VACUUM EMULSIFYING MIXING EQUIPMENT

MODEL: HS-500AS

OPERATION

MINOGA INDUSTRIAL CO., LTD

NO. 38 JIN HWA ROAD, LUCHU SHIANG
TAOYUAN HSIEN, TAIWAN
TEL: 886-3-3228328
FAX: 886-3-3228335
E-mail:[email protected]
 TABLE

1. ATTENTIONS OF TEST-RUNNING

2. DRIVING DIRECTION INDICATING DIAGRAM (1T00001D)

3. SPECIFICATION OF EMULSIFYING MIXER

4. OPERATION OF EMULSIFYING MIXER

5. SPECIFICATION OF OIL/WATER PHASE TANKS

6. OPERATION OF OIL/WATER PHASE TANKS

7. TROUBLE SHOOTING

8. MAINTENANCE

9. ROUTINE MAINTENANCE

10. ATTENTION OF OPERATION

11. OIL & LUBRICATION

12. ASSEMBLY OF TEFLON SCRAPER(100S005D,100S008D)

13. OUTSIDE LOOKING DIAGRAM OF MACHINE (500S189A)

14. SENSOR DIAGRAM (500S191A)

15. PIPING RECOMMEND ATION DIAGRAM (PIPE167-PIPE168)

16. ELECTRIC DIAGRAM OF MACHINE（500ASK01-500ASA27）

17. MANUAL OF INVERTER

18. MANUAL OF VACUUM PUMP

 ATTENTIONS OF TESTING-RUNNING
1. The location for machine must be stable and even and also make good water drainage
around the machine.

2. Move the equipment to the assigned location, and set the machine according to the
setting diagram, please pay attention to the even of machine and fix the base and
frame. Please prepare the supplies of power, cooling water, air in advance.

3. Check the items before installation and test-running：

(1) The power：380V X 50Hz X 3 PHASES，82 A
(2) Piping inlet of steam: 1.9kgf/cm2 (max)
(3) Steam inlet of vessel: 1.9kgf/cm2(27psi) lower
(4) Please make the piping of steam drain opened, so the steam can be released
quickly and freely.
(5) Please add filter unit on the piping that will be connected to the piping of
machine.
(6) The supply of steam and cooling water must be sufficient, so the heating time and
cooling time can be shorter.
(7) Water inlet of vessel: 2kgf/cm2(lower), under 20℃，flow rate：200L/min.
(recommend)
(8) The degree of circulation water for vacuum pump must be lower than 15℃
(recommend), if the degree is higher than 15℃, the working efficiency will be low,
the lower degree, the worse efficiency.
(9) Circulation water of vacuum pump: 14L/min(recommended), water pressure 0.4
bar
(10) Compressed air: 5kgf/cm2 for pneumatic solenoid valve of heating/cooling,
consumption is 20L/min.
(11) There is no power if the supply of compressed air is low.

4. Steps of power connection:

(1) Please confirm the voltage and stability of power(±10%) before the connection.
(2) Connect power to control box (L1.L2.L3.) and firmly connect the ground wire, the
ground wire connection is very important, because it will have induction current
when using inverter.
(3) Inspect each connector to make sure that they are firmly connected and without
any possibility of electric leakage.

TEST 1/4
 (4) Turn on the molded case breaker N.F.B. and check if the voltage is correct; the
power indicator will be on after switch on, if not, please check the tank is in
proper position.
(5) If the indicator is not on, please check:
a. The master power if phase-reversal, check the indicator RUN of”PVR-3”
RELAY inside the control box. Indicators RUN should be on when it’s normal.
If not, exchange the phase L1 & L3 in 3 phases.
b. The emergency stop button is not released.
c. The fuse is burned out.
d. The tank is not in correct position.(the limit switch LS1 does not work)
e. The limit switch of door of control box (under right corner) is bad contacted.
f. The air supply is weak.

5. Check the directions of each motor：

(1) Hydraulic motor: press the button of hydraulic up, if the tank lid goes up smoothly,
it means normal.(if not, please exchange two wire of L1/L2/L3 then it will be
normal)
(2) Vacuum motor: make the tank lid going down (the hydraulic back to the right
position), and close all valves, then start vacuum to see if the pointer of vacuum
gauge move to minus pressure, and it have large air release of vacuum releasing
valve.
(3) Scraping motor: turn on the power of inverter to check it the direction as same as
the figure.
(4) Center motor: turn on the power of inverter to check it the direction as same as the
figure.
(5) Emulsifying motor: turn on the power of inverter to check it the direction is
correct.
(6) Reverse running of all motors are prohibited.

6. The installation operator must be trained for electric and machine works.

7. Please do not make the central shaft and emulsifying head idling, or it will damage the
inner mechanism. Please pour necessary water or raw material which must be
15 ㎝ over the emulsifying head, it prevents the damages of idling.

TEST 2/4
8. Preparation of cooling piping:
(1) Please install pressure release valve(prepared by customer) before the steam inlet
of jacket of main tank, oil phase tank and water phase tank, and set the pressure of
steam inlet below 1.9kgf/cm2 (27psi) lower.
(2) When you are connecting the piping and plumbing for heating & cooling, please
clean the entire unexpected thing inside the piping before connection, it’s to help
the heating & cooling working smoothly.
(3) Before you start the steam heating, please use quick release to drain the water
inside the jacket of vessel, the heating speed can be normal.
(4) To prevent burning the workers and consuming the steam, please install the
thermal insulation material outside the steam pipes.
(5) Please turn off the steam entry valve temporary, when the temperature is too high
(manual ball valve).
(6) Please clean the filter net of piping and plumbing regularly.
(7) Please set the pressure of water inlet at 2 kgf/cm2, and the back pressure of
cooling water is not over 1.0kgf/cm2, if it’s over, please install a pump at the
cooling water outlet, it’s to regulate the pressure.
(8) Please make the steam quick release unit opened type, it prevent the problem that
the steam could not be drained naturally.

9. Preparation of circulation water of vacuum pump:

(1) Please check the circulation water and piping of vacuum pump if are well
prepared before pump operation. The recommend water flow rate is 14L/min for
vacuum pump and water pressure is below 0.4bar, if the flow rate is strong, it will
damage the blade inside the vacuum pump and noise occurred.
(2) Please check if there is water going into the inlet of vacuum pump and if there are
air and water come out from the outlet of pump. If yes, it means the pump is
running normally.
(3) The circulation water of pump is not clean water, please drain it out or use
individual circulation tank, do not connect to the other recycled water.
(4) There is one T unit at water inlet of vacuum pump, and there is one ball valve
above the T unit, please keep it opened. It’s to protect the blade of vacuum pump;
the blade may be damaged because of long running without air.
(5) Do not make vacuum pump no working for long time, please run the pump once a
week.
(6) Please check up the check valve which is in the vacuum entry of water sealed
vacuum pump for one to three months. If there is something seized up or the
check valve is damaged, the dirty water or oil would contra-flow into the tank.
Please observe if there is water or oil contra-flow into the hose which is up to the
check valve when the tank is empty or in the high vacuum situation.
TEST 3/4
 (7) It’s not allowed to raise the tank cover when the vessel is in vacuum.
(8) The vacuum indicator is on (PL5) when the vessel is in vacuum, the tank cover
can not be lifted. If the vessel is not in vacuum, but PL5 is still ON, please check
the limit switch of vacuum (LS4).
(9) Please do not operate the vacuum pump when emulsifying head is working. It’s to
avoid the material be sucked into the vacuum pump.

10. Check all the necessary preparation for test running again, such as power, cooling water,
drainage, pipelines etc.

11. When the test running is finished, turn off the power, and clean the whole machines for
the normal production.

12. As for the electric control parts and controls, please do not use water cleaning, just use
wet cloth to do the cleaning, it’s to prevent the damages of electric part and electric
leakage. Please turn off the power when doing maintenance.

13. All motors are not allowed to run in reverse direction (please follow the arrow label). If
you have to move the machine to other place due to some reasons, please follow the
above steps before the normal operation of machine.

14. Reverse running of all motors are prohibited.

15. Please keep the operation platform, stage and working area of machine dry, otherwise, it
may cause the operator to slip and fall.

16. Please operate the machine according to our operation manual, if any accident happened
due to wrong operation, the machine manufacturer is exempted from the responsibility.

TEST 4/4
 SPECIFICATION (MAIN TANK)

1. NAME：VACUUM EMULSIFYING MIXING EQUIPMENT

2. MODEL：HS-500AS

3. EMULSIFYING MIXING：15HP(11KW) (TECO), speed 540 – 3600 RPM with

inverter (MITSUBISHI)

4. CENTER MIXING：7.5HP(5.5KW) (TECO), speed 15 – 90 RPM with inverter

5. SCRAPING MIXING：10HP(7.5KW)(TECO)，variable speed 15 – 60 RPM with

inverter (MITSUBISHI)

6. LID RISING：2 HP(1.5KW) oil hydraulic motor，with oil pump assembly

7. VACUUM PART：5HP(3.7KW) vacuum pump (water type),with vacuum safety device

8. MIXING HEAD：LOW VISCOSITY TYPE(B TYPE)

9. TEMPERATURE CONTROL：temperature sensor, temperature control, indicator

10. HEATING TYPE：steam heating system (steam supply prepared by customer)

11. COOLING TYPE：cool water circulate in jacket (water supply prepared by customer)
12. TANK： three layer，inner layer SUS#316L x 6mm，400# polish
middle layer SUS#304 x 6mm
outer layer SUS#304 x 3 mm, 300# polish
full capacity：650L，working capacity：500L，pressure in jacket : 1.9 kg/cm²

SPEC 1/2 (MAIN TANK)

12. TANK LID OF FLANGE WITH ACCESSARIES：
a. PACKING OF TANK LID: VITON
b. VIEWING WINDOW WITH WIPER
c. LIGHT INJECTION DEVICE: 24V X 70W
d. MATERIL SUCKING INLET
e. LIQUID ADDING CHAMBER
f. VACUUM SAFETY DEVICE AND VACUUM METER
g. MATERIAL FILTER UNIT
h. AIR FILTER X 1
i. VACUUM VIEWING TUBE GLASS X 1
j. LEVEL SENSOR UNIT X 1

13. SAFETY DEVICES X 1 SET

14. PRODUCT DISCHARGE：a. by bottom valve：2-1/2” valve

b. by tank tilting ( oil hydraulic)
15. CONTROL BOX 1 SET (CONTROL ELECTRIC POWER DC24V)
16. WORKING PLATFORM AND LADDER X SUS#304 X 1 SET
17. POWER：380V X 50Hz X 3 PHASES

SPEC 1/2 (MAIN TANK)

 OPERATION(MAIN TANK)
1. RAW MATERIALS POURING：
(1) Lift the tank lid and pour the materials into the tank (please make sure that the
tank is not in vacuum condition before lifting)
(2) Or use vacuum for sucking the raw materials through filter into the mixing tank.

2. DISCHARGING：
(1) Lift the tank lid to highest position and use oil hydraulic to do tilting.
a. suitable for high viscosity product.
b. Make sure that the tank is not in vacuum condition before lifting.)
(2) Or use bottom valve to discharge.

3. EMULSIFYING PART:
The speed of emulsifying head can be adjusted by inverter 540 – 3600 rpm, the rpm
is indicated on the digital meter. When the stator rotates in high speed in the stator
will produce very strong force like pump, it will suck the product upward from the
bottom, and it will increase mass circulation. The product goes through the 0.3-0.5
mm tiny clearance of rotor in very high speed that will have powerful shearing and
friction. The mixture can be finely homogenized. The speed and time of each
emulsifying are related to the characteristics of product, you have to make complete
record of speed and time of emulsifying for each production. Then you can get the
product of same quality. And different type of emulsifying head will have different
operation; the operators have to make detailed record to assure the quality of each
batch. For emulsifying head change, please check the assembly diagram. (please
contact MINOGA)
The central shaft of MINOGA is equipped with, acid and alkali resistant seal of
sanitary standard(Germany made). The shaft is by ceramic of ultra high hardness
treated; the hardness is “60” it’s very strong structure.

4. SCRAPING MIXING：(TEFLON SCRAPER IS LONGER DESIGN)

The scraping is to scrape off the material that sticks to the tank wall during mixing, and
increase the efficiency of heat exchanging and circulation. The edge of outer scraping
frame are with scraper of Teflon or other materials which are close to the tank wall,
suitable for high or low viscosity mixture. The speed is controlled by inverter from
15-60 rpm; rpm can be shown on the indicator. The Teflon scraper can be taking off for
cleaning.

OPTE 1/5
5. CENTER MIXING:
The center paddle rotated in reversed direction with anchor scraping unit, the angles of
center paddle and blades of scraping are different, it helps the product to be mixed
completely and the cooling time can be shorter. The center paddles are welded type, it’s
easy for cleaning.

6. VACUUM PUMP：
It’s often to encounter the problem of air getting into the finished product during high
speed mixing or emulsifying, especially for mixture of high viscosity, cream or
ointment. The air will contaminate the finished product and become acidified. We can
use vacuum to eliminate the air appeared during mixing. The timing of using vacuum
is after emulsifying finished, and the temperature can not be too high (under 50℃). Do
not use vacuum in high temperature; it will suck the water of inner tank and change the
quality of product. And it’s easy to make mixture boiling in low temperature that will
have bad effects on the characteristics and structure of product. The mixture will be
risen upward quickly at the beginning of using vacuum, do not let the mixture going
over the stopper, when it reaches the stopper, turn off the vacuum and wait until the
product is going lower, then start the vacuum again. Do those steps several times until
the mixture does not going upward strongly, keep using the vacuum.

7. OIL HYDRAULIC PART：

The oil hydraulic can go upward and down, it can be raised to the max. highest
position and stopped by the control of limit switch. If you need to lower hydraulic,
use hydraulic down to lower it, it will stop until it reaches the limit switch. (the
function if for tank lid going upward and down.) There is warning alarm to remind the
operator be away from the emulsifying vessel, for safety reason.

8. STEAM HEATING SYSTEM：(SUPPLY IS PREPARED BY CUSTOMER)

(1) The jacket can bear 1.9kgf/cm 2, heating 100℃. Please set pressure-releasing valve
and filter on the supply of steam. And set the steam supply on 1.9kgf/cm 2.
(2) If you want to use the steam heating, please discharge the water inside jacket
before starting.
(3) When it reaches the set degree, the Y type actuator of steam will be stopped
automatically. When the degree gets lower than the setting, the actuator valve will
be turned on automatically to make it back to the setting number.
(4) During the heating, if it reaches the degree, the steam inside the vessel jacket will
be released automatically, so the temperature can be kept.

OPTE 2/5
 (5) Please clean the filter net of piping and plumbing regularly.
(6) When the solenoid valve is breakdown or not working smoothly, please open the
manual exhausted valve behind the tank and close the steam entry valve,

9. COOLING SYSTEM:
(1) This machine is with cooling water circulation system, when you want to use
cooling, please switch to HEATING OFF, and open the cooling water inlet valve
by manual.
(2) The water in and out are under same control system.
(3) Please clean the net of filter of pipelines regularly.
(4) When the temperature is down to about 55℃, we recommend you to use chilling
water to do the cooling circulation; it makes the degree lower in shorter time.
(5) If you need to recycle the cooling water, please choose the pipe that is
hot-resistant to be 80℃(recommended)

10. TEMPERATURE CONTROL：

The temperature is detected by the PT thermal couple that is equipped at the bottom of
vessel. After setting the requested degree on controller and switch to heating, the
controller will start the Y type actuator of steam to start heating. The degree keeps going
hotter from top to bottom for heat conduction, and the thermal couple will transmit the
detected degree to the temperature indicator. When it reaches the requested degree, the
controller will stop the Y type actuator of steam automatically; if the degree going lower,
then the controller will switch to on. With those steps to get the necessary temperature
gradually. But the extra heat in jacket will make the sensor to feel 3-4℃ higher than the
requested degree. There is a micro adjustment on the controller; operator will make the
adjustment if necessary.

11. LIGHT INJECTION：

If you need to check the inside situation during mixing, turn on the light for easier
viewing. Remember to turn off the light if it’s not in use.

12. SPEED ADJUSTMENT：

Use inverters to control the necessary speed, the proper parameters are input in inverter
before shipment, if there is any problem, please check the manual or contact with
MINOGA.

OPTE 3/5
 13. SAFETY DEVICES：
(1) There are limit switches to control the up and down position of oil hydraulic.
(2) The tank tilting and position are controlled by limit switches, if the tank does not
go back to the right position, all the buttons can not be operated. (only hydraulic
can go up)
(3) All magnetic valves are with over-loaded protections.
(4) Vacuum safety device：if the tank is in vacuum, the power of oil hydraulic will be
cut off; it’s to prevent the neglect of hydraulic operation.
(5) The mixer does not work when it’s risen to the highest position, if you must make
any adjustment, use “INCH” to run scraper.
(6) This equipment is with emergency stop device; use it to stop the machine
immediately for any urgent situation.
(7) There is alarm device for tank lid going down.
(8) If the door of control box is opened, the power will be cut off, all operations stop.
(9) Please turn off the power completely when maintaining.

14. There is level sensor for vacuum system, if the level of product reach the high point of
setting of sensor, the vacuum will be off automatically, and it will re-start working
when the level goes lower.

15. ATTENTIONS FOR VACUUM PUMP：(WATER SEAL TYPE)

(1) Please check if there is efficient water in inlet of pump and there is stronger air
gets into the pump or the water flow rate.
(2) Please pay attention to the water flow; it is about 14L every minute water pressure
is below 0.4bar. To maintain the operating life of the pump, please use the ball
valve to adjustment the water flow.
(3) When running 3 minutes the vacuum situation in 50cmHg has much noise, please
check the circulation water and piping of vacuum pump if are well prepared.
(4) When the vacuum reaches 70cmHg, if there is much noise from pump, the reason
may be the circulation water flow is too strong. You can close the water inlet of
pump and then open 1/4 of full opening.
(5) This type of pump will not have much noise when it’s in high vacuum situation,
and the water releasing will be weak in water outlet, please stop the operation of
vacuum pump temporarily until the vacuum pressure become lower, then re-start
the operation of pump. It’s to protect the usage time of pump. (please check the
pump manual)
(6) Do not make vacuum pump no working for long time, please run the pump once a
week.

OPTE 4/5
 (7) There is one T unit at the bottom of water inlet of vacuum pump, and there is one
ball valve at the T unit, please keep it opened. It’s to protect the blade of vacuum
pump; the blade may be damaged because of long running without air.
(8) Please check up the check valve which is in the vacuum entry of sealed vacuum
pump for one to three months. If there is something seized up or the check valve is
damaged, the dirty water or oil would contra-flow into the tank. Please observe if
there is water or oil contra-flow into the pipe which is up to the check valve when
the tank is empty or in the high vacuum situation.
(9) It’s not allowed to raise the tank when the vessel is in vacuum.
(10) The vacuum indicator is on (PL5) when the vessel is in vacuum, the tank cover
can not be lifted. If the vessel is not in vacuum, but PL5 is still ON, please check
the limit switch of vacuum (LS4).
(11) Please do not operate the vacuum pump when emulsifying head is working. It’s to
avoid the material be sucked into the vacuum pump.

16. Buzzer operation：

(1) When the lid goes down, the buzzer keeps ring to remind the operator and staff to
keep away from the running unit. Do not put anything on the machine.
(2) When the tank cover is lifted and opened, and you need to rotate the mixing
mechanism due to any reason, keep pressing FDW button and operate the
emulsifying or scraping shortly, the buzzer starts to ring to warn staff to keep
away of the machine.
(3) When it comes to the setting time of timer, (emulsifying is ready) the buzzer starts
to ring, you can switch emulsifying OFF/ON to OFF, the buzzer is shut off. Or
you can press RST of timer; it zeroizes the timer and stop the alarm of buzzer.
And make the emulsifying in ready condition.
(4) When the heating of emulsifying tank is finished, buzzer start to ring, switch the
heating to OFF to stop the buzzer.
(5) When the cooling of emulsifying tank is finished, buzzer start to ring, switch the
cooling to OFF to stop the buzzer.
(6) When cooling is finished, there is one T2 timer inside the control box, it will start
to count time (the setting is 20 minutes) when time is up, the power of
emulsifying and vacuum will be shut off. If you want it return to normal, switch
COOLING of emulsifier tank to OFF.

17. Cleaning and sterilizing for the tank :

(1) Use the steam of boiler to sterilize the main tank.
(2) After washing the main tank, use the steam to sterilize and dry out the main tank to
match the G.M.P. standard.

OPTE 5/5
 SPECIFICATION(O/W TANKS)
** OIL & WATER PHASE TANKS
A. WATER PHASE TANK：

1. TANK：3 LAYERS, FULL CAPACITY：400 L , WORKING CAPACITY：150-300L

INNER LAYER SUS#316L x 5mm, 400# polish
MID. LAYER SUS#304 x 5mm
OUTER LAYER SUS#304 x 3mm

2. MIXER MOTOR: 5 HP(3.75KW) (TECO ), speed 50 – 300 RPM with inverter

(MITSUBISHI) (Top entry mixing unit, propeller type)

3. TEMPERATURE CONTROL：Temperature sensor, indicator and control

4. HEATING：Steam heating system (supply prepared by customer)

5. COOLING TYPE：cool water circulate in jacket (water supply prepared by customer)

6. BOTTOM VALVE OF TANK：Pneumatic valve 1-1/2”(air prepared by customer)

7. MATERIAL TRANSFERING：BY VACUUM SUCTION INTO MIXER

B. OIL PHASE TANK：

1.TANK：3 LAYERS, FULL CAPACITY：400 L WORKING CAPACITY：150-300L

INNER LAYER SUS#316L x 5mm, 400# polish
MID. LAYER SUS#304 x 5mm
OUTER LAYER SUS#304 x 3mm

2.MIXER MOTOR: 5 HP(3.75KW) (TECO motor), speed 50 – 300 RPM with inverter

(MITSUBISHI) (Top entry mixing unit, propeller type)

3.TEMPERATURE CONTROL：Temperature sensor, indicator and control

4. HEATING：Steam heating system (supply prepared by customer)

5. COOLING TYPE：cool water circulate in jacket (water supply prepared by customer)
6. BOTTOM VALVE OF TANK：Pneumatic valve 1-1/2”(air prepared by customer)

7. MATERIAL TRANSFERING：BY VACUUM SUCTION INTO MIXER

 OPERATION(O/W TANKS)

** OIL & WATER PHASE TANKS

1. MIXER：mixer of motors, with inverter 50 – 300 RPM. If the oil ingredient is solid
mass, please do not run mixer until it’s roughly dissolved, then start the mixer to do
complete melting.

2. STEAM HEATING：
The jacket can bear 1.9kg/cm 2, heating 100℃. Please set pressure releasing valve and
filter on the supply of steam( pressure release valve prepared by customer). And set the
steam supply on 1.9kg/cm2. If you want to use the steam heating, please check if the
water in jacket is released completely from the quick releasing unit before starting
heating. Then, set the temperature of heating you need, and turn on the heating switch.
When it reached the set degree, the Y type actuator valve will be stopped automatically.
When the degree gets lower than the setting, the Y type actuator valve will be turned
on automatically to make the degree back to the setting. After the heating is finished,
set the degree to normal degree or the degree of cooling you need for your work, then
turn off the Y type actuator valve.

3. COOLING SYSTEM:
(1) This machine is with cooling water circulation system, when you want to use
cooling, please switch to HEATING OFF, and open the cooling water inlet valve
by manual.
(2) The water in and out are under same control system.
(3) Please clean the net of filter of pipelines regularly.
(4) When the temperature is down to about 55℃, we recommend you to use chilling
water to do the cooling circulation; it makes the degree lower in shorter time.
(5) If you need to recycle the cooling water, please choose the pipe that is
hot-resistant to be 80℃(recommended)

OPTE 1/2
4. TEMPERATURE CONTROL：
The temperature is detected by the PT thermal couple that is equipped at the bottom of
vessel. After setting the requested degree on controller and switch to heating, the
controller will start the heater heating. The degree keeps going hotter from top to
bottom for heat conduction, and the thermal couple will transmit the detected degree to
the temperature indicator. When it reaches the requested degree, the controller will
stop the heater automatically; if the degree going lower, then the controller will switch
to on. With those steps to get the necessary temperature gradually. But the extra heat in
jacket will make the sensor to feel 5℃ higher than the requested degree. There is a
micro adjustment on the controller; operator will make the adjustment if necessary.

5. Raw materials of oil & water phase are transferred into the emulsifying mixer by
vacuum suction. The material inlet of emulsifying mixer is equipped with filter; This
filter can get rid of impurities. The waste eate can be released from the bottom valve
after cleaning.

6. The jacket can stand water pressure 4 ㎏ f/㎝ 2 , the actual pressure is “0”, the water
outlet is prohibited to set any ball valve, it must be free releasing.

7. The safety valve of tank jacket is set 2.5 ㎏ f/㎝ 2 , it’s to release automatically the extra
pressure produced because of wrong operation. ( keep the working pressure at
1.9kgf/cm2)

OPTE 2/2
 TROUBLE SHOOTING

SITUATIONS REASONS RESOLUTIONS

1. Emulsifying 1. The tank is not in proper 1. Make the tank in proper position, the
mixer does not position indicator is on or adjust the tank
work position LS.
2. Lid is not closed properly 2. Close the lid or adjust the L.S.
3. The over-loaded device is 3. Check the reason and reset the thermal
off. relay.
4. The inverter is out of order 4. Check the inverter manual or contact
with MINOGA
5. The emulsifying timer is 5. Zeroize the timer
ended.
2. Scraping mixer 1. The tank is not in proper 1. Make the tank in proper position, and
/center mixer position. the indicator is on.
does not work 2. Lid is not closed properly. 2. Close the lid or adjust the L.S.
3. The over loaded device is 3. Check the reason and reset the thermal
off. relay.
4.The inverter is out of order 4. Check the inverter manual or
contact with MINOGA
5. The emulsifying timer is 5. Zeroize the timer
ended.
3. Oil hydraulic 1. The tank is in vacuum 1. Release the vacuum in tank
does not work. 2. The tank is not in proper 2. Make the tank in proper position, and
position the indicator is on.
3. The over-loaded device is 3. Check the reason and reset the thermal
off. relay.
4. The vacuum is released, 4. The vacuum safety valve is locked;
but the light is still on. touch it to make it normal.

TROUBLE SHOOTING 1/4

 SITUATIONS REASONS RESOLUTIONS
4. Vacuum pump 1. The over-loaded device is 1. Check the reason and reset the thermal
does not work off. relay
2. It’s rusty because of not 2. Check the pump fan or contact with
using for long time MINOGA
3. The tank is not in proper 3. Revert the tank, the indicator is on or
position adjust the tank position LS1.
4. Lid is not closed properly 4. Close the lid or adjust the L.S..

5. Mixer of oil or 1. Over-loaded device is off 1. Check the reason and reset the
water phase thermal relay.
tanks do not 2. The inverter is out of 2. Check the inverter manual or contact
work order with MINOGA.

6. Turn on the 1. The emergency stop 1. Release the emergency stop button.
power, but button is pressed
all 2. The fuse is damaged 2. Replace the fuse.
indicators 3. The wiring of emergency 3. Check and connect the wiring firmly.
are still off stop or power is not
connected correctly
4. The door of control box is 4. Close the door of control box and the
opened limit switch is contacted.
5. The 3 phase is wrong, or 5. Check the wiring completely, opens
voltage is too high or too the control box and pressures the limit
low or phase failure. switch to see of PR-1 is ON. (if the
light RUN ON, is normal)
6. The air pressure is low 6. Please check the pressure on air unit
should be around 5-6 kgf/cm2

TROUBLE SHOOTING 2/4

 SITUATIONS REASONS RESOLUTIONS
7. Heating or 1. The degree on temp. 1. The “FFF” indicator of temperature
cooling does not control is not normal control will be on, please check the
work probe connection and maintain it.
2. The set of degree is not 2. Change the set number and check of
correct. the indicator of temperature control
will flash. Flash is normal.
3. The switch cool/off/heat is 3. Switch to correct mode, or check the
on off, or the wiring is wiring and repair it.
disconnected.
4. The tank is not reverted. 4. Revert the tank correctly.
5. Heating (cooling) 5. When the heating indicator is on, and
indicator is on, but the the solenoid SOL.6 is running, the
solenoid valve does not wiring of connector TB2 38,2 should
work. be DC-24V; When the cooling
indicator is on, and the solenoid
SOL.7 is running, the wiring of
connector TB2 41A,2 should be
DC-24V; If the above mentioned are
normal, the reason may be one of the
solenoid valve SOL.6 or SOL.7, is out
of order. Please replace it.
The way to check:
a. Please started manual button on the
solenoid valve and check.
b. Disassemble the coil, and check if
there is magnetic force by
screwdriver.
6. The pneumatic solenoid 6. Check the pressure gauge of air unit,
valve works, but the Y the pressure should be 5-6kgf/cm2, or
type pneumatic valve does the air piping is jammed. There is an
not work. action indicator on Y valve, when the
valve is opened, there is a red bar;
when the valve is closed, and there is
a red dot.

TROUBLE SHOOTING 3/4

 SITUATIONS REASONS RESOLUTIONS
8. The actual 1. The indicated degree is 1. The temperature control or sensor is
degree is 10 lower than actual 3 degree out of order
degree over the 2. The temperature control is 2. The steam quick release valve is
set degree ok, but the heating closed when degree reached, please
indicator is off open.
3. The steam quick release is 3. The steam in solenoid valve is
opened, but the blocked, please take the center part of
temperature is keeping valve and clean it.(please close the
going up steam supply and wait until the piping
is cool down)

TROUBLE SHOOTING 4/4

 MAINTENANCE
1. Turn on the power, the indicator is on, it means the power input is normal, if the
indicator is not on, check if the tank is in correct position.

2. When lifting and lowering the lid (oil hydraulic), and the mixer is in highest
position, the power for all buttons and switches are off. They will be normal when the
oil hydraulic is in lower position, all the buttons and switches are normal. If it still can
not work, check the limit guide of oil hydraulic. (see sensor diagram)

3. If the machine stops suddenly, the reason maybe the over-loaded device is off,
please check the reason and reset the thermal relay to restart the operation.

4. When re-inputting the general power for machine, please check the lid lifting is
normal and the directions of motors are correct, if these parts are normal, all the
function are in good condition. Or check the indicator RUN of”PVR-3”RELAY inside
the control box. Indicators RUN & PW should be on when it’s normal. If not,
exchange the phase L1 & L3 in 3 phases.

5. If the motors of emulsifying and scraping are not in use, turn off the power any
time.

6. The Teflon scrapers of scraping mixer can be taken off for cleaning. (check the
assembly diagram)

7. Turn on the center mixer and scraping blades with hot water.

8. Make sure the water level must be 15 ㎝ over the emulsifying head, or it will
damage the head because of idling.

9. If there is some noise from the center shaft or emulsifying head, please contact with
MINOGA for further information.

10. Please operate the vacuum pump more than 5 minutes every week, when it is long
time unused.

MAINTENANCE 1/5
11. The safety valve of tank jacket is set 2.5 ㎏/㎝ 2 , it’s to release automatically the
extra pressure produced because of wrong operation.(keep the working pressure at
1.9kgf/cm2)

12. It’s not allowed to wash the control box and motors with water directly.

13. Clean the inside tank by steam heating. Please open all the valves which are on the
tank to prevent the explosion, when the temperature is boiling.

14. Greases of parts：

(1) Reducer：please check the oil level every years, maintain the oil level between
1/3~2/3. when the oil level below 1/3 must re-fill oil and machine oil.
(2) Oil hydraulic：check the oil level of oil hydraulic regularly, if it’s lower than half
volume, please adds necessary volume. And change the circulation oil of ISO 46
(SAE 20) if the color changes to be white-yellow.
(3) Clean the guide pillar of oil hydraulic lifting every month, and lubricate it with
grease.
(4) Vacuum pump: please operate the vacuum pump each week.
(5) Check the circulation water supply is normal weekly.
(6) Gear box: add 20gms grease every 3 months.

15. Please clean the pipelines every three months.

16. To prevent burning the workers and consuming the steam, please install the thermal
insulation material outside the steam pipes.

17. When maintain the machine, please turn off the power to prevent accident.

18. Keep clean in the electric control box..

19. please change the oil seal inside the emulsifying shaft after one year or working hour
after 400 hours.(please do as the provide shaft diagram)

MAINTENANCE 2/5
 ROUTINE MAINTENANCE
1. CHECK THE OIL PUMP：
(1) METHOD：When the tank cover is closed, the oil level should be over the oil
indicating window of oil pump. If the piping is leaking, please screw the
connector firmly.
(2) Please check oil pump every 6 months, if there is no leaking, check it yearly.

2. VACUUM PUMP：
(1) Please check if the circulation water of water seal pimp is normal every week.
(2) Do not make vacuum pump no working for long time, please run the pump once a
week.
(3) Please check up the check valve which is in the vacuum entry of water sealed
vacuum pump for one to three months. If there is something seized up or the
check valve is damaged, the dirty water or oil would contra-flow into the tank.
Please observe if there is water or oil contra-flow into the hose which is up to the
check valve when the tank is empty or in the high vacuum situation.

3. REDUCER OF SCRAPER：Check the oil level every year, and keep the level is
between 1/3 – 2/3. When the level is lower than 1/3, please re-fill oil.

4. GUIDING OF HYDRAULIC LIFTING：Lift the cover to max high, clean the

guiding bar, and grease it. (please maintain it every month)

5. Tank tilting gear should be lubricated every year.

6. GEAR BOX：There is a gear box on the crossbeam which between vacuum motor and
tank cover, please add 20GM grease every three months.

7. TEFLONS CRAPER：
(1) Check the fixture bolt of scraper before operation.
(2) Please make sure the bolt is correctly assembled.
(3) Please pay attention to the mark on each Teflon scraper when doing assembling
and disassembling.

MAINTENANCE 3/5
 ATTENTIONS OF OPERATION
1. Before each operation：
(1) Please check if there is anything dangerous to the machine unit.
(2) Please check if the assembly of each parts are ok.
(3) Please check all the screws and bolts are tightly fixed.
(4) Check all lubricant and grease of parts are normal.
(5) Check all valves and meters are ok.
(6) Check the power and voltage are normal.
(7) Please drain the water in tank jacket to ensure quick heating. When the degree is
reached, please open the steam quick release valve to prevent the degree going up.
(8) Check the inserting units of each Teflon scraper.
(9) Check the fixture bolt of emulsifying head.
(10) Check the water supply of vacuum pump is sufficient.(water sealed pump)
(11) If the vacuum pump is not operated for some time, please run it each week.
(12) If the vacuum pump usually shuts off because of high electric current please reset
the RST to restore the power. And check if the water flow of circulation water is
too strong. (you can close the inlet of ball valve and open it to be 1/4 of full
opening.

2. AFTER EACH OPERATION:

(1) Please check the circulation water of the water seal pump is sufficient, and clean
it.
(2) Please clean and maintain the machine.

3. Check the limit guiding of hydraulic lifting every month.

4. Check these items every year：

(1) The oil level of reducer
(2) The oil level of oil circulation
(3) Tank tilting gear should be lubricated.

5. Special attentions:
(1) Please always keep the steam quick release of vessel jacket opened.
(2) Before lifting the cover, please open the ball valve (charging ball valve or
discharging ball valve ) to prevent the steam blowout or in the vacuum condition.
(3) It’s prohibited to make all motors operating in wrong direction.
(4) If you change the general power, motor or electric control in control box, please
make sure the motor direction is correct. When you reconnect the general power,
please test the hydraulic lifting, if lift works, the direction is correct.
(5) When the high speed emulsifying is in using, please do not operate the vacuum
pump, otherwise the materials will be sucked into the vacuum pump.
MAINTENANCE 4/5
 (6) The material level must be 15cm higher over the emulsifying head when you
operate the emulsifying.
(7) Please do not use water to clean the electric wiring and control directly.
You should use wet cloth to clean this machine, it’s to prevent water getting into
electric part and causing damages.

6. Please keep the operation platform, stage and working area of machine dry, otherwise, it
may cause the operator to slip and fall.

7. Please operate the machine according to our operation manual, if any accident happened
due to wrong operation, the machine manufacturer is exempted from the responsibility.

MAINTENANCE 5/5
 OIL & LUBRICATION

1. REDUCER OF SCRAPING MIXER：

(1) VISCOSITY RANGE ISO VG 320
(2) CPC OIL：HD-320
(3) SHELL OIL：OMALA OIL 320
(4) MOBIL OIL：MOBIL GEAR 632
(5) FUCHS OIL：CKC 320 (GERMANY)

2. OIL PUMP
(1) VISCOSITY RANGE：ISO VG 46
(2) CPC OIL：R-46
(3) SHELL OIL：AW-46
(4) MOBIL OIL：MOBIL DTE 26
(5) ESSO OIL：H-46
(6) LYBO OIL：RO 46 (USA)
(7) FUCHS OIL：B20 (GERMAN)

3. GREASE FOR OIL HYDRAULIC LIFTING GUIDE & GEAR BOX

(1) GREASE OF 180℃ RESISTANCE
(2) CPC OIL：EP-3
(3) SHELL OIL：EP-3
(4) LYBO OIL：EP-3 (USA)
(5) FUCHS OIL：CEP-3 (GERMAN)

4. FILTER & LUBRICATOR & REGULATOR UNOT：

(1) VISCOSITY RANGE ISO VG 32
(2) CPC: R-32
(3) MOBIL OIL：MOBIL DTE 24
(4) ESSO OIL：ESSO NUTO H32
(5) BP OIL：BP ENERGOL HLP32
(6) ARAL VITAM GF32
真空乳化攪拌裝置
MODEL：HS-500AS

操作說明

彌之賀工業有限公司
桃園縣蘆竹鄉錦華路 38 號
TEL: 886-3-3228328
FAX: 886-3-3228335
E-mail：[email protected]
 目 錄

1. 試機注意事項

2. 轉向示意圖 (1T00001D)

3. 主機規格

4. 主機操作說明

5. 油水相規格

6. 油水相操作說明

7. 故障排除

8. 保養維護

9. 例行保養

10. 操作注意事項

11. 油品使用資料

12. 拆解清洗圖 (100S005D, 100S008D)

13. 外觀圖 (500S189A)

14. 感應開關位置圖 (500S191A)

15. 管路圖（PIPE167, PIPE168）

16. 電路圖(500ASK01-500ASK27)

17. 變頻器手冊

18. 真空泵浦手冊
 試機注意事項

1. 機台放置的地方必須是地基穩固並平坦的，機台周圍請設排水溝渠且排水良
好。

2. 將設備移至預定位置，依配置圖面安裝定位，機台須注意校正水平，完成之
後加以固定。電源及冷卻水來源、蒸氣來源、壓縮空氣等應事先準備完成。

3. 機械安裝試機前檢查事項：
(1) 電源：380V X 50Hz X 3 PHASES，電力總電量 82 安培。
(2) 蒸氣配管入口壓力：1.9 kgf/cm2(MAX)
(3) 蒸氣進入桶槽夾層壓力：1.9kgf/cm2(27psi)。
(4) 請將蒸氣快速排放管路採開放式配管，防止蒸氣無法自然快速排出。
(5) 蒸氣進入本機前請於工廠管路上加裝置過濾器。
(6) 蒸氣或冷卻水來源流量必須充足，才能縮短加熱或冷卻時間。
(7) 冷卻水進入桶槽夾層壓力：2 kgf/cm2 以下，水溫在 20 度 C 以下，冷卻水流量 200
L/min。
(8) 注入真空泵浦循環水的水溫，最好保持在 15℃以下，如果水溫過高於 15℃，將
會降低泵浦的效率。而且水溫愈高 泵浦的效率就愈差。
(9) 真空泵浦循環水進入泵浦水量(建議)：14L/min. 水壓保持在 0.4 bar (0.4 kgf/cm2 )
(10) 氣壓來源：5kgf/ cm2 供管路加熱及冷卻氣動電磁閥使用， 氣壓消耗量 20
L/min。
(11) 控制箱氣壓來源不足，機械不動作

4. 電源安裝程序：
(1) 接上電源之前，請先確認工廠的電源的電壓值及其穩定度，須保持在±10%。
(2) 把電源線接至工廠的電源控制箱 (L1、L2、L3 接點)並確實接地線，接地線步驟
不可省略，因變頻器使用會產生感應電流。
(3) 檢視各部接點均依標示接妥，各接點固定無鬆動及漏電現象。
(4) 打開無溶絲開關(molded case circuit breaker,N.F.B.)，檢查電壓值是否正確；打開電源開
關後定位指示燈應亮起。
(5) 如定位指示燈未亮起，請檢查：
a. 三相電源的相系錯誤，電源反相，檢查控制箱內的”PVR-3”RELAY 的 RUN
指示燈，正常時 RUN 燈均要亮。如果不對將電源線 L1、L2、L3 三相的
L1、L3 相對調。
b. 請檢查緊急停止按鈕被按下無復歸。
c. 請檢查是否保險絲燒毀。
d. 桶槽傾倒是否歸定位。(定位微動開關 LS1 未動作)。
e. 控制箱門右下角落的微動開關是否接觸不良。
f. 請檢查是否氣壓來源壓力不足。

試機注意事項 1/3
5. 檢查馬達轉向依指示標示方向是否正確，依序為油壓、真空、刮邊、中心攪
拌、乳化：
(1) 油壓馬達：按下油壓上昇鍵，如果可以正常上昇至上限即為正常。如無法昇降，
將電源線 (L1、L2、L3) 其中兩條電源線互換接線即可正常運作。
(2) 真空馬達：將油壓降至定位，關閉所有球閥，並按下真空 ON，注意真空錶的指
針是否指向負壓，且真空排氣管排氣量大。
(3) 刮邊馬達：啟動刮邊按鈕開關，並且旋轉調速旋鈕，查看轉向是否如所附圖示。
(4) 中心攪拌馬達：啟動中心攪拌按鈕開關，並且旋轉調速旋鈕，查看轉向是否如所附圖
示。
(5) 乳化馬達：啟動乳化按鈕開關，並且旋轉調速旋鈕，查看轉向是否如所附圖示。請參
考中心攪拌乳化轉向示意圖
(6) 馬達嚴禁逆轉。

6. 安裝人員應是合格且授有電機及操作機器訓練專業工程人員。

7. 乳化中心軸及乳化頭請勿空轉，以避免損害內部機構。在試機或生產前，請
務必注入清水或原料使其高出乳化頭 15 ㎝以上，可保護結構不會因空轉而
損壞內部構造。

8. 蒸氣配管注意事項：
(1) 請在主機/油相槽/水相槽配管蒸氣入口前裝置減壓閥(客戶自備)，蒸氣進入桶槽夾層壓
力請設定在 1.9kgf/cm2(27psi)以下
(2) 配接蒸氣來源與冷卻水來源段管路時，請先清潔管路中的雜物之後，再進行連結，以
確保管路運作順暢。
(3) 每次使用蒸氣加熱前，請先從快速排水閥，將桶槽夾層內的水全部排除，或是利用蒸
氣壓力將夾層中的水排放，加熱速度才會正常。
(4) 蒸氣管路須外覆保溫材質，可防止人員燙傷及蒸氣消耗。
(5) 溫度過高時，可先暫時關閉蒸氣入口閥處。（手動閘閥）
(6) 請定期清潔管路中過濾器的濾網。
(7) 冷卻入口水壓勿超過 2 kgf/cm2，而冷卻水出口的背壓不要超過 1.0kgf/cm2，若
是超過的話，請在冷卻水出口處加裝泵浦調節。
(8) 請將蒸氣快速排放管路採開放式配管，防止蒸氣無法自然快速排出。

9. 真空循環水配管注意事項：
(1) 水封式真空泵浦在啟動前須檢查真空泵浦循環水是否配管接妥及循環水來源正常。(建
議來源水量保持在 14 公升 L/min 左右，水壓保持在 0.4 bar (0.4kgf/cm2 )，如果水量太
大會降低真空泵浦內葉片的使用壽命，且噪音會較大。)
(2) 使用時可注意泵浦循環水入口處有無進水及出水口處有無大量空氣與水噴出，如果有
即表示運轉正常。
(3) 真空泵浦所排出的水已受到污染，請直接排放掉或做獨立循環水槽，不要與其他可以
回收的水系統接在一起。
試機注意事項 2/3
 (4) 真空泵浦入水口處有加裝一組 T 型裝置，在 T 型上部有一小球閥，請勿關閉，
此為防止在真空狀態下泵浦長期運轉會因無空氣而使葉片因振動而磨損。
(5) 真空泵浦請勿長期不使用，水封式泵浦最少一星期啟動一次。
(6) 請定期（約 1~3 個月）檢查水封式真空泵浦的真空吸入口處有一只銅逆止閥，
逆止閥內若有異物卡住或逆止閥片破損，會使污水或油逆流入主槽內，檢查方
式為時常觀察檢視主槽在無原料且在高真空度時，逆止閥上方的透明管內是否
有水或油逆流的現象。
(7) 桶槽在真空狀態中嚴禁昇降。
(8) 桶槽內在真空狀態時，真空指示燈（PL5）會亮，桶蓋不能上昇。（如果桶槽內確定為
常壓狀態下，但真空指示燈會亮，可能是桶蓋上的真空安全微動開關（LS4）錯誤動
作，請檢查。）
(9) 乳化運轉中請勿同時啟動真空泵浦，防止原料飛濺而吸入真空泵浦內。

10. 再次檢視試機準備所需事項，如電源、冷卻水源、排水、蒸氣來源、壓縮空
氣等事項。

11. 試機工作完成後，請關閉電源，將機體徹底清潔乾淨，以備正式生產使用。

12. 本機嚴禁用水直接向控制面板或馬達部位清洗，用濕布清潔即可，以避免產
生漏電或電子零件損壞。維修更換零件時必須關閉電源。

13. 本機馬達嚴禁逆轉。(請依機台貼紙箭頭為準)，如因故必須移動機台，則上
述事項須重新執行一次，以確保操作順利。

14. 槽內無原料狀態中嚴禁加熱。

15. 操作架台以及機台四周應保持乾燥，避免人員操作機台時滑倒導致受傷。

16. 請依照本手冊說明操作本機台，以避免使用操作失誤導致人員受傷，未依
照本廠使用手冊產生意外，機械製造商免除一切責任。

試機注意事項 3/3
 主機規格

1. 品名：真空乳化攪拌裝置

2. 型號：HS-500AS

3. 乳化攪拌部：15 HP(11KW)東元馬達，變頻器調速(三菱) 540 – 3600 RPM

4. 中心攪拌部：7.5 HP(5.5KW)東元馬達，變頻器調速(三菱) 15 – 90 RPM

5. 刮邊攪拌部：10 HP(7.5KW)東元馬達，變頻器調速(三菱) 15 –60 RPM

6. 昇降部：2 HP(1.5KW)油壓馬達，及油壓泵浦組合 。

7. 真空裝置：5 HP(3.7KW)水封式真空泵浦，含真空安全裝置。

8. 乳化頭：低粘度乳化頭。

9. 溫度調節方式：溫度探針感應，自動溫度控制器控制，自動蒸氣加熱，

自動冷卻水冷卻。

10. 加熱方式：桶槽三層式，夾層蒸氣加熱方式 (蒸氣來源客戶自備) 。

11. 冷卻方式：桶槽三層式，夾層水冷卻方式 (地下水、自來水客戶自備)。

12. 桶槽： 三層式，加溫及冷卻設備（夾層最大壓力 1.9 KGF/CM2，加熱 110℃）

內層 SUS#316L x 6mm，內層 400# 拋光處理

中層 SUS#304 x 6mm
外層 SUS#304 x 3mm，外層 300# 拋光處理
乳化中心軸 SUS#316L，搔邊攪拌 SUS#316L
全容量: 650 公升，處理量: 500 公升

13. 槽蓋配件

(1) 桶蓋法蘭附 VITON 密封圈

(2) 附視鏡 (附雨刷)
(3) 投光燈：24V X 70W
(4) 入料口 (含過濾器)
(5) 真空空氣過濾器
(6) 香料添加口
(7) 真空安全弁及真空錶
(8) 真空液位控制器

主機規格 1/2
14. 安全裝置及控制一式

15. 出料方式：A. 桶底閥出料：2-1/2 ” 手動球塞閥

B. 桶槽傾倒出料 (自動油壓控制)

16. 操作控制箱一式 (控制電源 DC 24V)。

17. 工作架台及樓梯 SUS#304 一式 。

18. 電源：380V X 50Hz X 3 PHASES

主機規格 2/2
 主機操作說明
1. 入料方式：
(1) 將桶蓋打開直接將原料投入。(昇起桶槽前請注意槽內真空是否已排除)
(2) 或利用真空將原料吸入攪拌槽內。

2. 出料方式：
(1) 將桶蓋昇至最高，利用油壓控制桶槽傾倒出料。
a. 產品性質粘稠度較高的。
b.在昇起桶蓋前請注意槽內真空是否排除。
(2) 利用桶底閥自然出料。(須為流體產品)

3. 乳化攪拌：
利用變頻器來控制乳化頭的速度，540 – 3600 RPM，轉速可顯示在操作儀表
上。在內導葉片的渦輪高速迴轉時，會產生類似幫浦般作用力，不斷將自底
部將產品往上吸，造成槽內強大的循環功能。產品在高速通過內導葉片僅
0.3-0.5mm 的間隙時，會產生強烈的剪斷力及摩擦力，可以將產品微粒均質
化。每一次乳化所需時間及速度均與產品特性有關。生產相同的產品必須記
錄其生產時間與轉速，始可每次均得出相同品質的產品。而且各種乳化頭有
不同的操作方式，操作人員必須詳加記錄生產程序，以確保每次生產的品質
都相同。如需更換不同型式的乳化頭組件，請參考更換的組立圖(請洽詢本
廠)。本公司所使用的乳化中心軸裝置有衛生級德製耐酸鹼的油封；
軸心油封磨擦處利用超高硬度的處理，硬度 60 是非常堅固耐磨損的構造。

4. 刮邊攪拌：(TEFLON 刮片加長設計)
刮邊攪拌功能是在冷卻熱交換過程中，負責將粘在桶槽內壁上的原料刮取下
來，可促進熱交換及移動對流效果。在刮邊的羽根上附有 TEFLON 材質的
翼片。這些翼片是緊貼於桶槽內壁上，無論高粘度物或低粘度物都非常適合。
攪拌速度可利用變頻器來調整，15– 60 RPM，轉速可顯示在操作儀表上，讓
操作人員可以輕易讀取並記錄下來。羽根 TEFLON 刮片採用可拆卸設計，不
需利用工具，即可輕鬆完成拆裝工作。

5. 中心攪拌：
中心攪拌槳葉與慢速刮邊採正反轉方向運轉，中心槳葉與刮邊翼片角度不
同，可使產品產生上下相互混合功能，縮短冷卻時間。中心槳葉為焊接固定
型，清洗容易方便。

6. 真空泵浦：
高黏性乳化物，特別是乳霜、軟膏類產品等在製造過程中，最容易遭遇的問
題是在高速乳化或攪拌過程中，有空氣混入製品中產生氣泡，而這些氣泡會
使產品污染並產生酸化。我們在操作真空泵浦時，必須待產品為乳化完畢狀
態，而且溫度不宜過高，最理想的操作溫度是在 50℃以下。避免在高溫時使
用，因為使用容易造成將內槽的蒸發的水分吸走，會影響產品的軟硬度。

操作說明 1/4
 而且在高溫中操作真空容易造成產品在低溫沸騰，影響產品特性並破壞其結
構。在剛開始使用真空泵浦時，產品會很快的上浮，本機設有真空自動控制
液位器，當產品上浮達最高點位置時，會暫時關閉真空，待產品下降時會自
動再次開啟真空，如此反覆操作幾次，等產品上浮力不大時，再讓真空持續
運作至產品完全脫泡再關閉真空電源即可。

7. 油壓部：
油壓可分為上昇及下降，當按上昇時，油壓會自動昇至最高點，由極限開關
控制停止高度。須下降時請將手押著下降鈕，油壓會降至接觸極限開關而停
止。下降時，非操作人員必須遠離主槽邊，以策安全。（下降時請勿將任何物
品置放在定點位置）

8. 加熱系統：
(1) 夾層承受壓力為 1.9kgf/cm2，加熱 100℃。蒸氣進入本機前請裝置減壓弁、過濾
器，並設定於 1.9kgf/cm2。
(2) 欲使用蒸氣加熱時，須先設定所須加熱溫度，打開加熱選擇開關，打開主槽下
方快速排放水手動閥，將夾層中的水全部排除後關閉快速排放水手動閥。
(3) 當溫度到達設定值時，蒸氣電磁閥會自動關閉。如果溫度下降時，則蒸氣電磁
閥會自動開啟使溫度回升至設定溫度。
(4) 在蒸氣加熱時，當溫度到達時夾層蒸氣會自動排放，使產品的溫度保持在所設
定的溫度，不會升高。
(5) 請定期清洗管路過濾器內之過濾網。
(6) 如果電磁閥故障或動作不良時，也可以手動打開桶槽後面的排氣手動閥(蒸氣快
速排放手動閥)及關閉 蒸氣入手動閥。

9. 冷卻系統：
(1) 本機設有冷卻水 (自來水或地下水) 循環系統，當需要冷卻時，請將溫控器調整
至所需冷卻溫度，再打開冷卻開關，水進出氣動閥也會打開。
(2) 循環水的進出均受同一控制操作。
(3) 請定期清洗管路過濾器內之過濾網。
(4) 當冷卻降溫至 55℃時，可以考慮使用冰水循環系統，使溫度下降更快。
(5) 如果冷卻水要回收使用，其管路須為可耐溫 80℃

10. 溫度調整及自動控制器：
溫度控制是依桶槽底部的 PT 測溫偶來傳導溫度。每次依所需溫度設定完成並
開啟電源後，控制器會啟動 Y 型氣動閥加熱。溫度是從桶槽上方往下傳熱。
而測溫偶便會傳輸所感應到的溫度。當溫度達到所需溫度時，控制器會自動
切斷 Y 型氣動閥，如果溫度下降時，它會馬上供給 ON 的電源。如此持續的
到達所需的溫度，但夾層中的餘溫會使溫度較所設定的溫度高 3-4℃左右。請
操作人員依現場實際操作情形來做調整。

操作說明 2/4
11. 燈光投入：
在操作中如需觀看內槽攪拌情形，請打開投光燈。如不須使用時，請隨手關
閉，可保持燈泡壽命。

12. 馬達速度調整：
利用變頻器調速旋鈕來調整所需速度，本機在出廠前已設定合適數據。如操
作中有任何問題，請參閱變頻器手冊或連絡本廠。

13. 安全裝置：
(1) 油壓的上昇及下降，傾斜及歸位均設極限開關控制其定位點。
(2) 桶槽傾斜及歸定位都由油壓控制。如果桶槽沒有歸定位則所有按鍵均不
能操作。(只有油壓上昇可以操作)
(3) 各部馬達均設負載保護裝置。
(4) 真空安全裝置：桶槽內如果在真空狀態中或是加壓狀態中，油壓上昇的電
源會自動被切斷。此為防範操作中不慎啟動油壓的安全裝置。
(5) 攪拌機在桶蓋昇高時無法動作，如果必須動作時，先將油壓上昇至最高
點，請按住寸動鈕，就會自動啟動刮邊攪拌。
(6) 此機裝有緊急停止裝置，遇緊急狀況必須立刻停機時，可用此鍵，在主
操作盤上。
(7) 槽蓋下降時，設有警示鈴裝置。
(8) 控制箱打開時，有安全裝置將控制電源切斷，所有動作均會停止。
(9) 維修任何動作時，請將電源完全關閉。

14. 真空液位控制：使用真空脫泡時會使產品液面上昇，而液位控制會使產品
液面在到達一定高度時，停止真空動作，液位過高指示鐙會閃爍，按真空 OFF
按鈕可以解除閃爍鐙。如此可防止產品被吸入真空內。

15. 真空泵浦使用注意事項：(水封式真空泵浦)
(1) 在每次使用時可注意泵浦循環水入口處有無進水及出水口處有無大量空氣與水
噴出。
(2) 真空泵浦的循環水請注意水量大小，建議每分鐘約 14 公升（L/min） ，水壓
2
保持在 0.4 bar (0.4kgf/cm )，請利用入水口的球閥調整水量，如果水量太大
或沒有水則會降低泵浦的使用壽命。
(3) 如果運轉 3 分鐘後，真空度在 50cmHg 以下且噪音很大，請確認泵浦循環
水是否配管接妥及循環水水量是否正常。
(4) 當真空達到頂峰時 70cmHg，如果出現極大的噪音，可能是真空泵浦循環
水之進水量太大現象，先將進水口處之球閥關小一點。

操作說明 3/4
 (5) 此型泵浦當真空達到頂峰時，會出現極大的音量，此時請將真空關閉，待
洩壓後再啟動，可維持真空泵浦壽命。（請參閱使用保養手冊）
(6) 真空泵浦請勿長期不使用，水封式泵浦最少一星期啟動一次。
(7) 真空泵浦入水口處有加裝一組 T 型裝置，在 T 型上部有一小球閥，請依需
要調整進氣流量，請勿關閉，此為防止在真空狀態下泵浦長期運轉會因無
空氣而使葉片因振動而磨損。
(8) 請定期（約 1~3 個月）檢查水封式真空泵浦的真空吸入口處有一只銅逆止閥，
逆止閥內若有異物卡住或逆止閥片破損，會使污水或油逆流入主槽內，檢查方
式為時常觀察檢視主槽在無原料且在高真空度時，逆止閥上方的透明管內是否
有水或油逆流的現象。
(9) 桶槽在真空狀態中嚴禁昇降。
(10) 桶槽內在真空狀態時，真空指示燈（PL5）會亮，桶蓋不能上昇。（如果桶槽
內確定為常壓狀態下，但真空指示燈會亮，可能是桶蓋上的真空安全微動開關
(LS4）錯誤動作，請檢查。）
(11) 乳化運轉中請勿同時啟動真空泵浦，防止原料飛濺而吸入真空泵浦內。

16. 蜂鳴器操作說明：
(1) 當油壓（桶蓋）正在下降中時，蜂鳴器會鳴叫，警告操作者要注意機台上
不要放置任何物品及人員要離開桶蓋及橫樑下方。
(2) 當桶蓋處於開啟狀態時，如果要強迫攪拌機構運轉時， 須將桶蓋昇至最頂
點，並按住寸動按鈕，才能啟動攪拌機構，此時蜂鳴器會鳴叫，警告人員須離
開攪拌葉片的運轉範圍。
(3) 當乳化的運轉計時器時間到時，（即乳化完成時）蜂鳴器會鳴叫，此時只
要將乳化計時器的”RST”按鈕按一下，將計時器歸零即可使蜂鳴器停止鳴
叫。
(4) 當主槽加熱完成時，蜂鳴器會鳴叫，只須將主槽加熱選擇開關轉至 OFF，
即可關閉蜂鳴器。
(5) 主槽冷卻完成時，蜂鳴器會鳴叫，只須將主槽冷卻選擇開關轉至 OFF，即
可關閉蜂鳴器。
(6) 當冷卻完成時，控制箱內有 1 計時器”T２”，會開始計時，
（出廠設定 20 分鐘），
當時間到，會自動關閉乳化，攪拌，及真空等功能。如須恢復功能只須將主槽
冷卻選擇開關轉至 OFF 即可，或關閉蜂鳴器停止蜂鳴器鳴叫。

17. 桶槽清洗、消毒操作說明：
(1) 主槽可利用蒸氣鍋爐的蒸氣消毒。
(2) 當主槽清洗乾淨後，可利用蒸氣來消毒及乾燥主槽內水分，達到 G..M.P.
的規範。

操作說明 4/4
 油水相攪拌規格

1. 水相攪拌槽
(1) 桶槽： 三層式，內層 SUS#316L x 5mm ，內層 400#拋光處理
中層 SUS#304 x 5mm
外層 SUS#304 x 3mm
全容量：400 公升，處理量：150-300 公升
(2) 攪拌馬達：5HP(3.75KW)固定型攪拌機，附變頻器(三菱) 50 – 300 RPM
(上部攪拌裝置，風扇型葉片)
(3) 溫度調節方式：溫度探針感應，自動溫度控制器控制
(4) 加熱方式：桶槽三層式，蒸氣加熱方式 （蒸氣來源客戶自備）
(5) 冷卻方式：桶槽三層式，夾層水冷卻方式 (地下水、自來水客戶自備)。
(6) 桶底弁：1-1/2”氣動球閥（氣壓來源客戶自備）
(7) 原料輸送：自吸式

2. 油相槽
(1) 桶槽： 三層式，內層 SUS#316L x 5mm，內層 400#拋光處理
中層 SUS#304 x 5mm
外層 SUS#304 x 3mm，
全容量：400 公升，處理量：150-300 公升
(2) 攪拌馬達：5HP(3.75KW)固定型攪拌機，附變頻器(三菱) 50 – 300 RPM
(上部攪拌裝置，風扇型葉片)
(3) 溫度調節方式：溫度探針感應，自動溫度控制器控制
(4) 加熱方式：桶槽三層式，蒸氣加熱方式(蒸氣來源客戶自備)
(5) 冷卻方式：桶槽三層式，夾層水冷卻方式 (地下水、自來水客戶自備)。
(6) 桶底弁：1-1/2”氣動球閥（氣壓來源客戶自備）
(7) 原料輸送：自吸式
 油水相攪拌操作說明
1. 攪拌部份：
固定型攪拌機，攪拌速度可利用變頻器調整。
油相固型物如果太大時，油相攪拌器請勿啟動，待固型物溶解後，不影響攪
拌時，再啟動轉速。

2. 蒸氣加熱：
本機夾層承受壓力為 1.9kgf/cm2，加熱 100℃。蒸氣來源請裝置減壓弁、過濾
器(客戶自備)，並設定於 1.9kgf/cm2。欲使用蒸氣加熱時，須先設定所須加熱
溫度，打開加熱開關，並打開排氣開關，從快速排氣 Y 型氣動閥將夾層中的
水全部排除後，關閉排氣開關。當溫度到達設定值時，Y 型氣動閥會自動關
閉。如果溫度下降時，則 Y 型氣動閥會自動開啟使溫度回升至設定溫度。
在蒸氣加熱時，當溫度到達時夾層蒸氣會自動排放，使產品的溫度保持在所
設定的溫度，不會升高。

3. 冷卻系統：
(1) 本機設有冷卻水 (自來水或地下水) 循環系統，當需要冷卻時，請將溫控
器調整至所需冷卻溫度，再打開冷卻開關，水進出氣動閥也會打開。
(2) 循環水的進出均受同一控制操作。
(3) 請定期清洗管路過濾器內之過濾網。
(4) 當冷卻降溫至 55℃時，可以考慮使用冰水循環系統，使溫度下降更快。
(5) 如果冷卻水要回收使用，其管路須為可耐溫 80 ℃

4. 溫度自動控制器：
溫度控制是依桶槽底部的 PT 測溫偶來傳導溫度。每次依所需溫度設定完成並
開啟加熱選擇開關後，控制器會啟動 Y 型氣動閥加熱。溫度是從桶槽上方往
下傳熱。而測溫偶便會傳輸所感應到的溫度。當溫度達到所需溫度時，控制
器會自動切斷蒸氣電磁閥，如果溫度下降時，它會馬上打開 Y 型氣動閥。如
此持續的到達所需的溫度，但夾層中的餘溫會使溫度較所設定的溫度高 3-4℃
左右。請操作人員依現場實際操作情形來作調整。

5. 油水相原料輸送可利用真空吸引方式投入主機。(如果油相原料後投入主機，
請保留少許水相原料，待油相原料進入後，再將剩餘水相原料吸入主機，可
順便清洗原料輸送管)

6. 夾層壓力可承受水壓 4kgf/㎝ 2 ，實際操作壓力為零。排水口嚴禁裝置球弁，

採用自然排洩方式。

7. 夾層壓力安全弁設定在 2.5 kgf/㎝ 2 ，此為防止操作錯誤，使夾層內如產生壓

力，安全弁會自動排除。(操作壓力請保持在 1.9kgf/cm2)
 故障排除

故障情形 原因 解決方法
1. 乳化不動作 1. 桶槽未定位 1. 將桶槽確實歸定位，定位燈亮或調整定
位極限開關。
2. 桶蓋沒蓋好 2. 將桶蓋蓋好或調整下限極限開關
3. 過載保護跳脫 3. 查明跳脫之原因再復歸
4. 變頻器故障 4. 請查看變頻器手冊或連絡本廠技術人
員。
5. 乳化計時器時間到達 5. 請按乳化計時器歸零鍵
2. 中心攪拌或刮 1. 桶槽未定位 1. 將桶槽確實歸定位，定位燈亮或調整定
邊攪拌機不 位極限開關。
動作 2. 桶蓋沒蓋好 2. 將桶蓋蓋好或調整下限極限開關
3. 過載保護跳脫 3. 查明跳脫之因再復歸
4. 變頻器故障 4. 請查看變頻器手冊或連絡本廠技術員。
5. 攪拌計時器時間到達 5. 請按攪拌計時器歸零鍵。
3. 油壓不能動作 1. 桶槽內有真空未排除 1. 將真空排除
2. 桶槽未定位 2. 將桶槽確實歸定位，定位燈亮
3. 過載保護跳脫 3. 查明跳脫之原因再復歸
4. 真空已排除但真空指示 4. 真空安全開關卡住，用手按下並放開，
燈仍亮著 使其正常運作
4. 真空泵浦不動 1. 過載保護跳脫 1. 查明跳脫之原因再復歸
作 2. 久未使用，生銹卡住 2. 利用真空泵浦的馬達風扇處轉動一下
(水封式泵浦) 即可再次啟動。
3. 桶槽未定位 3. 將桶槽確實歸定位，定位燈亮或調整定
位極限開關。
4. 桶蓋沒蓋好 4. 將桶蓋蓋好或調整下限極限開關
5. 液位過高 5. 檢查產品是否有黏在液位感應器上或
將感應器整個拆下確實清潔。
5. 油水相槽攪 1. 過載保護跳脫 1. 查明跳脫之因再復歸
拌機不動作 2. 變頻器故障 2. 請查看變頻器手冊或連絡本廠技術人
員。

故障排除 1/2
 故障情形 原因 解決方法
6. 電源已打 1. 緊急停止被按下 1. 復歸緊急停止按鈕
開，所有燈 2. 保險絲燒毀 2. 更換保險絲
均不亮 3. 電源選擇開關或緊急停 3. 將鬆動的接線確實接好
止開關的接線鬆動
4. 三相電源相系錯誤或欠 4. 檢查電源接線是否有變動，打開控制
相 箱，檢查 PVR-3 是否亮燈。（亮 RUN
及 PW 燈則正常）
5. 控制箱門未關好 5. 將控制箱門確實關好並檢查控制箱門
右下角之微動開關動作是否正常
6. 氣壓壓力不足 6. 檢查氣壓三點組合上的壓力表須在 5-6
Kgf/cm 2 之間
7. 加熱或冷卻 1. 溫控器顯示的溫度異常 1. 檢查溫控器是否顯示”FFF”，如果顯
不動作 高或是顯示”FFF” 示”FFF”的話，表示溫度探針與溫控器
之間的傳導線斷掉，或是溫度探針損
壞，請修復。
2. 改變設定值，並觀察溫控器上的 ON 指
2. 溫控器的溫度設定值不
示燈是否亮起，亮起即為正常
適當
3. 將開關選擇在正確位置上並檢視開關
3. 開關 COOL/OFF/HEAT
上的接點加以修復
轉在 OFF 或接點上的線
鬆脫
4. 將桶槽確實歸定位
4. 桶槽未定位，定位指示
燈未亮起
5. 當加熱指示燈亮起時，電磁閥 SOL.6
5. 加熱或冷卻指示燈亮
要動作，端子 TB2 的 38,2 應有
起，但是電磁閥無動作 DC-24V；當冷卻指示燈亮起時，SOL.7
要動作，端子 TB2 的 41A,2 應有
DC-24V 如果上述電壓值都正常，則為
氣壓電磁閥 SOL.6 或是 SOL.7 有損
毀，請更換。
檢查方法如下：
a. 請按住氣壓電磁閥上的手動強迫啟
動按鈕檢查測試。
b. 拆下線圈，用起子檢查是否電磁吸
力。

故障排除 2/3
 故障情形 原因 解決方法
6. 氣壓電磁閥有動作但 Y 6. 檢查氣壓三點組合上的壓力表須在 5-6
型氣動閥無動作 Kgf/cm 2 之間或氣壓管路阻塞。Y 型氣
動閥有動作指示器，當氣動閥閥門打開
時，有長條紅色標記顯示，當氣動閥閥
門關閉時，有一點紅色標記顯示。
8. 加熱中溫度 1. 溫控器顯示的溫度低於 1. 溫控器或溫度探針損壞（請先記錄不同
超過設定溫 實際溫度 3℃ 溫度時(40 至 85 度)，溫控器顯示的溫
度 10℃以上 度與實際溫度值）。
2. 溫控器正常，加熱指示 2. 蒸氣排放電磁閥 SOL.8 在溫度到達沒
燈不亮 有打開，請檢查是否故障。
3. 在蒸氣快速排放手動閥 3. 蒸氣入 Y 型氣動閥被異物卡住，請拆
下閥心部分加以清洗。 （請先關閉蒸氣
已打開的情況下，溫度
來源並等待管路冷卻之後再處理）
仍然上升

故障排除 3/3
 保養維護

1. 將操作箱內面板的電源選擇開關打開後，定位指示燈亮，表示電源輸入正
常。如果指示燈未亮，請注意桶槽是否確實歸定位。

2. 油壓昇降中及昇高至定位時，各部按鍵會切斷電源無法操作，必須等油壓
歸回定位時，才可恢復正常操作。如果油壓降下歸位後仍無法正常操作各
部按鍵，請檢查下降引導桿的下限微動開關，只要調整引導桿的定位器，
上下調整即可恢復正常。

3. 如果機械運轉中突然停止，就是過載保護開關跳脫，請重新按下 RESET 鍵
即可正常使用。

4. 如果重新輸入總電源時，請注意油壓上昇是否正常及攪拌機轉向，如果油
壓可正常上昇及馬達轉向正確，則其他功能也正常。或是檢查控制箱內左
側的”PVR-3”RELAY 的 RUN 指示燈，正常時 RUN 燈要亮。如果不對將電
源線 L1、L2、L3 三相的 L1、 L3 相對調。

5. 如果乳化馬達及刮邊馬達不使用時，請務必隨手關閉。

6. 刮邊攪拌鐵弗龍翼片可取下清洗。

7. 中心攪拌軸心及攪拌葉片可用熱水開啟高速乳化機清洗。

8. 清洗乳化頭，請注意水位必須高出乳化頭 15 ㎝以上，以免空轉造成損害。

9. 如果乳化頭或攪拌軸心運轉中有異聲，請連絡本廠更換所需零件。

10. 真空泵浦長期不使用，須固定每週運轉 5 分鐘。

11. 夾層壓力安全弁設定在 2.5 kgf/㎝ 2 ，此為防止操作錯誤，使夾層內如產生

壓力，安全弁會自動排除。(操作壓力請保持在 1.9kgf/cm2)

12. 嚴禁用水直接噴洗控制箱或馬達部位。

保養維護 1/2
 13. 用蒸氣清洗內槽，如果滿水位時，溫度達沸騰時，請注意內槽水溫及壓力，
最好槽蓋上方的閥門全部打開，避免壓力大，造成氣爆。

14. 機械各部用油： （請參考油品使用資料）

(1) 減速機：每年檢查油位一次，使油保持在油鏡的 1/3~2/3 間。油位低於油
位鏡 1/3 時，才須加油。須添加抗磨耗的齒輪機油。
(2) 油壓部份：定期檢查油壓降下時油箱的油位指示器，當油位低於一半時必
須立即補充；如果油的顏色變為白黃色時，須更換 ISO 46 (SAE 20)高級
液壓循環油。
(3) 昇降導桿須每月擦拭，並加黃油潤滑。
(4) 真空泵浦：真空泵浦請勿長期不使用，水封式泵浦最少一星期啟動一次。
(5) 水封式真空泵浦每個星期檢查一次循環水是否水量正常。
(6) 齒輪箱：每三個月加入約 20GM 黃油。

15.管路過濾器請定期清洗。（請設定三個月一次）。

16.蒸氣管路須外覆保溫材質，可防止人員燙傷及蒸氣消耗。

17.任何維修事項，維修人員必須關閉電源防止意外發生。

18.電氣控制箱內保持清潔。

19.乳化中心軸密封圈(油封)請於使用一年或是 400 小時之後更換，確保操作順暢。

(請依照軸心圖面作業)

保養維護 2/2
 例行保養項目
1. 油壓循環油部分：
(1) 檢查方式：當桶蓋閉合時，油位須超過油位視鏡。如果管路有漏油現象，須鎖
緊接頭部份。
(2) 每 6 個月檢查一次，如果無漏油現象，改為每年檢查一次。

2. 水封式真空泵浦，請於每次使用完畢後檢查。
(1) 水封式真空泵浦則每個星期檢查一次循環水是否水量正常。
(2) 真空泵浦請勿長期不使用，最少一星期啟動一次，連續運轉需超過五分鐘。
(3) 請定期（約 1~3 個月）檢查水封式真空泵浦的真空吸入口處有一只銅逆止閥，
逆止閥內有異物卡住或逆止閥片破損，會使污水或油道流入主槽內，檢查方法
為時常觀察主槽在無原料且在高真空度時，逆止閥上方的透明管內是否有水或
油逆流現象，如果有水或油逆流現象表示銅逆止閥內有異物卡住或逆止閥片破
損。

3. 刮邊的減速機，每年檢查油位一次，使油保持在油鏡的 1/3~2/3 間。油位低於

油位鏡 1/3 時，才須加油，

4. 桶蓋昇降導桿：將桶蓋昇到最高點，把油壓升降導桿擦乾淨，並重新抹上新
黃油。（每月保養一次）。

5. 桶槽傾斜齒輪每年抹黃油一次。

6. 齒輪箱：桶蓋上方與乳化馬達下方之橫樑有一齒輪箱，每三個月加入約 20GM
黃油。

7. 刮邊葉片：
(1) 刮邊葉片的固定插銷，每次使用前須檢查一次。
(2) 插銷的固定位置須正確，上方插銷須末入支架內。
(3) 刮邊葉片拆換時，須注意記號是否正確。
 操作注意事項
1. 每天（次）使用前請檢查：
(1) 檢查機械本體及動力部份是否有危險物品
(2) 機械各部零件組立是否正常
(3) 機械各部位螺絲是否已確實拴緊
(4) 機械各部潤滑油是否正常
(5) 機械球閥以及安全錶是否正常
(6) 來源電源、電壓是否正常
(7) 加熱前，先利用桶底快速排水閥將桶槽夾層的水確實排空，以利快速加熱。當溫
度到達設定值時，建議將蒸氣快速排放閥打開，防止溫度繼續上升。
(8) 刮邊葉片插稍檢查。
(9) 乳化頭底下固定螺絲是否鬆動。
(10) 真空泵浦循環水是否充足。
(11) 真空泵浦請勿長期不使用，最少一星期啟動一次，連續運轉需超過五分鐘。
(12) 如果真空泵浦使用時常常會電流過載跳脫，請將過載保護電驛 RST 按一
下，並且檢查真空泵浦循環水之水量是否太大 (先將球閥完全關閉再打開約
1/4 開度) 。

2. 每天（次）使用後：
(1) 真空泵浦循環水是否足夠，並且清潔。
(2) 機台外部清潔保養。

3. 每月保養昇降導桿，並檢查機台內部是否漏油。

4. 每年檢查：
(1) 減速機油位。
(2) 油壓循環油油位。
(3) 桶槽傾斜齒輪抹黃油

5. 特別注意事項
(1) 請將蒸氣快速排放管路採開放式配管，防止蒸氣無法自然快速排出。
(2) 桶蓋上昇前，請打開吸料球閥或中間添料球閥，以防止桶蓋打開時桶內蒸氣噴出。
或者，桶槽內有真空，無法將桶蓋上升。
(3) 馬達全部禁止反轉。
(4) 如有更換電源、馬達、控制箱內電路時，須檢查馬達轉向是否正確。拆換總電源
(5) 之後，只須試油壓昇降，可以上昇，表示轉向正確。或檢查控制箱內”PVR-3”須 RUN
亮燈。
(6) 使用高速乳化時，禁止啟動真空泵浦，防止原料被吸入泵浦內。
(7) 使用乳化時，原料須高於乳化頭上方 15 公分。
(8) 電氣控制、機台及桶槽外部禁止用水直接沖洗，應用擦拭法。此為防止水進入機台
內，損壞電子零件。

6. 操作架台以及機台四周應保持乾燥，避免人員操作機台時滑倒導致受傷。

7. 請依照本手冊說明操作本機台，以避免使用操作失誤導致人員受傷，未依照
本廠使用手冊產生意外，機械製造商免除一切責任。
 油品使用資料

1. 中心攪拌及刮邊攪拌減速機：
(1) 黏度範圍 (VISCOSITY RANGE) ISO VG 320
(2) 國光牌極壓機油 HD-320
(3) SHELL OIL：OMALA OIL 320
(4) MOBIL OIL：MOBIL GEAR 632
(5) FUCHS OIL：CKC 320 (德國)

2. 油壓泵浦：
(1) 黏度範圍 (VISCOSITY RANGE) ISO VG 46
(2) 國光牌液壓機油 R-46
(3) SHELL OIL：AW-46
(4) MOBIL OIL：MOBIL DTE 26
(5) ESSO OIL：H-46
(6) LYBO OIL：RO-46 (美國)
(7) FUCHS OIL：B20 (德國)

3. 昇降導桿及齒輪箱：
(1) 使用耐溫 180℃以上之黃油
(2) 國光牌 EP-3
(3) SHELL OIL：EP-3
(4) LYBO OIL：EP-3 (美國)
(5) FUCHS OIL：CEP-3 (德國)

4. 空壓三點組合(注油器)：
(1) 黏度範圍 (VISCOSITY RANGE) ISO VG 32
(2) 國光牌 R-32
(3) MOBIL OIL：MOBIL DTE 24
(4) ESSO OIL：ESSO NUTO H32
(5) BP OIL：BP ENERGOL HLP32
(6) ARAL VITAM GF32
件號 名 稱 圖 號/規 格 件 / 台 備 註 欄 件號 名 稱 圖 號/規 格 件/台 備 註 欄
35 乳化桶 500S534P 1 1 架台 500S581P 1
36 O型環 G100 2 2 主機平台 500S605P 1
37 導料板 500S322P2 1 3 導桿定位座 750S062P 1
38 投光燈座 100S319P3 1 油箱配置圖 500S011L
4 1 杰利
39 吊環 500S594P 4 油壓迴路圖 500S010L
40 視鏡座 500S373P 1 5 油壓缸(左側) 500S575P 1 ψ125x1400ST(RODψ100)
41 O型環 ψ12.5 1 VITON 約2960L(現配) 6 出料油壓缸臂(左側) 750S040P 1
42 出料油壓缸臂(右側) 750S039P 1 7 迴轉接頭 THA-4R-32A 2 明泰
43 油壓缸 MOB63x30x400ST 2 CA+CB+Y(杰利) 8 感測導桿 500S599P 1
44 真空泵浦 MEX125-5HP 1 川景 9 導桿滑座 750S063P2 1
45 視鏡組合圖 500S192A 1 10 定位支座 200S030P 4
46 下限近接開關組合 500S188A 1 11 定位支桿 500S600P 5 228Lx4支,255Lx1支
47 真空導管組合 500S187A 1 12 馬達座(橫樑) 500S574P 1
48 傳動機構 500S183A 1 馬達外蓋固定架 500S590P 1
13
49 齒輪軸承座 500S184A 1 馬達外蓋 500S591P 1
50 乳化攪拌機構 500S185A 1 14 攪拌馬達 7.5HPx4P 1 東元
15 架台 500S589P 1
16 減速機 THHX8-613-11-7.5HP 1 享盛
17 乳化馬達 15HPx2P 1 東元
18 透明壓克力 500S604P 1
19 減速機 THHX10-614-13-10HP 1 享盛
20 刮邊馬達 10HPx4P 1 東元
21 油壓缸固定環 100S055P 2
22 油壓缸固定座 50S0092P 2
23 油壓缸上法蘭蓋 500S607P 2
24 油壓缸保護蓋 500S608P 2
25 保護蓋 500S618P 2
26 油壓缸(右側) 500S576P 1 ψ125x1400ST(RODψ100)
27 真空泵浦緩衝水槽 500S611P 1
28 刮邊攪拌裝置 500S540P 1
29 乳化桶軸 750S038P 2
30 聯座軸承 UCP215 2
31 溫度探針 160L 1
刮板 500S603P 9
32 刮板轉軸 100S180P 7
刮板定位柱組 50S0059P2 2
33 桶底閥 2 1/2"球閥 1 金永祥(TC VALVE)
34 桶蓋 500S533P 1
件號 名 稱 圖 號/規 格 件/台 備 註 欄 件號 名 稱 圖 號/規 格 件/台 備 註 欄
29 油封座 500S606P 2 1 油水相架台 500S582P 1
30 O型環 G75 2 2 小架台 500S588P 1
控制面板 500ASCAD01 1 3 樓梯 500S586P 1
控制面板孔位圖 500ASCAD02 1 4 油水相馬達蓋 500S577P 2
31 控制箱外觀圖 500ASCAD03 1 5 攪拌馬達 5HPx4P 2 東元
控制箱門 500ASCAD04 1 6 減速機 MF300x5.77x5HPxF3 2 享聖
控制箱門螺條焊接位置圖 500ASCAD05 1 7 油水相橫樑 500S578P 2
8 水相攪拌桶 500S535P 1
9 油相攪拌桶 500S536P 1
10 油水相欄杆 500S602P 1
11 溫度探針 130L 2
12 桶底閥 1 1/2"氣動閥 2
13 油水相攪拌軸 500S597P 2
14 攪拌葉 1T00174P 4
15 馬達座 500S592P 2
ψ38(10x4.3K.W)
16 聯軸器 NM-97 2
ψ32(10x3.3K.W)
鎖緊螺帽 AN-07 2
17
止動滑司 AW-07 2
18 O型環 G95 2
19 軸承墊片 500S553P 2
20 軸承 6207ZZ 4 ψ35xψ72x17
21 油水相軸承座 500S593P 2
22 油封 TC-48x65x10 2
23 油水相攪拌接軸 500S596P 2
24 光電開關 PM12-04N 2
25 軸承固定座 500S595P 2
26 O型環 ψ4 2 約748L
27 O型環 G130 2
28 軸承 6009ZZ 4 ψ45xψ75x16
件號 名 稱 圖 號/規 格 件/台 備 註 欄
1 定位支桿 500S600P 1
2 定位座 200S031P 1
3 近接開關固定座 500S601P 1
4 近接開關 PM12-04P 1
件號 名 稱 圖 號/規 格 件/台 備 註 欄
1 軸承固定座 500S542P 1
2 軸承座 500S543P 1
3 軸承墊片 500S554P 1
4 軸承 6213ZZ 2 ψ65xψ120x23
5 中心齒輪間隔環 500S549P 1
6 齒輪箱 500S546P 1
7 止推軸承 51115 1 ψ75xψ100x19
8 軸承座 500S551P 1
9 軸承固定座 500S552P 1
10 軸承座 500S548P 1
11 軸承墊片 500S569P 1
12 馬達座 500S555P 1
13 刮邊齒輪間隔環 500S550P 1
14 止推軸承 51122 1 ψ110xψ145x25
15 軸承 6022ZZ 2 ψ110xψ170x28
16 密封固定座 500S531P 1
17 軸封 TG3201300-T40 1
18 軸承 6016ZZ 2 ψ80xψ125x22
19 軸承座 500S558P 1
20 O形環 G125 1 VITON
21 擋板 500S045P 1
22 中心攪拌軸承座 500S559P 1
23 O形環 G110 2 VITON
ψ42(12x3.3K.W)
24 連軸器 NM-112 1
ψ30(10x4.3K.W)
25 馬達座 500S541P 1
26 乳化接軸 500S564P 1
鎖緊螺帽 AN07 1
27
止動滑司 AW07 1
28 軸承墊片 500S553P 1
29 軸承 6207ZZ 2 ψ35xψ72x17
鎖緊螺帽 AN13 1
30
止動滑司 AW13 1
31 軸承固定座 500S544P 1
32 軸承座 500S545P 1
33 中心從動齒輪 500S539P 1 M5x36T
34 油封 TC-75x90x12 1
鎖緊螺帽 AN20 1
35
止動滑司 AW20 1
36 軸承 6020ZZ 2 ψ100xψ150x24
鎖緊螺帽 AN22 1
37
止動滑司 AW22 1
38 測轉速光電開關托架 500S613P 2
39 刮邊從動齒輪 500S538P 1 M5x45T
40 止推軸承座 500S556P 1
41 軸承座 500S557P 1
42 O形環 G250 1
43 O形環 ψ4 1 現配(約615L)
44 O形環 G145 1 VITON
45 油封座 500S560P 1
46 油封 TC-80x100x12 3 VITON
47 軸承 6007ZZ 2 ψ35xψ62x14
48 軸承固定座 500S566P 1
ψ30(10x4.3K.W)
49 連軸器 NM-82 1
ψ30(10x4.3K.W)
50 接座 500S561P 1
件號 名 稱 圖 號/規 格 件/台 備 註 欄
1 真空導管 500S610P 1
2 導管膠墊 200S208P 1
3 真空導管座 200S209P 1
4 六角螺帽 200S210P 1
5 固定座 500S121P 1
件號 名 稱 圖 號/規 格 件/台 備 註 欄
1 視鏡刷組合圖 750S168P 1
2 O型環 G145 1
3 視鏡 750S194A 1
4 視鏡座 500S373P 1
件號 名 稱 圖 號/規 格 件/台 備 註 欄
1 接座 500S561P 1
鎖緊螺帽 AN07 1
2
止動滑司 AW07 1
3 軸承墊圈 750S117P 1
4 軸承 6007ZZ 2 ψ35xψ62x14
5 攪拌軸心 500S565P 1
6 軸承 6006ZZ 2 ψ30xψ55x13
7 O形環 G60 1
8 油封座 500S567P 1
9 乳化頭套 500S571P 1
10 O形環 G110 2 VITON
ψ30(10x4.3K.W)
11 連軸器 NM-82 1
ψ30(10x4.3K.W)
12 軸承固定座 750S118P 1
13 乳化軸心 500S562P 1
14 油封 TPYX721602T251N 2 ψ25xψ47x7
15 乳化頭(低黏度型) 500S573P 1
16 乳化頭底蓋 500S572P 1
17 乳化頭固定座 200S239P 1
MINOGA
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 彌 之 賀 工 業 有 限 公 司
Minoga Industrial Co., Ltd.
最 終 檢 驗 記 錄 表

500AS-039-2009 編號：

檢驗日期： 98 年 9 月 02 日 品名：真空乳化攪拌裝置 檢驗員：

包裝日期： 年 月 日 型號：HS-500AS 陳 永 富

外觀： 外 觀 清 潔 且 有 警 告 標 示
檢

馬力： 與 訂 單 相 符 合

驗 動作： 廠 內 測 試 動 作 正 常

管、氣：空 油 壓 動 作 正 常
項

尺寸： 與 設 計 圖 相 符 合
目
其它：

合格: R 不合格: □ 簽章： 陳 永 富

MI-MT-803-03 REV A/0
 彌 之 賀 工 業 有 限 公 司
審 查 A
品名：500AS-039-2009 編號：
R合格 S不合格 頁次：1/2

內 容

1. 是否達成合約中之要求。 R
a. 電壓是否符合。 R
b. 馬力是否符合。 R
c. 特殊控制是否達成。 R
2. 是否達成保護馬達之功能。 R
a. 500w 以上之馬達是否均有過載保護。 R
b. 當過載情況發生時，過載保護是否可以切斷電源。 R
c. 馬達的運轉負載是否在額定容量內。 R
d. 馬達的轉速是否在額定之內或在控制之中。 R
e. 馬達的散熱情況是否良好。 R
3. 是否達成保護設備之功能。 R
a. 設備之使用是否可以盡力防止不當之操作。 R
b. 設備中之油壓、空壓、馬達等是否達成保護協調，不會因正常操作中而損壞。 R
c. 所有動力是否均有接地設施。 R
d. 所有配線在可活動部份是否有外加保護措施，防止發生勾、纏、磨損等情況。 R
e. 控制箱是否達一般防水功能。 R
4. 是否達成各動力間之保護協調。 R
5. 操作功能之規劃是否完善。 R
6. 是否保護或警告操作人員之安全。 R

全部均合格: R 檢查員簽章 陳 永 富 檢查日期 98 年 9 月 02 日

MI-MT-705-08-A
 彌 之 賀 工 業 有 限 公 司
審 查 A
品名：500AS-039-2009 編號：

R合格 S不合格 頁次：2/2

內 容
7. 動力電源規劃與合約中電源規格是否符合。 R
8. 所有電氣零件之操作電壓與控制電源是否符合。 R
9. 儀表與負載是否相符合。 R
10. 馬達負載與電磁開關容量是否符合。 R
11. 所有電氣零件之耐壓能力是否高於電源電壓。 R
12. 操作電源或控制電源或變壓器等是否均有過電流保護。 R
13. 電路圖中所有電線、接線是否均有線號，且規劃完善，標示清楚。 R
14. 操作面板上的操作開關等是否標示清楚。 R
15. 操作的方便性、安全性是否規劃完善。 R

全部均合格: R 檢查員簽章 陳 永 富 查日期 98 年 9 月 02 日

MI-MT-705-08-A
 檢驗表 EA1(控制箱配線)
R合格 S不合格
內容 檢驗 備註

A.控制面板

1. 壓克力名牌 R
2. 儀表之規格 R
3. 開關規格 R
4. 如圖配置 R
5. 安裝鎖緊 R
B.底板配置
1. 如圖配置 R
2. 零件規格 R
3. 固定牢靠 R
C.動力線
1. 端頭有端子 R
2. 端頭有絶緣 R
3. 線徑鎖緊 R
4. 螺絲鎖緊 R
5. 無漏接線 R
D.控制線
1. 依電壓區分顏色 R
2. 線徑正確 R
3. 各端頭均有線號 R
4. 螺絲鎖緊 R
5. 各零件接點有依圖接線 R
6. 各接點的相對接點均有接線 R
7. 接線力求美觀 R
8. 控制箱完成後有包裝 R

全部均合格R 檢查員簽章：陳 永 富 檢查日期： 98 年 9 月 02 日

 彌 之 賀 工 業 有 限 公 司
審 查 B
品名：500AS-039-2009 編號：
R合格 S不合格 頁次：1/1

內 容

1. 電氣控制功能及設備是否完善。 R
2. 各個功能是否達成合約之要求。 R
3. 傳動機構是否安裝固定完善。 R
4. 機器操作功能及性能是否完善。 R
5. 操作人員之安全保護是否完善。 R
6. 機械與電氣之間的協調保護是否完善。 R
7. 油、水、空壓的配管、配件是否完善。 R
8. 如有任何缺失或改進建議，詳細記錄於報告上，並由電機部門、機構設計部門、廠
務部門，開會討論進行修改。
R
9. 如有不良品之零件，請存放於不良品區，並填寫不良情況。並聯絡供應商進行退貨
R
更換。

全部均合格: R 檢查員簽章 陳 永 富 檢查日期 98 年 9 月 02 日

____ MI-MT-705-08-B