07p operating manual vc999

Operating Manual Art. no. 527.763 Vali

d from machine no. 07891246

Vacuum Packaging Machines 07P ...

Inauen Maschinen AG Tel. ++41 (0) 71 35 35 900 Melonenstrasse 2 Fax ++41 (0) 71 35 35 901 CH-9100 Herisau / Switzerland E-mail [email protected]

mailto:[email protected]


Hand-over declaration

IMPORTANT The following hand-over declaration must be completed by the purchaser. The purchaser shall return the completed hand-over declaration to us. He thereby certifies that he has gained knowledge of the contents of the Operating Manual and that his attention has been drawn to the safety notes for using the machine.

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Contents

Contents

1 Introduction ......................................................................................9

1.1 General information............................................................................9 1.2 Definitions.........................................................................................10 1.3 Protection of copyright .....................................................................10

2 Safety, warranty .............................................................................11

2.1 General safety instructions...............................................................11 2.1.1 Use as prescribed ............................................................................12 2.1.1.1 Machine with an inert gas system (07PN ...) ...................................12 2.1.2 Processing materials........................................................................13 2.1.2.1 Vacuum bags ...................................................................................13 2.1.2.2 Suitable products .............................................................................13 2.1.2.3 Inert gas (07PN ...) ...........................................................................13 2.1.3 Requirements for operators .............................................................14 2.2 Explanation of the safety instructions ..............................................14 2.3 Warranty, liability ..............................................................................14

3 Description of the machine ...........................................................15

3.1 Functional principle ..........................................................................15 3.1.1 Structure of the machine ..................................................................15 3.2 Control panel ....................................................................................16 3.3 Models..............................................................................................16 3.3.1 Ejection direction..............................................................................17 3.3.2 Interconnection.................................................................................17

4 Technical data ................................................................................18

5 Packaging and transport ...............................................................20

5.1 Packaging the machine....................................................................20 5.2 Transportation of the machine .........................................................20 5.3 Unpacking the machine....................................................................20

6 Setting up the machine..................................................................21

6.1 Criteria for the installation site..........................................................21 6.2 Foundations......................................................................................21 6.3 Ambient temperature........................................................................21 6.4 Safety space.....................................................................................21

7 Interface definition .........................................................................22

7.1 Electrical connection ........................................................................22 7.2 Pneumatic connection......................................................................22 7.3 Inert gas connection (07PN ...) ........................................................22

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Contents

8 Installation of the machine ............................................................23

8.1 Electrical installation.........................................................................23 8.2 Pneumatics installation.....................................................................23 8.3 Inert gas installation (07PN ...) .........................................................24 8.4 Control or fill with oil .........................................................................25 8.5 Cleaning the machine.......................................................................25

9 Commissioning...............................................................................26

9.1 Initial start-up ....................................................................................26 9.2 General instructions..........................................................................26

10 Operation.........................................................................................27

10.1 Requirements for operation..............................................................27 10.2 Preparation .......................................................................................27 10.3 Prepare the products for packaging .................................................27 10.4 Machine preparation.........................................................................28 10.4.1 Switching on the machine ................................................................28 10.4.2 Switch pump on ................................................................................28 10.5 Packaging.........................................................................................29 10.5.1 Start packaging cycle (single cycle) .................................................30 10.5.2 Interrupt in the packaging cycle when vacuuming ...........................30 10.5.3 Switching off the machine ................................................................30 10.6 Programming ....................................................................................31 10.6.1 Selecting the packaging programs...................................................31 10.6.2 Set values for packaging program (program level) ..........................31 10.6.3 Vacuuming modes............................................................................31 10.6.4 Inert gas supply (07PN ...)................................................................32 10.6.5 Intermediate ventilation ....................................................................32 10.6.6 Sealing and cutting...........................................................................33 10.6.7 Sealing type......................................................................................33 10.6.8 Product height ..................................................................................33 10.6.9 Preventilation....................................................................................33 10.6.10 Transport time ..................................................................................34 10.6.11 Autostart interval...............................................................................34 10.6.12 Number of locked programs .............................................................34 10.6.13 Sequence diagram Program level ....................................................36 10.6.14 Program table ...................................................................................37 10.7 Service settings ................................................................................38 10.7.1 Raise platform ..................................................................................38 10.7.2 Close lid............................................................................................39 10.7.3 Operating data..................................................................................39 10.7.4 Key switch ........................................................................................39 10.7.5 Sequence diagram service settings .................................................40

11 Malfunctions ...................................................................................41

11.1 Faults and their remedies.................................................................41 11.1.1 Sealing current monitoring ...............................................................43 11.2 Possible operating malfunctions.......................................................44

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Contents

12 Service program.............................................................................45

12.1 Structure of the service program......................................................45 12.1.1 Entry into the service program .........................................................46 12.2 Error diagnosis .................................................................................46 12.3 Initial settings....................................................................................47 12.3.1 Intermediate ventilation ....................................................................47 12.3.2 Gas flush ..........................................................................................47 12.3.3 Automatic Operation ........................................................................48 12.3.4 Mode of transport .............................................................................48 12.3.5 VVO-holding until ventilation ............................................................48 12.3.6 Lid closing pulse...............................................................................48 12.3.7 Sealing bar pressing time.................................................................48 12.3.8 Cooling time .....................................................................................49 12.3.9 Raise sealing bar time......................................................................49 12.3.10 Pneumatic oiler impulse time ...........................................................49 12.3.11 Pneumatic oiler cycle interval...........................................................49 12.3.12 Water separation after no. of cycles.................................................49 12.3.13 Tolerance conveyor levelling............................................................50 12.4 Test programs ..................................................................................51 12.4.1 Check procedure: vacuum calibration..............................................51 12.4.2 Check: chamber / pressure below....................................................52 12.4.3 Check procedure: platform adjustment ............................................53 12.4.4 Check procedure: sealing bar temperature......................................53 12.4.4.1 Calibration of the sealing time adjustment .......................................54 12.4.5 Check of EPROM.............................................................................54 12.4.6 Sequence service program ..............................................................55

13 Maintenance....................................................................................56

13.1 Checks .............................................................................................56 13.1.1 Checking vacuum chamber lid .........................................................56 13.1.2 Checking the lid seal ........................................................................56 13.1.3 Checking platform ............................................................................57 13.1.4 Checking compressed air service unit .............................................57 13.2 Cleaning ...........................................................................................58 13.2.1 Detergent..........................................................................................58 13.2.2 Cleaning interval ..............................................................................58 13.3 Maintenance work ............................................................................59 13.3.1 Displayed servicing works................................................................59 13.3.2 Service sealing bar and sealing pad ................................................59 13.3.3 Maintenance vacuum pumps ...........................................................61 13.3.3.1 Rotary slide vacuum pump...............................................................61 13.3.3.2 Roots vacuum pump (07P... / 220W500).........................................63 13.3.4 Replace fuses...................................................................................64 13.3.5 Replace the electronics board..........................................................64

14 Repairs ............................................................................................65

15 Spare parts......................................................................................65

15.1 Ordering spare parts ........................................................................65

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Contents

16 Disposal...........................................................................................66

17 Pneumatics diagram ......................................................................67

18 Circuit diagrams .............................................................................68

19 Sequence diagram..........................................................................72

20 Index ................................................................................................73

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Introduction

1 Introduction

1.1 General information

• This product manual must be read, understood and complied with fully by the operators who are responsible for the vacuum packaging machine.

• All the technical documentation should be kept beside the vacuum packaging machine (called the

machine below) at all times. • We recommend that you read the Operating Manual carefully before putting the machine into

operation as we will not accept liability for any injuries, damage or operational problems resulting from failure to comply with this Operating Manual.

• It is essential that you familiarise yourself with this Operating Manual in order to avoid operating

errors and to ensure that the system operates without any problems. Therefore, it is very important that the relevant personnel read this Operating Manual.

• This machine has been built according to the state of the art and carries on Inauen Maschinen AG’s

long tradition of Swiss high-quality workmanship, productivity and reliability. In particular, the machine complies with the Machinery Directive 98/37/EC and subsequent amendments to that.

• However, if any problems do occur, please contact our Customer Service Department who will be

only too happy to help. • The diagrams and data contained in this Operating Manual are subject to modifications if these are

required in order to improve the machine. • Dimensions and designs are subject to changes.

Customer Service Department, Switzerland

The manufacturer’s address is shown on the machine’s rating plate. Always quote the machine type and serial number, which are also shown on the rating plate. The rating plate is located on the back of the machine. Manufacturer: Inauen Maschinen AG Address: Melonenstrasse 2 CH-9100 Herisau Tel: ++41 (0)71 35 35 900 Fax: ++41 (0)71 35 35 901 E-mail : [email protected] Website : www.vc999.biz

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mailto:[email protected]

http://www.vc999.biz/


Introduction

1.2 Definitions

The following terms are used in this Operating Manual to describe the people who work with or on the machine:

Owner

Owners are firms which have entered into a contract with the manufacturer or its agent. Owners are legally entitled to sign contracts. They purchase the vacuum packaging machine and ensure that it is used as directed.

Operator, operating personnel

The operating personnel or operator are instructed or authorised by the owner to operate the machine and are trained how to do this. They must have read and understood the Operating and Maintenance Manual.

Technician, technical personnel

The technical personnel or technician are instructed by the owner to perform assembly, installation, maintenance, repair work or trouble shooting. They must have read and understood the Operating and Maintenance Manual.

1.3 Protection of copyright

This Operating Manual must be treated as confidential. All the data and information contained in this Operating Manual are protected by the Copyright Act. Breaches of copyright are punishable by law and will result in fines. This Manual contains information which is protected by copyright. It may not be duplicated, copied, transferred onto microfilm or disclosed to any third parties without the permission of Inauen Maschinen AG, in whole or in part. Breaches of copyright will result in fines.

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Safety, warranty

2 Safety, warranty

2.1 General safety instructions

Pay particular attention to the following instructions: • Anyone in the owner’s factory who is involved in the installation, commissioning, operation and

servicing (inspection, maintenance, repairs) of the machine must have read and understood the complete Operating and Maintenance Manual, in particular Chapter 2 "Safety, warranty".

• This machine has been manufactured and assembled according to the state of the art and is safe to

operate. We attach particular importance to the safety of the users and to arranging the controls ergonomically.

• In order to guarantee the safety of the operator, we have taken care to ensure that the purchased

parts of the machine also comply with the Machinery Directive 98/37/EC. The vacuum pump comes with a certificate. The declaration of conformity of the manufacturer of the vacuum pump is available from the machine manufacturer.

• Our Quality Assurance Department (QS) performs continuous tests on individual parts and on the

complete machine. • All safety and protective equipment is included in this safety concept which is geared towards

protecting everybody employed to work on or with this machine against dangers.

IMPORTANT o modifications may be made which change or prevent the functioning and action of the safety and protective equipment. The manufacturer refuses to accept liability in those cases!

• The machine should only be operated if all the safety and protective equipment is in place and working correctly.

IMPORTANT Always follow the switch-off procedures outlined in the Operating Manual during all installation, commissioning, operation, resetting, adjustment and maintenance work.

• No process should be carried out which reduces the safety of the machine. • The operator has to immediately report any changes to the machine which lessen safety standards. • The operator should only operate the machine if it is in perfect working order. • The user has to give appropriate instructions and perform checks to ensure that the area around the

machine is kept tidy and well organised.

IMPORTANT The machine MUST be switched off before installation, service and repair work is carried out on it. Before this work gets under way, switch off the main switch and put on a padlock to prevent the machine being switched on inadvertently. Keep the key out of the reach of other people!

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Safety, warranty

IMPORTANT Before working on any pneumatic components, remove the pressure from the relevant supply line!

• When the servicing is complete, check that all the safety equipment is in place and working properly before switching the machine back on.

• Following electrical installation or servicing, test the safety measures (e.g. earthing resistance). • The machine must be operated in compliance with local safety and accident prevention regulations. • This Operating Manual represents part of the machine. It must be replaced immediately if it is

damaged or lost. For another copy, contact our Customer Service Department or an official customer service centre.

2.1.1 Use as prescribed

The vacuum packaging machine 07P ... is designed for vacuum packing of goods in solid and liquid form, mainly from the foodstuffs field such as meats, sausages, etc in sealable vacuum bags. It can also be used for goods in the non-food sector (medical appliances, electrical and mechanical components.

IMPORTANT All of these machines can be dangerous if they are not used properly or as directed. In order to ensure that the machines are used as prescribed, it is also important to comply with the installation, operation and service conditions specified by the manufacturer.

2.1.1.1 Machine with an inert gas system (07PN ...)

The machine is used for the products described above.

Advantages of applying inert gas

• This enables products which are sensitive to pressure to be packed without any risk of damage. • The products keep longer and maintain their natural colours.

DANGER In line with international regulations, high-pressure gases may only be fed via a reducer valve!

DANGER If you used nitrogen and/or carbon dioxide, it is imperative that the room is well ventilated!

Refer to the sub-section on “Inert gas” in the next section, “Processing materials”, for further important information on the types of inert gas which may be used.

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Safety, warranty

2.1.2 Processing materials

2.1.2.1 Vacuum bags

The vacuum bags have to be suitable and permitted for sealing under pressure and heat. They must also conform to hygiene regulations in terms of the handling and packaging of foodstuffs. Obtain a certificate of suitability from the manufacturer. The vacuum bags also have to display the following properties: • resistance to refrigeration • resistance to heat • strength The machine owner is responsible for ensuring that the vacuum bags used are suitable for heat sealing and do not pose any potential dangers, such as fire hazards or the emission of toxic substances.

2.1.2.2 Suitable products

The products which are suitable for vacuum processing are those which neither explode nor emit toxic gases during this process or which are not damaged as a result of the effect of the vacuum.

IMPORTANT The products being packaged should not have any sharp parts which may penetrate the packaging over time, thus damaging the hermetic seal of the packaging. If you are in any doubt, check the suitability of the products using spare samples or contact the manufacturer of the machine for advice.

DANGER Generating vacuums kills living creatures! Do not vacuum pack anything which is alive and ensure that no living creatures are vacuum packed by unauthorised personnel or children!

DANGER Inflammable, potentially explosive substances and pressurised gas cylinders may not be packaged because they may endanger the health and well-being of the operator!

2.1.2.3 Inert gas (07PN ...)

The machines with the inert gas system are intended to use the following inert gases:

• nitrogen (N2) • carbon dioxide (CO2) • any mix of these two gases

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DANGER In the introduced gas mix, the ratio of oxygen (O2) should not exceed 20%. A different gas may only be used with the prior consent of the manufacturer of the machine. Especially explosive gases or a gas which may be harmful to the operator if inhaled are prohibited.


Safety, warranty

2.1.3 Requirements for operators

The machine should only be operated, maintained and repaired by authorised personnel who have received training and instructions on how the machine works. The owner has to point out potential dangers to the personnel. The owner has to clearly delegate responsibility for installation, operation and maintenance in order to ensure that there is no uncertainty about responsibility with regard to safety. The operator must also ensure that no unauthorised personnel work on the machine.

2.2 Explanation of the safety instructions

All the safety instructions in this operating manual provide the operator with an early warning of possible dangers, possible damage to the machine and peripheral equipment and of flawed, productive work. Any sections which are of particular importance to the operator are marked by a warning symbol. The operator must read and comply with this information.

Meanings:

IMPORTANT Important information for the operator to help him operate the machine correctly and efficiently.

CAUTION Danger or unsafe action which may only result in minor injuries, but which can result in considerable damage to equipment, property or the environment.

DANGER Danger or unsafe action which may result in serious or fatal injuries to the operator or other people.

2.3 Warranty, liability

The warranty is limited to the replacement of faulty materials. More far-reaching claims may not be made. The machine must be operated in the intended manner, as described in this Operating Manual. It should not be used for any other purposes. The customer is not allowed to carry out any modifications or changes. In these cases, Inauen Maschinen AG will refuse to accept any liability.

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Description of the machine

3 Description of the machine

3.1 Functional principle

The filled vacuum bag is laid with the opening flat over the sealing pad (or over the sealing beam for 07P+G). The sealing of the vacuum bag is carried out in the vacuum chamber by means of sealing the bag opening under vacuum or in an atmosphere enriched with an inert gas. After reaching the desired degree of vacuum (program-dependent), the vacuum bag is sealed and the bag projection is cut off. By ventilating the vacuum chamber the vacuum bag seals itself around the inserted product. After opening the vacuum chamber, the packed product is transported from the machine by the lifting of the platform.

3.1.1 Structure of the machine

The machine stands on 4 height-adjustable feet and is designed to be integrated into a vacuum packaging line.

Components

1

2

3

4

5

6

7

8

9

10

11

Vacuum chamber lid with hand safety-guard

Machine foot, height-adjustable

Platform with roller track

Extension for second vacuum pump, removable lid

Rating plate

Bag insertion frame

Upper sealing bars

Sealing pads

Lower sealing bars (07P+G)

Operator console

Front lid Fig. 3/1

12

13

14

15

16

17

18

19

20

21

Electrical switchbox

Main switch

Pneumatic service unit (access through separate removable cover)

Overload relays, vacuum pumps

Fine-wire fuse 2AT

Fine-wire fuse 16AT

Mains automatic circuit breaker

VCP-Basic module

VCP-Extension module

Inert gas nozzles (07PN ...) Fig. 3/2

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3.2 Control panel

The operator console contains the operating buttons and the display. Set values and program numbers can be read off from the display.

Fig. 3/3 25 Display 26 Button HELP = Help + Works settings 27 Button UP 28 Button PROGRAM 29 Button CONTINUE 30 Button START (Single cycle) 31 Button Control LED

32 Button PUMP ON 33 Button DOWN 34 Button SERVICE SETTINGS 35 Button STOP 36 Button START (Automatic operation) 37 Button PUMP OFF

Standard equipment

See section 4 "Technical data".

3.3 Models

The vacuum packaging machine 07P ... is available in the following models:

Basic designation Extension Explanation

Without vacuum pump 220 With rotary slide vacuum pump 220m3/h 220W500 With rotary slide vacuum pump 220m3/h and additional roots

vacuum pump 500m3/h F With flat vacuum chamber lid H With domed vacuum chamber lid N Equipped with inert gas insert S With bag pulling frame NB With bag holder frame (for inert gas insert) +G With counterseal (+3G = 3-sided counter sealing) 15° Platform with roller track – ejection angle 15°

07P ...

20° Platform with roller track – ejection angle 20°

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3.3.1 Ejection direction

The machine is available with the ejection direction either to the right or to the left. The machine can also be retrofitted. Contact the VC999 Customer Service Department for this purpose.

3.3.2 Interconnection

If two vacuum packaging machines type 07P ... are to be used, it is possible to interconnect them. Here two vacuum pumps usually create a common vacuum alternately in the machines. In this way the cycle time can be shortened or fewer vacuum pumps can be used making the work more economical. It must be noted that when interconnecting it is not possible to create a vacuum on both machines at the same time. In order to achieve the optimum working conditions, one machine should be provided with product while the other machine creates the vacuum. Thus, two machines can be served optimally with one operator. Please contact the VC999 customer service department if two machines are to be interconnected.

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Technical data

4 Technical data

Electrical connection data (Model to EN 60204-1)

40 AT 7,5/10/11,5 kW 40 AT 230V/3/50 Hz: 7,5/10/11,5 kW

208V/3/60 Hz:

7,5/10 kW 25 AT 7,5/10/11,5 kW 25 AT 400V/3/50 Hz: 11,5 kW 40 AT

440V/3/60 Hz:

Vacuum pumps

Type of pump Vacuum range ca. Vacuum time to 2 mbar ca.

mbar sec

220 1

15

220+W500 0,5 10

Pneumatic connection Pneumatic consumption

6 – 8 bar Standard litre per working cycle (NL) 35

Dimensions (usable internal dimensions)

Chamber width 950 mm Chamber height 180/250 mm Chamber depth 450 mm Sealing bars 3 pcs. Length of sealing bars 1 x 950 mm 2 x 450 mm External dimension see Fig. 4/1

Weight Without accessories ca. (2 Pumps) 710 kg (1 Pump) 610 kg

Standard equipment Built-in vacuum pump(s) Vacuum measurements to set value Vacuum measurements to evaporation point Gentle ventilation to set value Intermediate ventilation Therm. trimming of the bag projection 30 Lockable, freely selectable programs Automatic error display Pneumatic connection Temperature monitoring of sealing bar Sealing current monitoring Processor controlled automatic packaging procedure

Options Supply track Bag filling equipment

Continuous sound level To DIN 45635: processing / working place 1 ca. 70 dB(A)

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Technical data

Dimensioned drawing

Fig. 4/1

Legend

1 Vacuum packaging machine 07P ... 2 Extension for an additional roots vacuum pump (Option) 3 Working space for operator

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Packaging and transport

5 Packaging and transport

5.1 Packaging the machine

The machine must be carefully packaged in order to transport it safely. The machine manufacturer recommends you to transport it in the type of packaging which is used to transport it from the factory.

5.2 Transportation of the machine

IMPORTANT Always transport the machine in a horizontal position! The vacuum pump may be damaged if the machine is tilted!

5.3 Unpacking the machine

IMPORTANT Always leave the machine in a horizontal position!

The procedure for unpacking the machine is as follows: 1. Bring the packed machine as close as possible to the installation site. For more information on this,

read the sub-section “Choice of place” in the next section, “Setting up the machine”.

2. Remove the packaging and check that the entire consignment is complete, cross-checking with the delivery papers. Also check for any signs of damage in transport.

3. If the machine is damaged in transit, contact the forwarding agent and the machine supplier immediately. The address and contact numbers of the machine manufacturer are contained in the “Introduction”.

IMPORTANT If the machine is damaged, hold onto all the packaging materials and await further instructions!

4. Set up the machine at its installation site. As the box and pallet have been designed to fit the machine, we would recommend you to store them in a dry place in case the machine has to be transported again at a later date.

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Setting up the machine

6 Setting up the machine

6.1 Criteria for the installation site

It must be set up in a dry, well-ventilated room. The machine must be protected against continuous splashes, jets and gushes of water.

6.2 Foundations

A horizontal industrial floor is adequate as a foundation. Slight vibrations may carry from the vacuum pump to the floor.

6.3 Ambient temperature

The machine is designed to be operated at an ambient temperature of between +10°C and +35°C. At temperatures below 10°C, the starting current for the vacuum pump rises and the fuses may blow.

6.4 Safety space

Leave a space of at least 50 cm right around the machine for operating and service work. There must be clearance of at least 10 cm above the lid when it is opened wide.

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Interface definition

7 Interface definition

7.1 Electrical connection

See section 4 "Technical data".

• The connection data of the machine can be found on the rating plate (Fig. 3/1, Pos. 5) at the back of the machine.

7.2 Pneumatic connection

The pneumatic connection is situated at the back of the machine. Depending on the model, the back wall or the cover of the pump extension must be removed. Required pressure at site for working cycle 6-8 bar, 35 SL.

7.3 Inert gas connection (07PN ...)

The owner must ensure that there is an inert gas supply available. The inert gas is fed via a hose from the pressure reducer unit (40) on the gas cylinder (41) to the inert gas valve (42) in the machine. A pressure regulator (43) monitors the pressure in the gas bottle. If the pressure falls below 2 bar, error 18 is shown on the display (see Chapter 11.1 “Displayed malfunctions”) The procedure for connecting the inert gas line on the machine is described under “Inert gas installation” in the section on ”Installation of the machine“.

Fig. 7/1

IMPORTANT If there is no gas cylinder connected in the machine, set the “Inert gas” parameter in the service program to OFF (0). Otherwise, air can leak into the packaging bag! For more information read the sub-section on the “Service program” in the section on “Programming”.

Inert gas quality

For more information on this read “Processing materials” in the section on “Safety”. This contains information on the permissible types of inert gas.

DANGER Only use a different inert gas with the prior consent of the machine manufacturer. Expressly prohibited is the use of explosive or explosion prone-gas or a gas that is a danger to the health of the operator and where the risk of breathing it in is present.

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Installation of the machine

8 Installation of the machine

IMPORTANT The following work must be carried out before the arrival of the VC999 customer service. • Electrical installation (Section 8.1) • Pneumatics installation (Section 8.2) • Inert gas installation (Section 8.3) • Check oil level or top up with oil (Section 8.4) • Cleaning the machine (Section 8.5)

8.1 Electrical installation

DANGER The machine may only be connected to the mains by a qualified expert (electrician), complying with local regulations!

The machine is supplied ready for service with a 4-core electrical cable (3 phases + GND), although there is no plug fitted. • Check whether the local operating voltage frequency and fuses agree with the data on the rating

shield (Fig. 3/1, Pos. 5) or the technical data (Chapter 4). If they do not agree, the machine must not be connected.

• Wire a CEE round system plug to the electrical cable.

CAUTION The machine may only be switched on for the first time by VC999 Customer Service personnel!

8.2 Pneumatics installation

• Remove the back wall or the cover of the pump extension (Fig. 3/1, Pos. 4).

• Push the pneumatic hose (45) (Inside diameter =

9mm) on to the hose nipple of the pneumatic service unit (46) and clamp it with a hose clamp (47).

• Replace the rear wall or cover.

Fig. 8/1 IMPORTANT

In order that as little condensate (water) enters into the machine, an air drier must be placed in the pneumatic supply line. Otherwise, at least, a water-receiving container is required. The condensate that collects in the container (48) is discharged automatically through the valve (49) every time the machine is switched on.

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8.3 Inert gas installation (07PN ...)

The inert gas connection point is located in the bottom part of the machine. Remove the front cover for access (Fig. 3/1, Pos. 11) The inert gas valve with the hose connection nozzle (50) is situated in the lower right region. Feed the hose (51) (øi 9 mm) into the machine from below and connect it to the hose nipple by means of a hose clamp (52). The cable (43) from the pressure switch at the gas bottle is inserted into the socket outlet (44).

Fig. 8/2 IMPORTANT

Observe the regulations for the inert gas supply. Read Section 7.3 “Inert gas connection” in Chapter 7 “Interface definition”!

Retrofit the machine 07PN .. for "Production without inert gas usage"

In order to retrofit the machine the following work has to be carried out:

- Disassemble the gas nozzles (1) - Assemble the seal inserts (3) - Release the bag insertion frame (5)

Procedure: • Disassemble all the gas nozzles (1) by

unscrewing the screw (2). • Assemble the seal inserts (3) in the same

position.

• Swing the four clamps (6) in the vacuum chamber lid (4) outwardly. This releases the bag insertion frame (5), which is ejected via spring pressure.

Fig. 8/3

Fig. 8/4 IMPORTANT

If, at a later date, you change to "production with inert gas“, the gas nozzles have to be reused and the bag insertion frame retracted!

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8.4 Control or fill with oil

Rotary slide vacuum pump

The oil level must be visible in the level tube (55) between the Min. and Max. markings Recommended oil: BP Energol RC 100 ESSO Teresso 100 Mobil DTE Oil extra heavy Shell Corena Oil H100

If the machine has been delivered without oil, fill the two filling openings (56) with approximately 6 litres of oil. Check the oil level in the level glass (55).

Roots vacuum pump Fig. 8/5

The oil level must be visible in both level glasses (62). Recommended oil: BP Energol RC 100 ESSO Teresso 100 Mobil DTE Oil extra heavy Shell Corena Oil H100 If the machine is supplied without oil, fill the two filling points (61) with approximately 1.5 litres of oil. Check the oil levels at the sight glasses (62).

Fig. 8/6

8.5 Cleaning the machine

• Remove any adhesive tape or other material left over from the packaging.

• Clean the vacuum chamber and the vacuum chamber lid thoroughly. No dirt may get into the suction nozzle.

• Use a commercially available neutral cleaning medium for the vacuum chamber and the outer surfaces of the machine. Cleaned places must be well flushed and dried.

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Start-up

9 Commissioning

9.1 Initial start-up

The initial start-up should only be carried out by VC999 Customer Service personnel! Unauthorised initial start-up can result in injuries or damage to equipment and property! The customer’s personnel will also receive thorough training during initial start-up.

• Check whether the machine was tilted or dropped during transport.

CAUTION The vacuum pump motor automatically stops with incorrect phase sequence. Error message 16 appears at the display. For incorrect direction of rotation exchange 2 of the 3 phases of the motor cable at the plug.

9.2 General instructions

• Do not vacuum pack living creatures! • Do not pack rotten foodstuffs! • Do not put goods into circulation if the sealing seam is not intact! • Only use approved vacuum bags! • Do not leave things lying on the lid of the vacuum chamber! • Stop what you are doing if the vacuum chamber becomes soiled (e.g. if liquid leaks, etc.). Switch the

machine off immediately and unplug it from the mains. Clean the vacuum chamber first of all, the platform with roller track, and then the sealing bars. Dry any parts which get wet.

• Products must not be larger than the usable chamber height.

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Operation

10 Operation

This chapter is directed at machine operators. It contains all the information necessary to operate the machine; from starting the machine to operating and stopping it.

10.1 Requirements for operation

The following requirements have to be met before the machine can be put into operation: • The machine must be correctly installed and connected, as described in the section on “Installation”.

• The vacuum chamber has to be clean and dry.

10.2 Preparation

Before you start packaging; prepare the product to be packaged, prepare the packaging and adjust the machine to suit the product to be packaged.

10.3 Prepare the products for packaging

IMPORTANT Comply with hygiene regulations in handling and packaging foodstuffs and products which have to be sterile! Otherwise, there is a risk of food poisoning or infections!

• Clean the product which is being packaged.

• Place the portion of the product into the vacuum bag. Make sure that the opening of the bag is not soiled by the product.

• Filling tools such as funnels or scoops are available as accessories. You can obtain further information about the range of accessories from our Customer Service Department.

Fig. 10/1

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Operation

10.4 Machine preparation

10.4.1 Switching on the machine

• Turn main switch to position “I“.The machine switches on.

CAUTION The vacuum chamber opens automatically!

− The machine version appears at the display for a few seconds. − Then the last program used with its program number is displayed. − If during approximately 5 minutes neither packaging cycles are started nor buttons are pressed,

then the machine goes into a “sleep” mode. Now only the green LED (Fig. 3/3, Pos. 31) is lit. Pressing any button recalls the machine from the sleep mode.

10.4.2 Switch pump on

• Press the PUMP ON button.

− The vacuum pump starts.

CAUTION After switching the pump on, the platform automatically moves to the set product height. Do not reach into the vacuum chamber until the platform has come to rest. There is a danger of jamming the hands!

− The machine is ready for use.

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Operation

10.5 Packaging

IMPORTANT The vacuum chamber must be dry. If possible, package cooled products! The warmer moist products are, the less is the achievable vacuum due to the evaporation.

Strong evaporation can be prevented with the aid of evaporation steps (see Chapter 10.6 “Programming”).

Place product on chamber conveyor:

• Place the vacuum bag filled with the product for packaging on the chamber conveyor (1), if this has been lowered in the chamber. Make sure that the bag opening is lying flat on the sealing bar (2).

Bag position with inert gas:

Fig. 10/2 • Position the vacuum bag over the inert gas nozzle (3).

Select program

• Select the desired program with the PROGRAM button and UP or DOWN, see also Chapter 10.6 “Programming”.

IMPORTANT The programs can be locked against changes and the number of programs that can be called up can be set.

- see chapter 10.6.12 "Number of locked programs" - see chapter 10.7.4 "Key switch"

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Operation

10.5.1 Start packaging cycle (single cycle)

• Press the START button (single cycle).

CAUTION The vacuum chamber closes automatically.

The working process − Vacuuming − Possibly intermediate ventilation − Possible gas flushing − Sealing/separating − Possible preventilation − Ventilation − Opening vacuum chamber − Product removal

is carried out controlled by the program. The packaging cycle is shown as text in the display. Besides the set values, the display also shows the actual values.

End packaging

• Shut off the pump(s) with the PUMP OFF button after the packaging of the last cycle has been moved out of the chamber.

• Rotate the main switch to the “0” position, if no work is to be carried out for a longer period of time.

IMPORTANT Lock the main switch with a lock against unauthorized switching on.

10.5.2 Interrupt in the packaging cycle when vacuuming

The vacuuming can be re-programmed with the UP and DOWN buttons.

IMPORTANT The vacuum value can only be changed if the program is not protected (also see Section 10.6.12 "Number of locked programs").

10.5.3 Switching off the machine

• Switch off the pump(s) via the PUMP OFF button after the packages of the last cycle have been conveyed out of the chamber.

• Turn the main switch to position “0“, if the machine is to be out of operation for a longer period.

IMPORTANT Prevent unauthorised switching on of the main switch by securing it with a lock.

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Operation

10.6 Programming

10.6.1 Selecting the packaging programs

The internal memory has space for 30 packaging programs. In the initial position, the parameters of each program are shown; see also Chapter 10.6.13 “Sequence diagram – program level. In order to change from one program to the next, press the PROGRAM and UP or DOWN buttons.

10.6.2 Set values for packaging program (program level)

IMPORTANT Note Chapter 10.6.13 “Sequence diagram – program level! As a control and as safety against a possible defect of the electronics it is recommended to enter the program data into the program table in Chapter 10.6.14. The vacuum is shown on the display in per mille (‰). The machine reaches a maximum vacuum of 999 ‰ with a dry chamber. The vacuum is only as good as the condition of the vacuum pump permits (service the vacuum pump regularly).

10.6.3 Vacuuming modes

There are 3 possible types of vacuuming modes:

Vacuuming to the set value (for dry products) Vacuuming continues until the defined setpoint is reached (999 ‰ is the maximum vacuum).

Vacuuming to the evaporation (for moist or tempered products) The vacuuming mode takes place until the moisture in the vacuum chamber or in the goods being packed evaporates. The evaporation point depends on the moisture content and the temperature of the product. The colder the product is, the greater the vacuum that can be achieved. Vacuuming that takes too long can cause such products to dry out, which may not be desirable. Setting the sensitivity (from 0.0 to 10.0 seconds) has the effect that the vacuuming, after reaching the evaporation point is continued by the set time and then ends. 0.0 s = highest evaporation sensitivity 10.0 s = lowest evaporation sensitivity

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Operation

Vacuuming in stages to the set value (for sensitive and porous products) With these products there is the danger, with too-quick vacuuming, that they explode of swell up as they can evacuate only slowly (e.g. cheese, bread, etc). The vacuuming in stages starts with 500 ‰. Then vacuuming continues with the set vacuum stage and the value is held for the set delay time. This allows the gas to evacuate. The process is repeated until the set value is achieved.

IMPORTANT With the HELP button it is possible to select from the various types of meat a particular product with already assigned vacuuming modes and set values.

10.6.4 Inert gas supply (07PN ...)

For pressure-sensitive products that can only tolerate a small degree of vacuuming. After vacuuming to the set value, the inert gas flows in. The pressure in the vacuum chamber rises. For this reason the set value of the inert gas must be lower than that of the vacuum. If it is the same or higher than that of the vacuum, then no gas flush will occur. An inert gas set value of 999 ‰ stops the gas flush.

IMPORTANT With the HELP button it is possible to select from the various types of meat a particular product with already assigned inert gas set values. This function is only active when the initial setting “Gas flush” is set to ON in the service program.

10.6.5 Intermediate ventilation

For moist products that tend form a foam on the surface when vacuumed (evaporation and spot formation). The vacuum chamber can be ventilated intermediately prior to sealing via intermediate ventilation. This causes the vacuum bag to shrink onto the product, thus stopping the effect described above. Intermediate ventilation can be switched on or off. When switching on the function a value of between 0 and 0.5 seconds can be set. The default settings can be called up by pressing the HELP button.

IMPORTANT Intermediate ventilation should only be done if you are working with a high vacuum set point or in the “vacuuming until evaporation” mode! Keep the intermediate ventilation time as short as possible.

IMPORTANT This function can only be switched on if the initial setting "Intermediate ventilation" has been set to ON in the service program.

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Operation

10.6.6 Sealing and cutting

The programmed sealing and cutting times refer to the operating heat of the sealing bars. In order to obtain an optimum sealing quality independently of the operating temperature, a sensor measures the heating bar temperature. The sealing and cutting times are automatically corrected. A cutting time is only set when no counterseal has been pre-set. The cutting time can be different from the sealing time.

IMPORTANT With the HELP button it is possible to select a particular product from different types of bags with already assigned sealing times.

10.6.7 Sealing type

The machine possesses sealing bars in the vacuum chamber lid and for counterseal (07P+G) also in the vacuum chamber lower part left, right and at the front. The type of seal will determine which sealing bars are in use and which are not. With countersealing the, sealing is always carried out from the top and the bottom (biactive).

Setting Active sealing bar

OFF No sealing bar is active, Sealing is switched off

ALL 3 SEALING BARS All 3 sealing bars in the vacuum chamber lid

SIDE BARS ONLY Both side sealing bars in the vacuum chamber lid

FRONT BAR ONLY Only the front sealing bar in the vacuum chamber lid

COUNTERSEAL ALL BARS (07P+3G)

All 6 sealing bars in the vacuum chamber lid and in the vacuum chamber lower part

COUNTERSEAL SIDEBARS (07P+2G)

Each both side sealing bars in the vacuum chamber lid and the vacuum chamber lower part

COUNTERSEAL FRONTBAR (07P+G)

Only the front sealing bar in the vacuum chamber lid and the vacuum chamber lower part

10.6.8 Product height

In order to obtain an optimum sealing seam, it is important that the setting of the platform is adapted to the product height. By entering the corresponding product height, the platform automatically travels after the program selection to the correct height and thus ensures an optimum seal.

10.6.9 Preventilation

Preventilation has the effect of a fold-free clinging of the bag against the product and is suitable for products which can be damaged by the sudden ventilation and/or which could damage the bag.

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Operation

The setting shows up to what remaining vacuum, a slow preventilation can take place. After that the main valve opens.

IMPORTANT Enter 999 to deactivate the preventilation function. Preventilation extends the packaging cycle!

10.6.10 Transport time

After the end of the packaging cycle the products are automatically transported out of the vacuum chamber. The set transport time determines how long the roller track must remain in the ejecting setting in order to transport all products out of the vacuum chamber.

IMPORTANT With the setting “0” the ejection mechanism is switched off completely. The products must be removed from the vacuum chamber manually.

10.6.11 Autostart interval

The time to be entered is the delay time after the ending of a cycle up to the automatic start of the next cycle (automatic operation button START).

IMPORTANT Automatic operation can be switched on in the service program.

CAUTION In automatic operation with manual feeding, special CAUTION must be exercised. After the end of the delay time, the vacuum chamber closes automatically. There is a danger of jamming the hands.

10.6.12 Number of locked programs

With this program point, the number of programs to be locked can be selected. 29 of the 30 programs that are available can be locked. The locked programs can be selected and started but are locked against changing.

IMPORTANT The remaining (unlocked) programs are accessible to the operating personnel. These programs can be locked with the key switch at the “Service settings” level and they can then no longer be called up. In order to change the number of locked programs the key switch must first be set to "OPEN"!

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Operation

Open key switch:

• Press the SERVICE SETTINGS button 4 times. • Press the button combination HELP-CONTINUE-HELP. • Press the UP button to open the key switch. • Press the STOP button to return to the initial position.

Making locked programs accessible:

• Select program 30 with the PROGRAM and UP or DOWN buttons. • Use the CONTINUE button to leaf through the program 30 until position "NUMBER OF LOCKED

PROGRAMS“. • Set the number with the UP or DOWN button to 0. • Press the STOP button in order to return to the initial setting.

CAUTION Because of product responsibility, check whether the product with the set parameters fulfils the requirement of foodstuffs hygiene.

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10.6.13 Sequence diagram Program level

Fig. 10/3

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Operation

10.6.14 Program table

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10.7 Service settings

For certain servicing and cleaning work, it is necessary to bring the machine to a certain service setting, see Chapter 10.7.5. “Sequence diagram service settings”.

IMPORTANT The service settings are exited with the STOP button and the machine returns to the initial setting. With the exception of “OPERATING DATA”. In this service setting the further activation of the CONTINUE button takes the machine back to the initial setting.

Fig. 10/4

10.7.1 Raise platform

In this service setting, the platform moves upwards to the stop. This service setting enables cleaning of the vacuum chamber.

Procedure: • Press the SERVICE SETTINGS (34) button. The display shows RAISE PLATFORM START? • Press the START (30) button. After a danger message, the display shows SERVICE PROCEDURE

ACTIVE! STOP! STOP!

CAUTION When carrying out the next step, the platform automatically moves upward into the service position. During this procedure do not reach into the chamber. There is a danger of jamming the hands!

• Press the START (30) button until the platform has reached the service position. In the service position the roller track is at a slant position (Fig. 3/1). In this position the roller track can be additionally lifted upwards.

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Operation

• In order to lower the platform again press the STOP (35) button 2 x.

CAUTION During this procedure do not reach into the chamber. There is a danger of jamming the hands!

After the platform has been lowered, the machine is in the initial position.

10.7.2 Close lid

For cleaning purposes (spraying down) it is necessary to switch off the machine with the vacuum chamber closed. When this service setting is triggered the vacuum chamber closes. The pump is started for a short time in order to tighten the vacuum chamber lid by means of vacuum and thus to close the vacuum chamber watertight.

Procedure: • Press the SERVICE SETTINGS (34) button 2 x. The display shows CLOSE LID START? • In order to open the vacuum chamber again, press the STOP (35) button.

After the vacuum chamber has been opened the machine is in the initial setting.

10.7.3 Operating data

In this service setting, the following operating data can be called up:

- Operating hours - Cycle counter - Operating hours since last service - Operating hours since oil control - Cycles since sealing bar control

Procedure: • Press the SERVICE SETTINGS (34) button 3 x • With the CONTINUE (29) button the individual operating data can be called up in sequence. • Press the CONTINUE (29) button continuously until the display again shows the initial setting.

10.7.4 Key switch

The key switch is used to lock the non-locked programs. These can then no longer be called up.

Set key switch: see chapter 10.6.12 “Number of locked programs”

If the service setting key switch set to CLOSED then the service program is not accessible.

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Operation

10.7.5 Sequence diagram service settings

Fig. 10/5

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Malfunctions

11 Malfunctions

DANGER Before the removal of malfunctions always separate the machine from the electrical power supply with the main switch. Repairs may only be carried out by the VC999 customer service department.

11.1 Faults and their remedies

Nr. Fault Cause Remedy

03 LID SAFETY SWITCH ACTIVATED

When closing lid comes up against a resistance.

GS07 Module defective

Relay hand protection has a loose connection.

Remove foreign body from locking area.

Call VC999 Customer Service Dept.


16 MAIN POWER - REVERSE PHASE

Phases of the machine connecting cable wrongly connected.

Exchange two of the three contacts.

18 LOW GASFLUSH PRESSURE

Inert gas line not connected to the inert gas valve.

Leak in inert gas line

Pressure in gas bottle under minimum pressure of 2 bar

Connect inert gas line (Chapter 8.3)

Inspect inert gas line for leaks and repair if necessary

Connect full gas bottle

19 GASFLUSH LEVEL SET POINT NOT REACHED

Inert gas line not connected to inert gas valve.

Leak in inert gas line

Connect inert gas line (Chapter 8.3)

Inspect inert gas line for leaks and repair if necessary

22 VACUUM LEVEL SET POINT NOT REACHED

Vacuum pump does not perform properly

Product evaporates under vacuum

Vacuum chamber not tight

Vacuum chamber / platform moist or wet

Carry out an oil change (Chapter 13.3.3.1 + 13.3.3.2)

Select type of vacuuming “Vacuum to evaporation” (Chapter 10.6.3)

Change lid seal

Dry vacuum chamber and platform.

23 OVERLOAD RELAIS VACUUM PUMP TRIPPED

Incorrect setting thermo-relay (Fig. 3/2, pos. 15)

Defect at vacuum pumps

De-oiling filter is blocked

Pump too hot

Set and control thermo-relays


Replace oil separator insert (Chapter 13.3.3.1)

Allow pump to cool

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Malfunctions

Nr. Fault Cause Remedy

32 CHECK PUMP AND/OR VACUUM MEAS. SYSTEM

Measuring switchover valve defective, pressing membrane of the sealing bar not tight, Measuring hose has loosened itself from sensor.


34 OPEN LOOP AT TEMPERATURE MEAS. SENSOR

Plug not properly pushed in (Chapter.12.4.4.1) Cable break

Insert plug


35 SHORT CIRCUIT AT TEMPERATURE MEAS. SENSOR

Overheating of the sensor, short circuit on the sensor or supply cable.

Setting of the sealing time adjustment too low.


Undertake a calibration of the sealing time correction (Chapter. 12.4.4.1)

36 VACUUM RELEASE (VENTILATION) MALFUNCTION

Air inlet filter blocked, Valve defective.

Check preventilation

64 LID OPEN SWITCH NOT ACTIVATED

65 LID CLOSED SWITCH NOT ACTIVATED

End switch setting incorrect

Mechanical obstruction of movement.

Main ventilation too slow.

End switch defective

Defect in the supply to the end switch or valve.

Check end switch setting

Check mechanical movement


Replace end switch


66 TOP POSITION OF PLATFORM NOT REACHED

Position pickup defective or not properly adjusted Platform cylinder not working correctly

Check cycle count in the Service program (Chapter. 12.4.3) and inform VC999 customer service Dept.

67 PLATFORM LEVEL IS NOT ADJUSTABLE

Position pickup defective

Position pickup incorrectly connected

Platform cylinder not working correctly

Check position pickup

Check connection


99 MACHINE MALFUNCTION NOT ANALIZED

Too low voltage supply Check power supply


As soon as these errors occur, the corresponding text will appear at the display until they are confirmed with the STOP button. The machine returns to the initial position.

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Malfunctions

11.1.1 Sealing current monitoring

The machine is equipped with a sealing power monitor which checks whether the sealing and cutting function properly. If there is an interruption in one of the selected sealing power circuits, an error message appears during the packaging cycle. You will be asked to press the STOP button briefly. An automatic error diagnosis now takes place. The result appears at the display symbolically: “OK” for in order, “ER” for error, “00” not programmed.

Example: Seal top left front right cutting left front right

Fig. 11/1

Seal bottom left front right In this example the cutting power circuits of the left and right sealing bars are interrupted at the (ER). The bottom row is only displayed with countersealing.

CAUTION During the diagnostic process, the machine must not be turned off at the main switch.

After reading off the diagnosis press the STOP button again. The machine completes the already started cycle. On restarting the error will not be displayed again. In this way it is possible to work in emergency operation with the sealing bars in which no “ER” (error) was shown. If the error is not corrected immediately, it is displayed again when the machine has been switched off and started again. Please check sealing bar, possibly a mains automatic circuit breaker (Fig. 3/2, Pos. 18) has been triggered. Possibly contact VC999 customer service department.

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Malfunctions

11.2 Possible operating malfunctions

Malfunctions Cause Remedy

Machine does not appear on the display after turning on the main switch

El. Supply not ensured Mains automatic circuit breaker (Fig. 3/2, Pos. 18) triggered

Fine wire fuse (Fig. 3/2, Pos. 17) burnt through

Check El. connections Switch on mains automatic circuit breaker

Replace fine wire fuse 16 AT

Main switch does not remain in the On position

Main switch defective

Fine wire fuse (Fig. 3/2, Pos.6) burnt through

Interruption in 48 VAC supply

Excess temperature switch at the sealing transformer has been triggered

Voltage setting at the transformer incorrect

Check main switch and possibly replace

Replace fine wire fuse 2 AT

Call the VC999 Customer Service Dept.

Allow sealing transformer to cool off


Keyboard and display do not react

Malfunction of the microprocessor by power supply

Defective microprocessor

Turn off main switch and after ca. 10 seconds switch on again. Possibly repeat again.


Platform does not move products out

Transport time in the packaging program set to “0 “ Transport type in service program on “OFF“

Set transport time in accordance with Chapter 10.6.10 "Transport time" Set mode of transport in the service program to “ON”.

Program cannot be altered anymore

Programs locked Set number of locked programs to “0”, see Chapter 10.6.12 "Number of locked programs"

Program cannot be selected Key switch closed Open key switch, see Chapter 10.7.4 "Key switch"

Malfunctioning seal Sealing time not properly set

Teflon tape on sealing bar damaged

Power contact springs on sealing bar make no contact

Pressure too low

Set sealing time

Replace Teflon Chapter, see Chapter 13.2.2 "Maintenance sealing bar"

Clean power contact springs


Vacuuming too weak The partner machine is vacuuming with evaporation

Condensate in measuring system

Switch off VVO extension


Ruined products Bag material unsuitable

Cooling chain was interrupted

See Chapter 2.1.2.1 "Vacuum bag"

Dispose packaging properly

Partner machine not ready

(Interconnection s. Chap. 3.3.2)

Main switch not turned on Machine not in initial position or in sleep mode

Error in the wiring of the interconnection

Turn on main switch


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Service program

12 Service program

The service program contains various information important for the service. Basic settings for optimum machine running and test programs are also included.

IMPORTANT The service program is only of use to trained personnel. Therefore it is only accessible with key switch "OPEN" setting.

When using the service program, note the following points: • The service program can only be opened when the key switch is set to "OPEN". • "Number of locked programs" has to be set to zero (0) so that values are changeable and the error

diagnosis as well as the test programs can be started. • The set values apply to all 30 operating programs. • Use standard values for as many parameters as possible as changing the values may cause

problems.

12.1 Structure of the service program

The service program consists of three parts: Error diagnosis (diagnostic data of last error). When you call up this subroutine of the service program, the last fault will be displayed again. You can then display all the parameters set at the time of the error message (for description see Chapter 12.2 "Error diagnosis")

IMPORTANT At the end of error diagnosis, change to the initial position with the STOP button.

Initial settings General machine setting applicable to all programs. (For description see Chapter 12.3 Initial settings)

Test programs In the service program, the test programs follow on directly from the general machine settings (for description see Chapter 12.4 Test programs).

For this purpose also see the sequence diagram Service Program (Chapter 12.4.6)

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Service program

12.1.1 Entry into the service program

Call up the service program as follows: • If a packaging cycle is running press the STOP button. The started cycle is completed nut no further

cycle is started. • Press the following buttons in sequence SERVICE SETTINGS, PROGRAM and START.

• Operate the service program with the following command buttons.

Command buttons

When the service program has been selected, use the following buttons to navigate through the program:

UP button • To enter into the error diagnosis • To start the control program

DOWN button Within the program To switch on or off or to increase or decrease values

CONTINUE button Changes to the next diagnostic point until the program has worked through them all and reached the initial position again.

Calls up the works settings.

Changes from any desired position back to the initial position or ends the error diagnosis.

12.2 Error diagnosis

The starting point of the error diagnosis is the initial position. After entering the service program, the sub-program "DIAGNOSTIC DATA OF LAST ERROR" appears. This has the following data stored in it. - Display of the error messages - Initial positions display of the run programs - All operating data at the time of the error - All set values of the run programs - All initial settings at the time of the error If it is not desired to enter the error diagnosis, press the CONTINUE button. This returns to the initial settings (see Chapter 12.3 Initial Settings).

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Service program

Entry into the error diagnosis

• Press the UP button. This brings up the error diagnosis. With the CONTINUE button, all the conditions which were set at the time of the last error display can be called up sequentially. The displayed settings and values cannot be edited.

IMPORTANT The error diagnosis can be paged through with the CONTINUE button up to the "END OF DIAGNOSTIC DATAS" or can be exited at any time with STOP button!

For this purpose also note the sequence service program diagram (Chapter 12.5)

12.3 Initial settings

The following described initial settings are valid for all programs. These deal with machine settings, which make it possible for trained personnel (service technicians) to optimise the running of the machine. Mistakenly changed values can be reset to the default values by pressing the HELP button again.

IMPORTANT The machine settings can only be changed when the "NUMBER OF LOCKED PROGRAMS" is set to zero (0)!

The individual parameters can be called up in the service program in sequence by pressing the CONTINUE button.

For this purpose also note the Sequence Service Program Diagram (Chapter 12.4.6)

12.3.1 Intermediate ventilation

If the Intermediate ventilation is set to ON, then an individual ventilation time can be set for each of the 30 programs. If the Intermediate ventilation is set to OFF, then the function is switched off for all programs. When viewing the program data, the display "INTERMEDIATE VENT." Is not shown. Further information on this function can be found in Chapter 10.6.5 "Intermediate ventilation".

12.3.2 Gas flush

This function is only switched on when the machine is equipped for the use of inert gas s (07PN) and when at least one program with inert gas is used.

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Service program

12.3.3 Automatic Operation

The automatic operation is only switched on when the START button (Automatic operation) is to be activated.

CAUTION In Automatic operation special care must be exercised with manual loading. After the completion of the set delay time, the vacuum chamber closes automatically. There is the danger of damage by collision with the vacuum chamber lid!

12.3.4 Mode of transport

In a malfunction at the platform positioning this can be taken out of operation or set to OFF.

IMPORTANT With switched-off platform positioning, it must be ensured that the platform is not higher than the top edge of the chamber bottom portion. There is the danger of collision with the vacuum chamber lid.

12.3.5 VVO-holding until ventilation

The VVO-holding is only important when interconnecting two machines. Set the VVO-holding to OFF. Nevertheless, the control prevents incorrect calibration. Vacuum stability is checked prior to vacuuming; otherwise the next cycle is carried out without recalibration. NC (not calibrated) is shown on the display. If VVO-holding is set to ON, the cycle time is unnecessarily prolonged. The default setting is called up by pressing the HELP button.

12.3.6 Lid closing pulse

A closing impulse is a short pulse of compressed air with the aim of hastening the closing of the vacuum chamber. The setting range is between 0 and 0.5 seconds. The time is set to the default setting by pressing the HELP button.

12.3.7 Sealing bar pressing time

The pressing time is understood to be the time required to press the sealing bar completely onto the bag before sealing starts. The setting range is between 0 and 5 seconds. The time is set to the default setting by pressing the HELP button.

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Service program

12.3.8 Cooling time

Before the sealing bar is lifted from the sealing position, a cooling period of the seal must occur or the cooling time must elapse. The setting range is between 0 and 5 seconds. The time is set to the default setting by pressing the HELP button.

12.3.9 Raise sealing bar time

This determines the time from the lifting of the sealing bar up to the ventilation of the vacuum chamber. The setting range is between 0 and 5 seconds. The time is set to the default setting by pressing the HELP button.

12.3.10 Pneumatic oiler impulse time

The compressed air oil mist is added during the oil mist generator pulse duration by the oiler to the compressed air service unit (Fig. 13/1, Pos. 48). The setting range is between 0 and 0.5 seconds. The time is set to the default setting by pressing the HELP button.

12.3.11 Pneumatic oiler cycle interval

The oil mist supply to the compresses air system is carried out only after the number of packaging cycles set here. The setting range is between 0 and 100 cycles. The number of cycles is set to the default setting by pressing the HELP button.

12.3.12 Water separation after no. of cycles

The water separator is opened for a short time to discharge the condensate after the number of packaging cycles set here. The setting of the water quantity depends on the quantity of water that the compressed air brings with it. The setting range is between 0 and 100 cycles. The number of cycles is set to the default setting by pressing the HELP button.

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Service program

12.3.13 Tolerance conveyor levelling

The tolerance value defines the positioning accuracy of the platform. With normally functioning platform, this value should not be changed. If the tolerance is set too low, then the platform cannot reach the set value in a useful time and thus triggers an error message. The setting range is between 0 and 50 mm. The tolerance value is set to the default setting by pressing the HELP button.

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Service program

12.4 Test programs

The individual test programs can be called up in the service program in sequence by pressing the CONTINUE button.

For this purpose also note the Sequence Service Program (Chapter 12.4.6)

12.4.1 Check procedure: vacuum calibration

This program checks the calibration of the analogue/digital converter, as well as the vacuum measuring system.

Procedure: • Start the test program by pressing the UP button. A query will appear to start the vacuum pump if

this is not already running.

After about 20 seconds, the following will appear at the display. The upper line shows the limiting values, the lower line the actual measured values (example values).

Self-test of the el. Circuits of the vacuum measurements (without vacuum sensor) Example: Limiting values (fixed) MT 9296 to 11264 0Pt: -150 to -24 Values outside the limiting values: Error in the VCP base module

Test of the vacuum circuit and the vacuum sensor Example: Limiting values (variable) MT -4152 to 1400 0Pt: 174 to 47 Values outside the limiting values: MT: Error in the ambient pressure calibration 0Pt: Error in the vacuum calibration

With measuring values outside the limiting values, the VC999 customer service must be contacted.

• To exit from the test program press the STOP button until the initial position is shown at the display.

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Service program

12.4.2 Check: chamber / pressure below

This test program checks the tightness of the vacuum chamber and the pressing cushion.

Procedure: • Start the test program, by pressing the UP button. The query to start the pump appears if this is not

running already.

The vacuum chamber closes and the vacuuming process is started. Independently of the type of vacuuming stored in the current packaging program and the set value. The vacuuming in this test program is always carried out in accordance with the set value up to a maximum value of 999. The test program can be ended with the STOP button.

After completed vacuuming, the display stops as follows and shows the further pressure course in the vacuum chamber.

The vacuum chamber is not tight when the actual value drops more than ca. 10 units in a minute.

• In order to control the tightness of the pressing cushion press the CONTINUE button. This triggers the pressing.

The pressing cushion is not tight when the actual value drops more than ca. 10 – 15 units in a minute.

• To end the program, press the STOP button.

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Service program

12.4.3 Check procedure: platform adjustment

This test program controls the platform positioning. The displayed cycle value is used by the service technician (expert) for setting and controlling position pickup. The cycle value must be between 17 (upper position) and 193 (lowest position).

Procedure: • Start the test program, by pressing the UP button. With the UP and DOWN buttons, the platform can be moved up or down whereby the cycle count shows the momentary platform height .

• Press the STOP button to end the test program. The machine returns to the initial position.

12.4.4 Check procedure: sealing bar temperature

The sealing bar temperature measurement is for correction of the sealing time . With the aid of the sealing time adjustment the selected sealing time during the heating period is equalized.

*The values displayed for the front and side sealing bars are times in seconds. These time values depend on the actual sealing bar temperature and are added to the effective set sealing and cutting times. For a cold machine, the desired time values can be set in the switch box at the potentiometers (Fig. 12/1, Pos. 22). With elevated sealing bar temperatures, the correction value should fall and the operating temperature should reach zero. The programmed time corresponds to the actual sealing and cutting time.

IMPORTANT If the CVP extension module must be replaced in the switchbox, then the sealing time adjustment must first be subjected to an initial calibration as otherwise the values in the test program cannot be correctly set. For this purpose read the description “Equalizing the sealing time adjustment”.

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Service program

12.4.4.1 Calibration of the sealing time adjustment

After installation of a new VCP extension module undertake the calibration of the sealing time calibration as follows: • Switch the machine off.

• On the VCP extension module (20) in the

switch box, pull out the plug of the temperature sensors (21) and insert in its place the calibration plug supplied with the new VCP extension module (Art. No. 518.432).

• Switch on the machine and, in the service program activate the test program "Control of Sealing bar temperature measurement”.

• Adjust both potentiometers (22) such that the same time value of 0.22 is shown at the display at “front” and “side” (see previous Chapter).

Fig. 12/1 • Switch the machine off again. • In the switchbox, pull out the calibration plug and insert the plug for the temperature sensors again.

12.4.5 Check of EPROM

This test program is to check whether the contents of the EPROM are still correct and whether this is also properly read by the microprocessor. • Start the test program by pressing the UP button. After the start, the display shows on the bottom line the respective tested address in HEX decimal form. If the testing is in order the program will return to the initial position. Otherwise a corresponding error message will appear.

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Service program

12.4.6 Sequence service program

Fig. 12/2

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Maintenance

13 Maintenance

Service the machine regularly in order to ensure that it works properly. Maintenance includes all work which serves to keep the vacuum packaging machine in good working order, including the following: • checks • cleaning • service work

CAUTION The machine MUST be switched off before installation, service and repair work is carried out on it. Before this work gets under way, switch off the main switch and put on a padlock to prevent the machine being switched on inadvertently. Keep the button out of the reach of other people!

CAUTION After switching off the machine, wait as long as necessary for the machine to cool down. There is a danger that you may get burned on the vacuum pump and sealing bars!

13.1 Checks

Checking interval

daily

• Checking vacuum chamber lid (see chapter 13.1.1) • Checking the lid seal (see chapter 13.1.2)

weekly • Checking compressed air service unit (see chapter 13.1.4)

every month • Checking the lid seal (see chapter 13.1.2)

• Checking platform (see chapter 13.1.3)

13.1.1 Checking vacuum chamber lid

Daily

• Check the correct functioning of the lid safety mechanism at the vacuum chamber lid. When closing the vacuum chamber and simultaneous activating the lid safety, the machine must shut down.

13.1.2 Checking the lid seal

The lid seal in the vacuum chamber lid consists of a silicon hollow profile which is placed in a circumferential slot in such a way that the ends touch.

Daily

• Check lid seal for dirt and clean if necessary.

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Maintenance

Every month

• Check whether both ends of the lid seal touch and seal.

IMPORTANT If an end piece has cone out of the slot, simply press it in lightly with the fingers.

13.1.3 Checking platform

Every month

• Check the complete ejection mechanism for appearances of wear.

13.1.4 Checking compressed air service unit

Every week

The oiler (48) of the compressed air service unit must be filled at least 1/3 with oil. • Top up with oil.

Oil recommendations

Shell Tellus 22, or equal quality of other makes.

Oil misting occurs automatically via the valve (44).

Fig. 13/1

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Maintenance

13.2 Cleaning

The machine can be sprayed down with the vacuum chamber closed; see Chapter 10.7.2 "Close lid".

13.2.1 Detergent

Do not use anything that will scour or scratch! Use standard detergents which conform to hygiene regulations, for: - Vacuum chamber - Platform - Sealing bars - Operator console - Lid seal Use standard chromium steel detergents.

13.2.2 Cleaning interval

Daily

• Clean platform (3). The platform can be lifted out of the vacuum chamber by 2 persons.

• Clean the inside of the vacuum chamber.

• Remove all foreign bodies such as bag

remainders, etc. from the vacuum chamber.

• Remove sealing dirt at the sealing bar (7, 10) or sealing pad (9). Do not use any sharp-edged instruments for this.

Fig. 13/2

• Remove sealing remainders at the cutting wires with steel wool (or similar).

• Clean the lid seals (see chapter 13.1.2 "Checking the lid seal").

• Keep the working space around the machine free and clean.

Weekly

• Clean the filters in the two openings in the rear of the vacuum chamber. • Clean the outer surfaces of the machine.

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Maintenance

13.3 Maintenance work

We recommend that the machine has a full service once a year at least. The VC999 Customer Service Department is available for all service and servicing, on request.

13.3.1 Displayed servicing works

The machine monitors the required services intervals itself. The following messages appear at the display. every 2,000 operating hours: PREVENTATIVE MAINTENANCE REQUIRED every 100 operating hours: CHECK VACUUM PUMP AND PNEUM. OIL LEVELS every 4,000 packaging cycles: CHECK SEALBARS PLEASE

IMPORTANT Organize the required servicing works and confirm these messages with the STOP button. When the key switch is set to "CLOSED" this message will appear again at every second start.

13.3.2 Service sealing bar and sealing pad

The Teflon strips (75) on the sealing bar (72) will show burn marks after a time and must be replaced. At the same time the cutting and sealing wires must be replaced. The sealing pads will develop unevenesses and burn points with time. Such sealing pads must be ground down or replaced.

Procedure

• Pull the sealing bar out of the support.

• Release the cutting wire (70) by loosening the threaded pin (74). Clean the cutting wire with steel wool or replace it with a new one.

• On both sides screw the clamping strips (76) off

and pull the Teflon strip (75) from the sealing bar.

• Clean the sealing bar in a well ventilated room

with acetone. Fig. 13/3

CAUTION Acetone is highly inflammable! No smoking! There is a danger of fire!

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Maintenance

IMPORTANT If, when changing the Teflon strip, it is noticed that the sealing wire (71) is not taut enough anymore or even damaged, then it must be replaced.

• Release the sealing wire (71) by loosening the threaded pins (73) (do not take out completely).

• Remove the sealing wire (71) and replace it with a new one. Clamp it taut with the threaded pins (73).

• Glue a new Teflon strip (75) tight and without folds and rub it well in with a clean rag.

• Clamp the Teflon strip by fixing the side clamping strips (76).

• In order to obtain as little wear as possible at the cover strips, the cutting wire is stretched over the

Teflon strip. Cut the Teflon strip at its ends in the region of the cutting wire back about 1 cm (78) with a scissors. Insert the cutting wire and clamp it with a flat pliers taut with the threaded pins (74).

IMPORTANT The sealing bar can also be sent to the VC999 customer service department for renewal of the Teflon strips or the sealing and cutting wires. Recommendation: Order a set of sealing bars as a spare.

Installation of the sealing bar

• Make sure that when installing the contact surfaces of contact pins (77) and contact spring that they are bright and that contact is ensured.

Replacing the sealing pads

The sealing pads are fixed in a slot with adhesive tape. • Remove the damaged sealing pads and clean the slot in a well ventilated space with acetone.

CAUTION Acetone is highly inflammable! No smoking ! There is danger of fire!

• Make sure that when inserting the sealing pads in the slot that there is play on all sides.

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Maintenance

13.3.3 Maintenance vacuum pumps

13.3.3.1 Rotary slide vacuum pump

See oil change label on the machine.

Every week

The oil level in the level glass (55) must be between Min. and Max. • Top up with oil.

Oil recommendation: - BP Energol RC 100 - ESSO Teresso 100 - Mobil DTE Oil extra heavy - Shell Corena Oil H100

Fig. 13/4

CAUTION If foreign bodies or fluids or dirt are pulled in by the vacuum pump, then the oil will be discoloured. In this case, do not continue working. Change the oil immediately according to the following description!

Oil changes

IMPORTANT An oil change at the rotary slide vacuum pump must be carried out at least annually but certainly after 500 working hours. When changing the oil, the vacuum pump must be in the operating warm condition!

Procedure: • Unscrew both covers (56). • Place an oil pan under the vacuum pump!

• Unscrew the plug screws (57) and allow the old oil to drain into the oil pan. Dispose the old oil

according to regulations.

• Replace the plug screws (57) again.

• Pour in ca, 6 litres new oil. The oil level in the level glass (55) is decisive (½ to ¾).

• Close the oil filler opening (56) again.

• Check the oil level in the level glass (55) (after a short switching on) with vacuum pump at rest.

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Maintenance

Suction filter

The suction filter of the vacuum pump must be cleaned more or less frequently depending on the amount of dirt in the sucked in air. Procedure: • At the suction nozzle, unscrew the cover (80). The

suction filter is behind the cover. • Clean the suction filter with compressed air or by

washing and replace it again.

• Install the cover again. Fig. 13/5

Oil separator insert

After a longer period of running the pump, particles of dirt in the oil separator insert can obstruct the flow of air through the pump. The pump then absorbs more power, which can lead to the machine switching off (see error 23, Chapter 11.1 "Displayed malfunctions"). In this case the oil separator inserts must be replaced.

Procedure:

Fig. 13/6

• Remove the cover (82) at the pump. For this purpose loosen the screws (Fig. 8/5, Pos. 58).

• Replace the oil separator inserts (81) and then replace the cover again.

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Maintenance

13.3.3.2 Roots vacuum pump (07P... / 220W500)

The oil level must be visible in the sight glass (60+62). Top up with oil if necessary.

Oil recommendations: - BP Energol RC 100 - ESSO Teresso 100 - Mobil DTE Oil extra heavy - Shell Corena Oil H100

Oil changes

IMPORTANT An oil change at the roots vacuum pump must be carried out after 5000 operating hours. When changing the oil, the vacuum pump must be in the operating warm condition

Procedure: • Loosen the vent screws in order to vent the pump

(see oil change label on the machine). • Unscrew the filler plugs (61).

• Place an oil pan under the drain plugs (63)!

Fig. 13/7 • Unscrew the drain plugs (63) and allow the old oil to drain into the oil pan. Dispose the old oil

according to regulations.

• Replace the drain plugs (63) again.

• Pour in (in accordance with description in Chapter 8.4) approx. 1.5 litres new oil. Check the oil level in the sight glasses (62).

• Replace the filler plugs (61) again.

• Tighten the vent screws again.

• Check the oil level after a short switch-on with vacuum pump at rest at the sight glasses (62).

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Maintenance

13.3.4 Replace fuses

IMPORTANT Installation, service and repair work at the machine must always be carried out with the machine at rest. Before beginning this work, the main switch must be turned off and locked with a hanging lock to prevent unintended starting. The key must be secured so as to be inaccessible to third parties.

Procedure:

• Unscrew the lid of the electrical switch box (12) (see also Fig. 3/1).

• The fine wire fuses (16, 17) are now accessible

for replacing.

• After replacing the fine wire fuses replace the lid of the electrical switch box.

Fig. 13/8

13.3.5 Replace the electronics board

IMPORTANT In order to replace electronic components contact the VC999 customer service department.

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Repairs - Spare parts

14 Repairs

IMPORTANT Repair work may only be performed by skilled technicians because this work entails special expertise and skills. This Operating Manual does not provide either.

Where necessary, call the VC999 Customer Service Department. The address and contact numbers of the Customer Service Department are contained in the “Introduction”.

15 Spare parts

15.1 Ordering spare parts

The VC999 Customer Service Department can provide you with a separate list of spare parts, on request. Comply with the following instructions when you order spare parts: • Check the machine to ascertain which part you need to order.

• Find the relevant part number on the spare parts list and make a note of the name of the part.

• We require the following details for the order:

Characteristic data Company name, address, address to which to send the spare parts if this is different to the address of the company.

Machine type and serial number You will find this data on the rating plate on the back of the machine.

Order quantity, description of the spare part and part number The descriptions of the spare part and part numbers are contained in the separate spare parts list.

• Order the spare parts directly from the machine manufacturer or from an authorised Customer Service Department. Refer to the “Introduction” for further details.

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Disposal

16 Disposal

When you purchase lubricant and bag material, check that they are environmentally friendly and are not harmful to people. Also check the disposal regulations and the possibilities for disposing of these properly in your local area. The owner is responsible for disposing of the machine. It is responsible for ensuring that the machine is disposed of carefully and in compliance with valid local regulations. It is required to comply with the following instructions, in particular: Before the machine is disassembled, disconnect it from outside supply lines:

Power supply

• Unplug it at the mains and remove the plug from the electric cable.

Inert gas (07PN ...)

• Cut off the inert gas supply. Close the valve on the gas cylinder and detach the hose which is attached to the inert gas valve with a clip.

IMPORTANT The machine must be dismantled by a skilled technician.

Procedure for final decommissioning: • Drain fluids (e.g. oil) into separate containers and send them to appropriate processing firms. • Dispose of hazardous substances, in accordance with regulations, as special waste. • Separate plastic parts and send them off for recycling. • Separate metal parts and arrange to have them shredded or scrapped.

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Pneumatics diagram

17 Pneumatics diagram

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Circuit diagrams

18 Circuit diagrams

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Circuit diagrams

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Circuit diagrams

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Circuit diagrams

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Vacuum Packaging Machine 07P ...

Sequence diagram

19 Sequence diagram

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Index

20 Index

A Automatic operation 52 Autostart interval 36 C Calibr. of the sealing time adjustment 58 Calibration plug 58 Chamber / pressure below 56 Check of EPROM 58 Checks 60 Circuit diagrams 72 Cleaning 62 Cleaning interval 62 Cleaning the machine 27 Close lid 42 Closing impulse 52 Command buttons 50 Compressed air service unit 61 Connection data 20 Cooling time 53 Customer service 9, 12 Cutting 35 Cycle value 57 D Decommissioning 70 Diagnosis 47 Dimensioned drawing 21 Disposal 70 E Ejection direction 19 Electrical connection 24 Electrical installation 25 End packaging 32 Error diagnosis 50 Evaporation 33 F Filling tools 29 Functional principle 16 Fuses 68 G Gas flush 51 Gas mix 13 H Hazardous substances 70 Heat sealing 13 I Inert gas 13, 16, 24, 51 Inert gas connection 26 Inert gas device 13 Inert gas installation 26

Inert gas nozzles 17 Inert gas quality 24 Inert gas supply 34 Inert gas system 12 Initial settings 49, 51 Initial start-up 28 Insertion frame 16 Installation of the sealing bar 64 Interconnection 19 Intermediate ventilation 34, 51 K Key 42 L Lid seal 60 M Maintenance 60 Maintenance work 63 Malfunctions 45 Mode of transport 52 N Number of locked programs 36 O Open key switch 37 Operating data 42 Operating malfunctions 48 Oxygen 13 P Packaging 31 Packaging programs 33 Platform 16, 61 Platform adjustment 57 Platform height 57 Platform positioning 52, 57 Pneumatic connection 20, 24 Pneumatic consumption 20 Pneumatic oiler cycle interval 53 Pneumatic oiler impulse time 53 Pneumatics diagram 71 Pneumatics installation 25 Positioning accuracy 54 Pressing cushion tightness 56 Pressing time 52 Preventilation 35 Product height 35 Production without inert gas usage 26 Program level 38 Program table 40 Programming 33 Protective equipment 11 Pulse duration 53

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Index

R Raise platform 41 Raise sealing bar time 53 Rating plate 16, 69 Repair work 11, 68, 69 Replace the electronics board 68 Replacing the sealing pads 64 Roots vacuum pump 67 Rotary slide vacuum pump 65 S Safety instructions 11, 15 Safety space 23 Sealing 35 Sealing bar 63 Sealing bar temperature 57 Sealing current monitoring 47 Sealing time correction 57 Sealing type 35 Sequence diagram 76 Sequence diagram Program level 38 Sequence diagram service settings 43 Sequence service program 59 Service settings 41, 43 Servicing works 63 Setting up the machine 23 Spare parts 69 Start packaging cycle 32

Structure of the machine 16 Suction filter 66 Switch pump on 30 Switching off the machine 32 Switching on 30 T Technical data 20 Teflon strip 63 Test programs 49, 55 Tightness of the vacuum chamber 56 Tolerance conveyor levelling 54 Transport time 36 Type of packaging 22 V Vacuum bags 13 Vacuum calibration 55 Vacuum chamber lid 16, 60 Vacuum pump 11 Vacuuming modes 33 VCP extension module 58 VVO-Holding 52 W Weight 20 Works settings 50

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07p operating manual vc999

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