontal or inclined to the base of the bowl.
After the cutter insert has been assembled, tighten the fastening nut to the hexagon bolt using the
special spanner that is provided.
NOTICE Sequence of the slanted rings
The slanted rings (2 and 4) determine the inclination of the knife. They
have been numbered consecutively from the bottom to the top.
When assembling the cutter inserts the outer adges are to be positioned aligning to each other.
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Knife alignment:
1 Surfaces are flush 2 the lowest point
Stacking with 2 cutters: Stacking with 3 cutters:
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Operation 47
HV A.0
7.3.2 Mechanical and thermic product processing
Mechanical processing
Product mechanical processing, i. e. chop, mix, emulsify, etc.
Switch on the mixing wing.
Select the main motor speed on the OP.
Switch on the motor
Thermic processing
Process the product thermically.
Select the temperature on the OP.
Switch on the mixing wing.
Switch the mixing baffle on.
Open the steam nozzles of the steam valve to heat directly the product.
After the required temperature has been achieved, the function switches off
automatically.
Hold the temperature. Refer to the indicator on OP 177 B
Open the double jacket steam valve to heat the product indirectly or to hold the
temperature.
After the preselected temperature has been achieved, the function switches off
automatically.
Open the double jacket cooling water valve to cool the product indirectly or to hold the
temperature.
After the preselected temperature has been achieved, the function switches off
automatically.
Select the water amount on the OP and open the valvels for the water dosing to cool the
product directly.
Select the cooling water amount on the OP to cool the product.
7.3.3 Working under a vacuum

Processing products under a vacuum enables products that are almost air-free, substantially
reduces germ formation and leads to better and smoother consistency. A prescribed filling quantity,
e.g. in tubes, is more practical without air ingress.
When working under a vacuum it must always be noted that changes in the pressure conditions
lowers the boiling point of the product. The effect of the bubbling is further fortified by the running
working tools. For this reason, first close the ventilation cock, if required create the vacuum and
then allow the working tools to run.
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CAUTION Suction of product constituents
If, when switching on the vacuum pump, the working tools also start
running with high speed at the same time, the product can get suctioned
into the vacuum system and damage the vacuum pump (not covered by
the guarantee)
When the vacuum reaches a desired level, normally between 60 and
80%, after a short time, the pump must be switched off. The cocks are
closed. Only then is the motor switched on.
NOTICE Emerging white oil
The vacuum manometer is filled with white oil for damping. In the event
that the white oil leaks out, the filling screw on the manometer must be
tightened carefully.
7.3.4 Cleaning
NOTICE Clean the machine after completion of production
After the end of production the machine must again be brought to a

clean condition having only a low level of germs. A clean machine is the
basic requirement for each production. Thorough cleaning enhances the
life span of the machine and seals.
• The addition of commercially available rinsing agents reinforces the cleaning effect.
• Rinse out the bowl in flowing water to remove product residues that are stuck loosely. Clean
the production environment using water in accordance with the given conditions.
• Loosen impurities that are stuck persistently using a brush or a scraper.

• Clean the machine surfaces only with a moist cloth.
The cleaning must be done prior to disinfection since the smallest of product residues have a
negative impact on the disinfection. Thus, cleaning is not a substitute for disinfection under any
circumstances.
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Troubleshooting and fault elimination 49
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8 Troubleshooting and fault elimination
8.1 Details for STEPHAN Service and customer services

If you should have any questions or problems when troubleshooting and rectifying faults, our
customer service department would be more than pleased to help you.
We require the following data when queries are made:
• the type of machine

• the serial number of the machine
• customer number
These details avoid inquiries through our service department and speed up the processing. These
details can be obtained in the chapter Machine information and can also be read-off from the name
plate of the machine.
In case of queries regarding your machine, we are pleased to be at your service:
Stephan Machinery GmbH
Service division
Stephanplatz 2
31789 Hameln
Telephone : 05151/583-0
Telefax: 05151/583-110
E-mail: Vertrieb@stephan-machinery.com
Service@stephan-machinery.com
8.2 Notes on fault rectification

All maintenance and repair activities must be carried out only by qualified technical personnel. This
applies especially to all electrical work.
Hazard through electric shocks.

All the work on electrical systems should only be carried out by certified
electricians.
DANGER Energy guided despite the mains disc onnection
The condensers installed in the frequency inverter remain loaded 5

minutes. There is a danger of life when touching the alive assembly
parts. Do not open the machine until 5 minutes after switching off the
supply voltage.
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WARNING Mechanical hazards
Hazards through the incorrect application of mechanical components.

All maintenance and repair work carried out on the machine may only
be carried out by professionally suitable and trained personnel.
cutting edges
cutting edges.
the tools.
8.3 Faults in the vacuum pump

Fault Cause Rectification
Intake volume of the pump Intake line leaky Check the hose connections and
not adequate tighten them.
If required, replace the seal.
Suction volume flow reduction as Increase the flow of fresh liquid

a result of increased operating
Increase the flow of cooling liquid
liquid temperature
Deposit formation in the pump Clean the pump
The pump makes squeaky The pump works with very low Connect cavitation protection
noises suction pressure
(Cavitations) Very high operating temperature Increase the flow of fresh and / or
cooling liquid.
Liquid discharge between Seal leaky Replace the seal

the motor and the pump
Increased liquid discharge at Flow of fresh liquid too high Reduce the flow of fresh liquid
the gas outflow
Flow of waste liquid too low, Check the overflow for adequate
overflow blocked passage and, if required, remove the
blockage.
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8.4 Faults in the switchgear

Fault Cause Rectification
The plant does not switch on The main switch is off Put on the main switch.
The EMERGENY-STOP button is Pull the EMERGENY-STOP

pressed. button.
The safety switch is activated. Close the cover.
The operating voltage is incorrect Check the operating voltage.
The controller is defective Check the controller.
The Simatic backup battery is Replace the battery.

discharged. (Configuration-
dependent)
Individual functions do not The over-current protection has Reset the over-current protection.
operate triggered. Have the switchgear checked by
qualified electricians.
Fault indications on the display of The motors or the end switches After rectifying the fault,
the OP are faulty. acknowledge the indication with
the ACK button of the OP.
8.5 Faults in the drive motors

Fault Cause Remedy
The motor does not start. The supply line is not connected Check the voltage at the supply
or connected incorrectly, e.g. line. Rectify the loose contact.
loose contact.
The fuse has blown. Insert a new fuse (check the fuse
rating).
The motor protection has got Allow the motor to cool,

triggered. switch on the motor protection,
check the adjustment of the
motor protection.
The motor protection does not get Have it checked and rectified by
activated. The controller is qualified technical personnel.
defective.
The motor does not start The machine is overfilled. Check the maximum filling
smoothly. quantity
The voltage or the frequency Rectify the circuit.

deviate considerably from the
nominal values at least when
switching the motor on.
(Machine data [? 23] )
The fuses blow or the motor The winding is defective The motor must be sent for
protection gets triggered repair.
immediately.
There is a short-circuit in the Rectify the short-circuit.
motor or the lines (cables).
The motor has an earth fault or a Have it checked and rectified by

winding short-circuit. qualified technical personnel.
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Fault Cause Remedy
The motor runs in the wrong The motor has been connected Interchange 2 phases.
direction of rotation. incorrectly.
The motor has been connected Have it checked and rectified by

incorrectly. qualified technical personnel.
The motor gets very warm. (can The mains voltage deviates by Ensure that the mains voltage is
only be determined by more than 5% from the rated correct.
measurements) motor voltage. (Machine data
[? 23] )
Higher voltages have an
unfavourable effect on multi-polar
motors having a large number of
poles, since in such motors, even
at normal voltage, the current at
idling speed is close to the rated
current.
The motor is overloaded Reduce the load by using lower

fill quantity.
Rated duty is exceeded Observe the permissible

operating time.
The rated duty is exceeded. Adjust the rated duty to the

If, for example, the motor prescribed conditions. Involve
becomes too warm as a result of Stephan Service to determine the
very frequent switching correct drive system.
operations, then it is not enough
just to use a bigger motor, since
the same conditions would occur
here also
The cool air quantity is too low. Ensure unhindered inflow and
For example, the cool air paths outflow of the cool air. Clean the
are blocked (dirty). cooling fins.
Cool air is pre-warmed. Ensure availability of fresh air and

repair the fan.
The motor hums. The motor has been connected Have it checked and rectified by
incorrectly. qualified technical personnel.
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Servicing and maintenance 53
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9 Servicing and maintenance
9.1 Details for services

Our customer service department is available if queries or problems arise during service and
maintenance work. Information on services is provided in the chapter on Troubleshooting and fault
elimination [? 49] .
9.2 Safety measures
Hazard through electric shocks.

All the work on electrical systems should only be carried out by certified
electricians.
cutting edges
cutting edges.
the tools.
After every cleaning procedure the connected bows and hoses have to be mounted so that the
steams can be harmless discharged.
9.3 Servicing and maintenance schedule
9.3.1 Daily inspection during operation

Assembly group / part Action Result / Measure
Overall machine Pay attention to any unusual noise Excessive noise generation or
generation unusual noises often indicate that
defects are starting to take place. If
such symptoms are found then a
specialist must be involved for
further assessment.
Working tools Check working tools for bluntness Replace working tools. Give the
and damages. cutters for regrinding.
Cover Check seals for damage Replace the damaged seal.

In addition, the following must be paid attention to for the vacuum unit:
Vacuum unit Pay attention to any unusual noise If required, connect the cavitation
generation protection or reduce the operating
liquid temperature.
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9.3.2 Weekly Maintenance
NOTICE Carrying out maintenance work
These maintenance measures must be performed by specialists.

Please observe the description of the maintenance measures.
Safety equipment Inspection Inspect the cover, insulation and protective

grates for damage. Check that the warning
and instructions labels are legible.
Inspection Check the EMERGENCY STOP switch for

its functionality.
Inspection Check the safety valve for impurities and

clean it, if necessary.
Machine in general Inspection Check all accessible assembly groups for

visible signs of damage.
Inspection Pay attention to any unusual noise

generation during operation.
Inspection Assess the state of hygiene of the assembly

groups, especially the surfaces coming into
contact with the product
Operating elements Inspection Check the screens and other operating

elements for damage and faulty display
Check lamps and LEDs to see that they are
working.
Shaft seal, Dismantling, inspection Dismantle, clean and check for damages.
main drive Replace the damaged shaft seals.
Assembly Grease and assemble.
Cover seal Cleaning, inspection Dismantle it, check for damages and replace
damaged cover seals.
Tools Inspection Check cutting tools for bluntness,

deformation and breakages
Inspection Check the remaining tools for deformation

and breakages
Steam transfer station Cleaning, inspection Check the steam filter for impurities. Replace
very dirty and worn filters.
Depending on the configuration variant
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9.3.3 Semi-Annual Maintenance
NOTICE Carrying out maintenance work
These maintenance measures must be performed by specialists.

Please observe the description of the maintenance measures. The
measures described should be carried out as part of the routine semi-
annual maintenance.
Vacuum unit Remove precipitation of In case of hard water, open the

scales in the pump. pump and remove the scale
precipitation.
9.4 Specific maintenance instructions
9.4.1 Sharpening the cutter
cutting edges
cutting edges.
the tools.
Only sharp ground cutters may be used. Blunt cutters must be reground on a special knife grinding
machine. In order to prevent the warming up and glowing of the cutters, use wet grinding. The
grinding burr must be removed in the wet condition using a water stone.
NOTICE Regrinding
If there is no specialised grinding service division in the operating area,

you can send the cutters to Stephan for grinding.
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9.4.2 Maintenance of the shaft seal
1 O-r ing 5 Receiving bush

2 Cylinder sleeve 6 O-r ing
3 Threaded pin 7 Shaft sealing ring
4 O-r ing 8
Dismantling the main shaft seal

Operational steps:
• Remove the working tools

• Loosen the nut (pos. 8)
• Remove the rec eiving bush, pos.5
• Loosen the screw, pos. 3
• Remove the cylinder sleeve, pos. 2
Prior to re-assembly, the following parts should be replaced.
• O-rings, pos. 1, 4 and 6

• Shaft sealing rings, pos. 7
Prior to re-assembly, the following parts should be checked for abrasion and damages.
• Cylinder sleeve, pos. 2
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Mounting the main shaft seal
• Mount the pos. 1, 4, 6, 7 with the receiving bush, pos. 5

• Push carefully the cylinder sleeve into the seals to calibrate them. The seal lips should not
be folded or damaged.
• All spaces between the seals must be filled in with grease (ref. to appendix for
recommendations)
• Remount the receiving bush, pos. 5, with the seals into the machine and fasten with the pos.
8.
• Mount the cylinder sleeve, pos. 2, with the O-ring, pos. 1, and push them onto the motor
shaft of the main drive. When proceeding with this, the following factors must be taken into
consideration:
i. - the seal lips should not fold
ii. - the threaded pin of the cylinder sleeve must enter the corresponding drilled holes
in the motor shaft.
• Fasten the cylinder sleeve, pos. 2, by means of the threaded pin, pos. 3. The pin must enter
the corresponding drilled holes in the shaft. When assembled, the threaded pin does not
protrude from the cylinder sleeve.
9.4.3 Maintenance of the gear shaft seal
1 Mixing baffle 10 Shaft sealing ring double lip

2 O-ring 11 Shaft sealing ring
3 O-ring 12 Spacer ring
4 O-ring 13 Reception sleeve
5 Cylinder sleeve 14 Screw
6 Screw 15 Screw
7 Proximity switch 16 Nut
8 Sheet steel angle Z form 17 Scr ew
9 Washer
Dismantling the drive shaft seal:
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• • Remove the screw Pos.14.

• • Remove the screw Pos.6
• • Remove the mixing baffle Pos. 1 and, if necessary, replace the barrel casing Pos. 5 and O-
ring Pos.2 on the mixing baffle.
• • Unscrew the nut Pos. 16.

• • Remove the reception flange Pos. 13.
• • Remove the screw Pos.17.
• • Remove the cover washer Pos.9.
• • Remove the shaft sealing ring Pos. 10 and 11 and spacer sleeve Pos. 12.
Mounting is done in reverse sequence, and when doing so the following parts should be replaced:
Pos. 2, 3, 4, 10 and 11
9.4.4 Lubricant change of the mixing baffle drive

The mixing baffle gear is provided with the required quantity of lubricant ex-factory. The
maintenance of the mixing baffle gear is limited to regular checks of the lubricant at the inspection
glass and lubricant change about every 2 years.
The intervals of lubricant change depend on the operating temperature, the number of hours of
operation and the operating conditions. For harsh operating conditions, such as, for example, high
humidity and large temperature variations we recommend shorter intervals for lubricant change.
NOTICE Recommended lubricant
We recommend gear, circulation or bearing lubricating oil conforming to

DIN 51517 Part 3 ISO VG 220 for ambient temperatures ranging
between 0-40°C (32-104°F).
IMPORTANT
Anti-friction bearing with grease filling
NOTICE
In the case of anti-friction bearings with grease filling the grease must
be replaced when changing the lubricant. The quantity of grease must
be filled up to one third of the hollow space between the rolling
elements on the input side in the case of fast-moving bearings and in
the case of slow-moving bearings, up to two thirds in the gear and on
the gear power take-off side.
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9.4.5 Drive change for the end tipping

The dead weight of the bowl moves this in its vertical position. In some situations there is however
a danger that the bowel can accidentally tilt forwards (horizontal bowel, open cover).
Before the linear drive can be removed, the the bowl must be secured in its position. The securing
is carried out in an horizontal position, in both swivelling directions and when this is a vertical
position, then only against further movements. The cover hood of the motor must have been
removed before carrying out the supporting.
1 Front safety supports

2 Rear safety supports (under compressive load)
3 Motor cover (Dismantle)
In the vertical position the bowel is secured between the frame and the motor as illustrated in
position 4.
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1 Bowl 4 Clamping element

2 Linear drive 5 Bolts
3 Lever arm 6 Retaining ring
Assembly sequence, electrical and mechanical:

The assembly should only be carried out by electrically and mechanically trained personnel.
• Support the bowl (Pos. 1) as described, previously remove the motor cover,
• Electrically disconnect the linear drive (Pos. 2), note the line / clamping allocation,
• dismount the front retaining rings (Pos. 6),
• Check the bowl support, warn personnel in the surroundings,
• Press the bolts (Pos. 5) towards the back from the bore holes,
• Remove the linear drive (Pos. 1),
• insert the new linear drive (Pos.1) and connect the cable connection,
• Check the rotating field, one clockwise rotary field drives the piston rod out = tilt the bowl in
the direction of the emptying position,
• Press the bolts (Pos. 5) back in and safeguard using the retaining rings (Pos. 6),
• Remove the bowl supports,
• Remount the motor cover,
• End of the assembly.
Infrequent special cases:

If the bowl position is disabled during the tilting procedure or has been adjusted by other external
influences caused to the machine then the clamping element (Pos. 4) may have changed its
position. The clamping element must be readjusted in this case.
Mechanical assembly sequence:
The assembly should only be carried out by mechanically trained personnel.
• Support the bowl (Pos. 1) as described, previously remove the motor cover if possible,
• Mark the position of the clamping element (Pos. 4) and the lever arm (Pos. 3),
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• Loosen the clamping element (Pos. 4) according to the instructions (see the documentation),
• Move the bowl to its vertical position using the lifting gear,
• Drive-in the linear drive (position the bowl vertically)
• Return the lever arm (Pos. 3) and the clamping element (Pos. 4) back to the previously
marked axial position. The screws are tightened crosswise, equally and in several steps up
until the specified tightening torque (see table).
• Remove the bowl supports,

• Remount the motor cover,
• End of the assembly.
9.4.6 Linear drive

The „COMPAKT“ is an electro-mechanical sliding spindle drive for implementing a linear motion.
NOTICE Reliability
The drive works with a high degree of reliability, assuming that it has
been installed correctly.
a Mechanical connections
To fix the „COMPAKT“ there are fixing elements both on the housing and the end of the piston rod,
which are to be used for the mechanical connection of the drive.
(see dimensional drawing or dimensions specified in the graphic picture)
During installation it must be ensured that no radial and / or torsion forces can have an effect on
the piston rod. Mechanical blocking of the movement of the piston rod must be prevented, since
this can damage the drive. Electrical lines must be laid in such a manner that the possibility of
damage on account of crushing or tensile loads is ruled out.
b Electric connections
It is not permitted to commission the device without the controller being connected. The electrical
connections of „COMPAKT“ must be carried out by a certified electrician in compliance with
respective VDE guidelines. In order to protect the drive from overload, we recommend
corresponding protective circuits or the additional use of mechanical or electro-mechanical
components. The power on period specified is related to an ambient temperature of 20° C and this
gets reduced at higher temperatures
CAUTION Do not exceed the voltage!
Connection to a supply having a voltage exceeding the rated voltage

specified on the nameplate is not permitted. If your drive is equipped
with a brake, then this must be connected in accordance with the
description enclosed prior to commissioning the drive. An operating
without released brakes is not allowed and leads to the damage of the
device!
Operate the device only with the released brake and right voltage.
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Troubleshooting in case of fault:

If the drive is fitted with a brake then it must ventilate audibly when switching on the operating
voltage.
Check the supply lines using a voltage measurement instrument.
If the drive moves up to the safety end switch then the direction of the rotary field on the motor
cable must be checked and established as given in the circuit diagram. To re-commission the drive,
move the corresponding switch in the „+“ direction, move the piston to the centre position of the
stroke, and put the end switch back to its original position by turning it in the „-„ direction.
c Adjusting the end positions

A hexagon wrench key of size 4 is required to adjust the end positions.
The end positions may be adjusted by maximum 10 mm in the direction of stroke reduction, i.e. the
minimum dimension (2) of the drive may be increased by a maximum of 10 mm. and the maximum
dimension (1) of the drive may be reduced by a maximum of 10 mm. Further adjustment of the end
switch is not permitted.
The adjusting screws for the end positions are located at the front housing cover (3) of the device.
Turning the adjusting screws in the direction shown „-„ reduces the stroke and turning them in the
„+“ direction increases the stroke adjusted. With the help of the adjustment screw (1) the end
position of the position is adjusted in the drawn-out (extended) condition. With the help of the
adjustment screw (2) the end position of the position is adjusted in the drawn-in (retracted)
condition.
NOTICE Piston position
To adjust one adjustment screw the piston rod must be located at the
other end position.
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9.4.7 Mounting work on the cover
1 Washer 8 Washer
2 Thrust washer 9 Bolts
3 Bearing 10 Drive lever
4 Cover lever 11 Covering
5 Fit- in key 12 Retaining ring
6 Thrust washer 13 Lifting drive
7 Bearing 14 Bolts
Dismantling:
• Dismantle the gear and mixing wing.

• Close the cover. All further assembly works take place when the cover is closed.
• Depending on the configuration variant and latch type, dismantle the available pneumatic
cylinder
• Dismantle the covering (11)

• Remove the lifting drive bolts with safety elements (13) and take off the lifting drive.
• Dismantle the washer (1) and thrust washer on the rear side of the machine.
• Loosen and remove screws and pins on the cover lever (4).
• Bring the cover lever with the parts (5,6,7) into the marked position after turning it 120°. At
the same time, the shaft feather key should be aligned with the groove in the bearing. The
lever (4) can be pulled out of the machine forwards. Hammer it slightly out with a rubber
hammer hitting the machine rear side. If more force is required to accomplish this process
step, transmit all the forces only to the housing bush at the machine front side as well to the
shaft end of the lever (1). In no case the forces may be transmitted through the housing of
the cover mechanics. Pulling out the lever (4) the drive lever (10) can be taken out.
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Assembly:
• Clean and grease plentifully all parts.

• If the bearings (3 and 7) have to be replaced, both should be mounted with the groove to the
machine left side leaning at 30° downwards.
• Push the thrust washer (6) onto the lever axel (4) up to the stop collar and mount the feather
key (5) with the corresponding screw.
• The lever (10) is hold on the inner side of the mechanic housing before the bearing opening
and fitted, for this purpose, with the feather key groove. In this position the lever shaft (4) can
be mounted.
• Mount the thrust washer (2) and washer (1).

• Mount the screws and pins on the cover.
• Mount the bolts (9) with safety washer.
• Mount the thrust linear actuator on the bottom side. The maximum extended drive length (in
the electrically provided final position) must exactly fit the intake drilled holes in the housing.
If it is not the case, the drive final position must be correspondingly adjusted (Linear drive
[? 62] ).
• Mount the bolts (14) with safety rings (12).

• Set the closed final position of the thrust linear actuator. The measure “S” must be 8mm.
(See the image below)
• Mount the covering (11).

• Depending on the configuration variant and latch type, mount the available pneumatic
cylinder
• Open the cover and mount the mixing wing with gear.
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Setting dimension by the closed cover
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Spare Parts 66
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10 Spare Parts
10.1 Installation assembly group
10.1.1 Installation machine
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Pos. Designation Type Part No. Qty Dim. OI Other

311AG102 Motor 3C0040-04 Pc E
311AP701 Pneumatic cylinder ADVU-63-80-A-PA-R3 3H0079-10 Pc FTK001MUL E
311GS101 Limiting switch ENM2-U1Z RIW 3Q6011-24 Pc E
311GS103 End switch 3Q6006-53 Pc GBJ000ENG E
311GS121 End switch GC-U1 RIW 3Q6011-12 Pc E
311GS123 End switch GC-U1 RIW 3Q6011-12 Pc E
311GS701 End switch 3Q6006-06 Pc HKJ000ENG E
311GS702 End switch 3Q6006-06 Pc HKJ000ENG E
311MO103 Gear motor 400V, 50Hz 3C2131-02 Pc E
311MO110 Linear drive 400V, 50Hz, H250, 3H0051-15 Pc ELB002MUL E
F12kN
311MO120 Linear drive 400V, 50Hz, H250, 3H0051-01 Pc ELB002MUL E
F12kN
311MO801 Lubricant pump 3H0076-01 Pc E
311NR501 Non-return valve 3P0002-35 Pc EAJ001ENG E
311PI411 Pressure gauge 3P4004-03 Pc E
311PI501 Pressure gauge 3P4005-20 Pc ARJ000DEU E
311PR411 Pressure reducing valve 3P0017-52 Pc E
311PT501 Pressure transducer 3P4006-54 Pc JUJ000ENG E
311PU510 Vacuum pump V30-GRD-55 3H0011-01 Pc WSB000MUL E
311ST411 Condensate drainer SBP30HCV R3/4 3H4100-18 Pc SPA001ENG E
311TT101 Temperature sensor PT100 3Q2011-17 Pc E
311VA310 2/2 way valve 550 DN 32 3P0301-04 Pc E
311VA312 2/2 way valve DN25 3P0301-03 Pc E
311VA503 2/2 way valve 3P0301-02 Pc E
311VA510 2/2 way valve 3P0301-02 Pc E
311VA701 Throttle non-return valve DN6 MS/KST 3P0002-28 Pc E
311VA702 Throttle non-return valve DN6 MS/KST 3P0002-28 Pc E
311VA710 Non-return valve HGL-1/8-QS-6 3P0002-41 Pc FTD002ENG E
311VS402 Safety valve 3P0001-12 Pc E
311VS501 Non-return valve DN40 3P0002-96 Pc E
311VM 510 Sleeve tap 1/2 3P1010-04 Pc ANJ000DEU E
I09009
UM 130
Spare Parts 68
HV A.0
10.2 Machine assembly groups
10.2.1 Main drive

1 Centrifugal washer 3K1105-10 1 Pc E
2 Motor 3C0040-04 1 Pc E
3 Covering cap 3L0012-04 1 Pc E
I09009
UM 130
Spare Parts 69
HV A.0
10.2.2 Shaft seal, main drive

1 Bushing 3K0500-56 1 Pc E
2 O ring 3I0004-54 1 Pc E
3 O ring 3I0004-19 1 Pc E
4 O ring 3I0008-21 1 Pc E
5 Shaft sealing ring 3I0055-70 1 Pc E
6 Shaft sealing ring 3i0055-73 1 Pc E
I09009
UM 130
Spare Parts 70
HV A.0
10.2.3 Lid opening, assembly group

1 Feather key B14*9*120 3L2001-26 1 Pc E
3 Thrust washer 3K0506-38 1 Pc V
4 Bearing bush 3K0506-37 1 Pc V
5 Bolt 3K2522-52 1 Pc E
6 Lever arm 3G2001-39 1 Pc E
7 Bearing bolt 3K2593-11 1 Pc E
8 Linear drive 400V, 50Hz, H250, 3H0051-15 1 Pc ELB002MUL E
F12kN
9 Bolt 3K2522-39 1 Pc E
10 Washer 3K0214-12 1 Pc E
11 Limiting switch ENM2-U1Z RIW 3Q6011-24 5 Pc E
12 Linear drive, cover 3H0051-15 2 Pc E
opening
I09009
UM 130
Spare Parts 71
HV A.0
10.2.4 Lid latch

1 Covering cap 3L0034-16 1 Pc E
2 Flange 3H0079-15 1 Pc E
3 Pneumatic cylinder ADVU-63-80-A-PA-R3 3H0079-10 1 Pc FTK001MUL E
4 Pivot mount 3H0079-20 1 Pc E
5 Gear motor 3C2131-02 1 Pc E
6 Lid seal 3I0104-06 1 Pc V
7 Lid assembly 3B6351-06 1 Pc E
10 Pressure transducer 3P4006-54 1 Pc JUJ000ENG E
11 Pressure gauge 3P4005-20 5 Pc ARJ000DEU E
12 Non-return valve 3M1005-55 2 Pc E
I09009
UM 130
Spare Parts 72
HV A.0
10.2.5 Mixing baffle

1 Feather key C10x8x110 3S0281-11 1 Pc E
2 Mixing baffle 4D2049-03 1 Pc E
3 Nut M10 3K0200-31 1 Pc E
4 Scraper, bowl 3L5006-20 1 Pc V
5 Washer 3K0301-66 1 Pc E
6 Scraper, lid 3L5006-19 5 Pc V
7 O ring 2-220---34,52*3,53 3i0021-22 2 Pc V
I09009
UM 130
Spare Parts 73
HV A.0
10.2.6 Shaft seal, mixing baffle

1 O ring 2-249---123,42*3,53 3I0006-27 1 Pc V
3 O ring 88,57 x 2,62 3I0004-16 1 Pc V
4 Shaft sealing ring 55x72x10a 3I0059-05 1 0 V
5 Coil 60/71,8*11,5 3K0301-57 1 Pc E
6 Shaft sealing ring 55x72x10ia 3I0055-71 1 Pc V
7 Washer 90*2 3K0214-23 1 Pc E
8 O ring 2-224---44,04*3,53 3I0006-08 5 Pc V
9 Cylinder sleeve Di40xDA55xL101 3K0501-31 2 Pc V
I09009
UM 130
Spare Parts 74
HV A.0
10.2.7 Bowl, assembly group

2 Machine stand LBE 13/24 3S4016-05 1 Pc E
3 Linear drive 400V, 50Hz, H250, F12kN 3H0051-01 1 Pc ELB002MUL E
4 Bolt 3K2522-39 1 Pc E
5 Clamping element RF Clampex 200, 95x135 3S4008-06 1 Pc E
6 Switch segment 3K0717-08 1 Pc E
7 Lever arm 3G2001-23 1 Pc E
I09009
UM 130
Spare Parts 75
HV A.0

9 End switch GC-U1 RIW 3Q6011-12 1 Pc E
10 Bearing bush 3K0529-01 5 Pc E
11 Bearing bolt 3K2593-11 2 Pc E
10.2.8 Machine tool set, hollow edge knife

1 Centrifugal washer 3K1130-02 1 Pc E
2 Knife 3D0017-02 1 Pc V
3 Slanted ring 3K0329-03 1 Pc E
4 Slanted ring, top 3K0329-02 1 Pc E
5 Pressure ring 3K0310-55 1 Pc E
6 Nut 3K0015-06 1 Pc E
7 O ring 3I0004-48 5 Pc V
8 Screw 3K2040-08 2 Pc E
10.3 Accessories and additional Parts

-
I09009
UM 130
Affix 76
HV A.0
11 Affix
11.1 Specific lubrication substances
11.1.1 Shaft sealing rings
Type of lubrication grease mineral/synthetic

Suitable for Plain bearings and seals
Authorisation under the food regulation FDA-H1, EU
Operating temperature range approx. -30 to 140 °C
Worked penetration DIN ISO 2137 0,1mm 25 °C 215 to 245
apparent dynamic viscosity class S
Velocity parameter n [U/min] • D [mm] 2,5 x 105
Example: Klüber Paraliq GA351
Stephan Part No. 9S2035-02
11.1.2 Static seals - O-rings
Type of lubrication grease Silicone Grease

Operating temperature range approx. -50 to 150 °C
Worked penetration DIN ISO 2137 0,1mm 25 °C 220 to 255
apparent dynamic viscosity class S
Example: Klüber Paraliq GTE 703
11.1.3 Gear motors

Viscosity DIN51517 T3 ISO VG 220
Ambient temperatures 0 to 40 °C
Example: Oil Klübersynth UH1 6-220
I09009
UM 130
Affix 77
HV A.0
11.1.4 Hydraulics

Suitable for Hydraulic systems
Viscosity class 68 mm²/s at 40°C
10.2 mm²/s at 100°C
Example: Mobil-Arctic Gargoyle SHC 226
11.1.5 Vacuum pump
Classification DIN 51825/DIN51502 KTC E 2 R

Example: Anti-friction bearing grease Microgel Aero Shell Grease 16
I09009
UM 130
Service addresses 78
HV A.0
12 Service addresses
Main factory:
Stephanplatz 2
31789 Hameln
GERMANY
Telephone : 05151 / 583-0
Telefax: 05151 / 583-110
E- mail: Vertrieb@stephan-machinery.com
Service@stephan-machinery.com
Foreign subsidiaries
Sympak France S.A.R.L Stephan bvba Stephan Nederland B.V.
- Stephan Division -
ZAC du Madinet Sluis 11 Plesmanweg 15

Rue de Campanules 9810 Nazareth NL-7602 PD Alelo
77185 LOGNES BELGIUM NETHERLANDS
FRANCE phone +32 (0) 9 / 3 85 83 55 phone +31 (0)5 46 / 87 41 11
phone +33 (1) 64 80 54 30 fax +32 (0) 9 / 3 85 81 87 fax +31 (0)5 46 / 86 45 46
fax +33 (1) 60 06 74 14 info@stephan-belgium.be info@stephan.nl
sympak-france@sympak.com
Stephan Machinery GmbH & Co. Stephan UK Ltd. Sympak Inc.

Swiss sales representative PO Box 162 1385 Armour Boulevard

Gewerbehaus Tüfiwies Deeside Mundelein, IL 60060
Schickmattweg 8 CH5 3XS USA
8332 Russikon UK phone +1 / 8 47 / 2 47 01 82
SWITZERLAND phone +44 (0)8 45 / 4 56 08 23 fax +1 / 8 47 / 2 47 01 84
phone +41(0)1 / 9 55 06 08 fax +44 (0)8 45 / 4 56 08 24 stephansales-usa@sympak.com
fax +41 (0)1 / 9 55 06 88 info@stephan-uk.co.uk
stephan-machinery@bluewin.ch
Sympak Asia Pacific Pte. Ltd. OOO Sympak St. Petersburg Branch OOO Sympak Moscow Head Office
- Stephan Division - Office - Stephan Division -
23 Tagore Lane Business Center „Evro-Auto“ Sretenskiy Boulevard 6/1,

#03-12 Tagore 23 Warehouse 3rd Floor, Office 332 Korpus 2, Office 101
Singapore 787601 Levashovskiy Pr. Dom 13, Litera G Moscow, 101000
SINGAPORE St. Petersburg, 197110 RUSSIA
phone +65 / 64 55 / 76 70 RUSSIA phone +7 / 0 95 / 9 37 59 25
fax +65 / 64 55 / 62 20 phone +7 / 8 12 / 1 02 11 84 fax +7 / 0 95 / 9 37 59 26
sympak-asiapacific@sympak.com fax +7 / 8 12 / 1 02 11 87 sympak-russia@sympak.com
sympak-stpetersburg-
russia@sympak.com
Stephan Machinery
Polska zo.o.
Borówiec ul. Lesna 148

62-035 Kórnik
POLAND
phone +48 (0) 61 / 8 17 12 01
fax +48 (0) 61 / 8 17 12 01
rosik@stephan-machinery.com
Representatives in more than 40 countries Addresses provided upon request.
I09009
UM 130

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Type description UM 130

Serial number I09009

Year of manufacture 2009

Manufacturer Stephan Machinery GmbH

' Service +49 5151 583-0

' Sales +49 5151 583-200

4 Technical data and description of performances 21

6 Installing, commissioning and decommissioning 33

7.2.2 Operator menu 39

8 Troubleshooting and fault elimination 49

9 Servicing and maintenance 53

10.3 Accessories and additional Parts 75

1.1 Table of Abbreviations

EEPROM Electronical Erasable and Programmable Read Only Memory.

Emulsion O/W Oil-in-water emulsion

Emulsion W/O Water-in-oil emulsion

LED Light Emitting Diode

pü describes a pressure indication in relation to the ambient pressure.

1.2 Definition of Terms

F Insulation The classification of the insulation classes

1.3 Instructions for orientation

1.4 Notes for The Use of This Manual

DANGER Brief description of the hazards

WARNING Brief description of the hazards

CAUTION Brief description of the hazards

There is a low risk of injuries or a hazard of damage to property or to

Attention is pointed to special conditions or additional important

NOTICE Brief description of the additional information

Contains additional information for work assisting features or for

1.6 Used warning symbols

General dangerous spot

Dangerous working voltage

Risk of hand injuries

Warning of automatic start

Danger of heavy loads

Danger of hazardous materials

Risk of cutting damages

Warning of hot surfaces

Never spray with water

2.1.1 Safety instructions for general machine safety

• The safety instructions contained in this operating instruction must be observed.

2.1.2 Safety instructions for general production safety

2.1.3 Safety instructions for handling and operation

• The messages of the display devices must be observed.

2.1.4 Safety instructions for maintenance and care

• Do not use intensive corrosive cleaning solvents.

2.1.5 Safety instructions for trouble shooting

• Avoid standing in the working area of the bowl and cover.

• Close the on-site media feed when eliminating faults.

• Observe the fault messages of the machine.

2.1.6 Notes for specific hazards

3.1.2 Factors for the multiplication of the micro-organisms

• High level of moisture

3.2 Production hygiene

3.2.1 Likely sources of risk for the production

• as a result of improper hygiene of the operating and maintenance personnel

3.3 Cleaning, Disinfection and Sterilisation