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USER MANUAL

1. gt Manual programming 20 Automatic programming 21 MACHINE MAINTENANCE gt nmm nnn nnn nnn nn nnn nn nnn nnn nn General 23 Important before and during maintenance 23 Standard maintenance schedule 24 Vacuum pump maintenance 24 Seal system maintenance 27 Silicone holder and lid gasket maintenance 29 List of maintenance parts 30 TECHNICAL SPECIFICATIONS ELECTRICAL DIAGRAMS ERRORS CODES PNEUMATIC DIAGRAMS PROBLEM SOLVING FACTORY SETTINGS CONTROL RS aH aV S n CV c a SPECIAL APPLICATIONS 0 0 0 266mm nnne nnn nnn nnn nnn nnn nnn nnn n Machine with gas flush system 41 Packaging liquid products 41 External vacuuming of food containers 42 EEC DECLARATION OF CONFIRMITY _ nnn nnn nnn nn nnn nnn nnn nnn nnn MAINTENANCE SCHEDULE NOTES __ nnn nnn nnn nnn nnn nnn nn an REMOVAL FRONT PANEL nnn nnn nnn nnn nnn nnn nnn nnn nnn Version 11 10 DIG EN Oo N Aa 13 20 23 NKELMA cuum system BOXER MAR
2. Voltage 24 V Indentification number ORIGINAL N Y HENKELMAN __ Mode OUCAN vacuum systems 2 MAIN SUPPLY MAIN FUSE CONTACTOR CONTACTOR SEAL CONTROL TRANSFORMER CONTROL SWITCH MOTOR SEAL TRANSFORMER MAIN PCB CONNECTOR 1 TR1 SEAL BAR R1 Qc 1 2 200 230 Volt FT 4 4 N 2 0 u A u nv Green Yelow Ti a es ESSEN a mds ta 5 4 3 2 1 1 T c e 1 A d 9 8 7 6 2 3 0 MM is 14 1312 11 14 416 0 15 417 0 N N Indentification number HENKELMAN 5 Diagrams are shown for standard configurations Version 11 10 DIG EN Control Current Diagram MARLIN 46 52 90 FALCON 52 80 POLAR 52 80 THERM_ RELAIS VAC COMP INPUT VALV VOLT
3. 1 2 4 7 MAIN SUPPL AUTOMATIC OVERLOAD CONTACTOR PUMP CONTACTOR SEAL SEAL TRANSFORMER CONTROL TRANFORMER CONTROL SWITCH Ls 1525 12 FA K1 K2 TR2 Tb1 S2 IN SWITCH THERMICAL OVERLOAD SEAL TRANSFORMER SEAL BAR MAIN PCB CONNECTOR Q1 TRI R2 MOTOR SEAL M1 R1 a 1 QUD 1 2 1 3 11 9 1 1 ScD 1 25 1 32 L2 a 5 1 22 1 3 5 G qa ER dull po O 4 51 m rif 3 55 5 L3 7 L4 K2 4 ww rll 1 2 380 400 Volt e DIDID FS FT J Green Yellow f M WALA 04 0 416 0 2 li TR2 _ yi S sat AL 5 3 1 1 40 10 3 0 a 14 13 1 1 Date Name Description luced 01 01 09 MD Connection Diagram Main Power Supply Checked 27 01 09 MD Voltage 580 400 V R N a L lndentification number Phase 2 EB DT Model SINGLE DOUBLE m Diagrams are shown for standard configurations List of fuses Fuses are located where the power enters the component board Fuses are located on transformers control and seal Two fuses are placed on the control circuit Due to different mains voltages and machine models there is a variety of fuse types that can be present in the machine R
4. 8 1 10 1 11 12 12 1 A a A Al 1 L A L K LZ I AC Y1 4 Ae vo k2 AD C343 5 42 CO Con e SE 22 Keyboard 1111 345678 ion Diagram Digita Pane Diagrams are shown for standard configurations Control Current Diagram FALCON 2 60 2 70 POLAR 2 40 2 50 2 75 2 85 2 95 THERM_RELAI 3 MISCOSWITCH 54 24_VOLT PUMP VDC board JUN G SOFTAIR DECOMP _VOLT VOLT INPUT INPUT CONTACTOR ALVE VALVE ALVE CONTACTOR ALVE ALVE INPUT INPUT FUSE_F9 K1 Y24Y2 K2 Y4 5 FUSE_F8 ey a ee ae ee MEE 22 MAIN NNECTOR PC BOARD
5. 1 7 5 1 r 8 2 1 5 14 0 6 02 7 0 8 02 9 0 10 02 011 02 12 0 14 02 15 02 3 L wu 5 5 Le 74 ae See e CS Se ear A aa See Se SS E ee SS ees oS Se Se SS Se ee Sa See c SS ety SS SSeS St a 6 15 CLIM 1 p a 10 o 8 12 Wes NC T imt Q 4 8 2 A 15 1 n 7 1 A 51 IP 8 35 12 15 X K co A 1 411 12 gt YA P V 3 2 5 32 y 4 AB t ke A Ae gt N c 5 0 3 2 5 04 02 3 02 X 03532 17 0 16 0 x r Volt 0 olt ce 9 Volt 0 Volt e e une Tex 565 5 5 _ 1 7 Di gital Pane Indentification 004 PC number Version 11 10 DIG EN 34 Main Circuit Diagram MARLIN 46 52 90 FALCON 2 60 2 70 POLAR 2 40 2 50 2 75 2 85 2 95
6. Hes ORIGINAL HENKELMAN vacuum systems USER MANUAL BOXER SERIES MARLIN SERIES FALCON SERIES POLAR SERIES HENKELMAN BV Adress Titaniumlaan 10 5221 CK s Hertogenbosch The Netherlands Postal Address Box 2117 5202 CC s Hertogenbosch The Netherlands Tel 31 0 73 621 3671 Fax 31 0 73 622 1318 E mail info henkelman com Internet httpz www henkelman com Versie 11 10 DIG EN This manual is for the MARLIN FALCON POLAR series The general instructions apply to the models this category Henkelman B V cannot be held responsible for any damage caused by deviating machine specifications This manual has been established with care Henkelman B V does not accept liability for errors in this manual and or consequences of misinterpretation of the instructions Henkelman is not liable for damages and or problems that arise from using spare parts that are not supplied by Henkelman Henkelman reserves the right to change specifications and or spare parts without prior notification All rights reserved No part of this publication may be reproduced by photocopy printing or in any other way without prior consent from Henkelman LIABILITY 1 We exclude all liability as far as it is not provided for by law 2 Our liability shall never exceed the total amount of the order in question 3 Barring the generally applicable legal rules of publ
7. is are pulled taught and straight with the help of a pair of pliers before the wires are screwed down It is handy to use a pair of adjustable pliers as a lever for optimal wire tension Place one end of the sealing beam in the vice and stretch the wire wires by pressing down the bar Cut off the extruding wire end s on both ends after having screwed it tight Cut a piece of teflon tape as long as the sealing bar plus about 5 cm 2 inches Stick the new teflon tape straight over the new sealing wire wires Ensure that the teflon is straight on the sealing bar and that the sticky part is stuck on the side Ensure that the teflon is stuck on the bar smoothly and without folds Cut the teflon tape off so that the sticky part does not get stuck on the sides of the clamps but that the teflon extends over the top of the clamps Place the sealing bar back in the machine Ensure that the sealing beam is properly clicked onto the holders or that the screws are firmly screwed in Special remark bi active sealing system The sealing wire must be accurately placed on the upper and lower beams so that the sealing wires line up with each other exactly during sealing See page 30 for correct parts and quantities Cut off the ends of the sealing wire and stick Teflon tape over the sealing beam without folds 28 BOXER MARLIN FALCON POLAR SERIES USER MANUAI H N ELMAN SILICONE HOLDER AND LID GASKET MAINTENANCE Replac
8. per 10 hours When the operation hours counter is turned off the number of operating hours will not be displayed instead the message OFF will immediately appear after pressing the key for 3 seconds D Press the FUNCTION SELECT Key for at least 3 seconds After 3 seconds the number of operating hours The original setting can be modified using the and keys between 0 and 990 hours If set to then the next time OFF will automatically be displayed The new settings are stored by using the REPROG Key The actual operation hours are then also reset to zero After pressing the REPROG key the control panel automatically switches over to operation mode Version 11 10 DIG EN 19 PROGRAMMING The function values in a selected program number can be changed using either manual or automatic programming For units range and limits of the function values refer to the previous chapters 10 programs can be selected and set number 0 to 9 Note program 0 cannot be programmed for user The values in this program are set for service and reference use Authorized suppliers van open program 0 for changing values for testing by pushing REPROG button for 5 seconds After program 0 switches to PROGRAM MODE MANUAL PROGRAMMING starting situation machine is in normal operation mode and the lid is open select the correct program with PROG 0 9 key for setting function values Program number is displayed on the small display Press REPROG key to
9. are delivered with the machine This makes the operation easier and reduces the cycle time The vacuum bag must be placed over the sealing bar BOXER and MARLIN or silicone holder FALCOM and POLAR without folds For a gas flush system the opening of the vacuum bag must be pulled over the gas nozzles see illustration Multiple vacuum bags can be placed over the sealing bar silicone holder if the sealing bar silicone holder is longer than the vacuum bag Vacuum bags may not FALCON POLAR series however be laid on top of each other on the bar holder If there are multiple bars holders then all bars holders can of course be used during the same cycle Use the PROG key to choose the desired program See page 18 for instructions about programming Close the lid and the machine automatically runs through the full cycle of all activated functions The lid opens automatically when the last function ventilation has been completed If necessary the cycle can be partially or fully interrupted by pressing the VACUUM STOP key or the STOP key The VACUUM STOP key interrupts the active function vacuum gas flushing sealing or soft air ventilation and automatically continues with the next function The STOP key interrupts the entire cycle and goes immediately to the ventilation function After cycle completion the packed product or products can be removed from the machine If the machine is equipped with a cut off sealin
10. damaged or stretched For instructions see page 27 Inspect the transparent lid if applicable When cracks are visible turn off the machine immediately and contact the supplier or Henkelman BV Every Six Months Replace oil at least once every 6 months Yearly Inspect the oil exhaust filter for saturation If saturated replace the filter For instructions see page 24 Contact the supplier for a professional service Four yearly Replace transparent lid and the lid s gas springs if applicable Replace membranes seal cylinder if applicable VACUUM PUMP MAINTENANCE It is very important to regularly service the pump to ensure extended and correct operation The following activities are essential for correct maintenance If the machine is used regularly then it is advisable to have the pump fully inspected at least once a year by the supplier to ensure extended and problem free operation Contact the supplier or Henkelman BV for more advice and information Conditioning Program The conditioning program ensures that the pump is thoroughly rinsed During the program the pump and oil reaches operation temperature so that the oil can better absorb any moisture and contaminants and filter them The high temperature enables any moisture in the pump to evaporate minimising the risk for rust spots e The program lasts 15 minutes and it is advisable to run it at least once a week Turn on the machine press the key condit
11. filter is then screwed off and replaced by a new one The pump can now be filled with new oil For the correct type of oil filters refer to the list of maintenance parts on page 29 filter Inspect and change oil exhaust filter There are one or more oil exhaust filters in the pump which absorb and filter oil vapours The filters will become saturated after a period of time and need to be replaced This is on average between 12 and 18 months When the filters are saturated it is no longer possible to achieve maximum vacuum Filter housing types Filter housings can be located at the side or behind the machine Appearance can vary depending on the model multiple housings on pump or multiple filters in one housing 016 021 m3 h 040 063 100 m3 h 160 300 m3 h Version 11 10 DIG EN 26 Change oil exhaust filter s Open rear or side of Screw the cover s The filter s is are visible Release the tensioner s machine for pump from the filter behind a tensioner with a spanner housing Place and tension the new filter take care that the gasket is correctly positioned in the housing Screw the cover back onto the housing Screw the back or side plate on the machine Remove tensioner s and Take care that the filler gasket does not filter s from the housing remain behind when removing the filter Pumps and housing can have a different appearance but the principle of replacing remains the same Take care that the correc
12. mode is used to change the function values within the programs The control panels are implemented standard with an automatic conditioning program for the regular maintenance of the pump and two STOP keys for complete cycle interruption or for only active function interruption There are also a number of built in service programs The value of all active functions can be set for a certain time period The vacuum function gas flush function if installed and soft air function can be set in whole seconds up to a maximum of 99 seconds The seal function can be set with an interval of 0 1 seconds and a maximum of 6 0 seconds The value of the vacuum function and the gas flush function if installed can be set as a percentage of the vacuum This is the percentage of the under pressure in the vacuum chamber related to the outside pressure 1 atmosphere ATO 0 The maximum vacuum percentage setting of the vacuum function is 99 The minimum vacuum percentage setting of the gas flush function is 30 This means that the chamber is flushed with gas to 30 under pressure in relation to 1 atmosphere It is often expressed as 70 is flushed with gas 99 30 70 The time for the soft air function can be set on whole seconds max 99 seconds The time for the seal function can be set on 0 1 seconds max 6 0 seconds The digital sensor control comes standard with the VACUUM PLUS function The VACUUM PLUS function is a time operated additional
13. opening is Clean the vacuum bag s opening contaminated There is too much gas in the package Check this by setting the gas function to the OFF position The amount of gas in The gas bottle is empty or nearly empty Replace the gas bottle the vacuum bag is The gas bottle is still closed Check if the valve on the gas bottle is insufficient optional closed If so open it Gas flush time is too long or too short Shorten or extend the gas flush time The gas flush pressure is incorrectly set Check if the manometer or the secondary pressure of the gas is set to 1 atmosphere 1 WARNING The pressure of the gas mixture may never be more than 1 atmosphere ATO In the case of other problems or questions contact the supplier or Henkelman BV Version 11 10 DIG EN 39 DIGITAL TIME CONTROL FACTORY SETTINGS Program 0 Vacuum time 30 20 20 15 10 30 25 20 20 15 Gas flush time OFF OFF OFF OFF OFF 5 5 10 15 15 Sealing time 2 5 2 5 2 5 2 5 2 5 2 5 2 5 2 5 2 5 2 5 Soft air time 3 3 2 2 2 OFF OFF 2 OFF OFF Only applicable if the machine is equipped with the options question If the machine is not equipped with the gas flush system and or soft air ventilation then these options will not be available on the control panel Program 0 cannot be modified DIGITAL SENSOR CONTROL FACTORY SETTINGS Program 0 Final vacuum pressure 50 80 90 50 90 60 Vacuum plus time OFF OFF OFF OFF Final vacuum pressum
14. remains on after 99 is reached and during the time set for VACUUM PLUS During the VACUUM PLUS vacuum cycle a dot appears in the right lower corner of the large display Display during operation and program mode If the VACUUM PLUS time is activated during the selected program then a dot appears in the lower right hand corner of the large display during the operation and program mode If the functions are selected using the function selection keys then the indicator light in front of VACUUM comes on twice and the vacuum percentage and VACUUM PLUS time are shown consecutively Special Remark If the machine has the gas flush function implemented and the function is activated within the selected program then a dot appears in the lower right hand corner of the small display when selecting the program no Version 11 10 DIG EN 14 8 STOP VACUUM Key Function during cycle Interruption of the active function during the program cycle The cycle immediately continues with the next function Function in program mode Raise the value of the selected function within the program selected in the program mode 9 STOP Key Function during cycle Terminates the program cycle completely The cycle immediately switches to the ventilation function Function in program mode Lower the value of the selected function within the program selected in the program mode 10 Vacuum meter Displays the pressure in the vacuum chamber See the following table
15. switch into program mode The program number now starts to blink on the small display select the required function for programming with the FUNCTION SELECT Key The indicator lights will turn on for the active functions when selected Remark on Seal function for option 1 2 Cut Off seal At option 1 2 cut off seal the indicator SEAL lights up twice when selected The first time is for setting the seal time and the second time for setting the cutting time Remark on option Digital Sensor Control and Quick Stop H20 Control At option sensor control the indicator VACUUM lights up twice when selected The first time for the vacuum function vacuum percentage The second time for the vacuum plus function time duration see pages 8 9 Digital Time Control set the amount of time required for the selected function by using the and keys Digital Sensor Control and Quick Stop H20 Control set the percentage of vacuum required or the amount of time required for the selected function by using the and keys Remarks Set values are displayed on the large display The functions vacuum plus sensor control gas flush and soft air can be turned off in the programme if required For turning off a function press the key until OFF appears on the large display Repeat steps C and D for setting other function values Press the REPROG key after setting all relevant functions to store the changes in the program The control then automatica
16. time per second starting at the time set max 99 sec and a dot in the lower right hand corner The vacuum meter will very slowly increment counter clock wise hardly noticeable Remark can only be installed with a vacuum function whereby the value is set to the maximum of 99 Once the vacuum function has completed the gas flush function starts to flush gas into the vacuum chamber The light in front of GAS is burning Large Display decrementing percentage vacuum until the set percentage min 30 Vacuum meter starts decreasing clock wise Once the normal gas flush phase is finished it is possible to add time for additional gas flushing With this extra gas can be inserted while the sealing system is closing When the vacuum function or gas flush function if installed ends the seal function starts to seal the vacuum The light in front of SEAL is burning Large Display decrementing time per second starting at the time set max 6 0 sec The reading on the vacuum meter stays the same After ending the seal function the soft air function starts to slowly ventilate the vacuum chamber The light in front of SOFT AIR is burning Large Display decrementing time per second starting at the time set max 99 sec Vacuum meter starts slowly decreasing clock wise After ending the seal function or the soft air function if installed the ventilation function starts ventilating the chamber to 1 atmosphere ATO
17. vacuum function for setting extra time after reaching the 99 value of the vacuum function only applicable if 99 is set for the vacuum function This function provides additional vacuum time for escaping any trapped air out of the package The principal for the Quick Stop 2 function is a very sensitive sensor control system If H2O is shown in the display it indicates that the function is active The option can be activated in each program separately The maximum vacuum percentage that can be reached at this setting is 99 The special highly sensitive H2O sensor is capable to detect the moment liquids from the product starts to evaporate boiling At that moment the control system will interfere and step to the next phase and therefore prevents the product from dying out losing weight boiling out of the vacuum bag and consequently polluting the sealing area and chamber excessive liquids to end up into the vacuum pump with corrosion as a possible result and at last create the optimum cycle time to prevent needless vacuum time The Quick Stop 20 sensor control comes standard with the H2O PLUS function The 20 PLUS function is a time operated additional vacuum function for setting extra time after reaching the 99 value of the vacuum function The time for the H2O Plus function can be set per 0 1 seconds with a max off 5 0 seconds BOXER MARLIN FALCON POLAR SERIES USER MANUAL Ed H NKEI Mi N CONTROL PANEL LAYOUT 1 Smal
18. 15 minutes to heat up and clean the pump For instructions on the conditioning program see page 22 5 J OA After switching to the user mode it is possible that OIL appears on the display This means that the operating hours counter is turned on and the number of operating hours that has been set has elapsed The hour counter is turned off by default but can be set by the customer or supplier to be used as a reminder for regular maintenance activities When Oil is displayed the machine can still be used as usual but we advise to change the oil and reset the warning function Please contact your supplier for more information about setting or turning off the operating hours counter Version 11 10 DIG EN 11 STANDARD OPERATING STEPS FOR THE MACHINE 1 10 11 Turn the machine on with the ON OFF switch Heat up the pump with the condition program when machine has not been used for a while instructions page 22 Fill the vacuum bag with a product Select the correct size of the bag The bag has to fit easily around the product but should not be too large Make sure you respect hygienic conditions during this aging materials product and hands must be clean and dry if possible ET 5 Place the vacuum bag in the chamber The open end must be placed over the sealing bar The bag should not be outside the chamber If the product is much lower than the height of the sealing bar you should use the black insert plates that
19. 20 10 D 2 mbar Boiling Point Temperature C 100 94 06 76 60 45 33 18 7 2 13 A handy tip when packaging liquid products is to use a liquid insert plate so that the product remains at the bottom of the packaging during the vacuuming process and there is less risk of liquid splashing out of the packaging Contact the supplier or Henkelman BV for more information about the liquid insert plate Version 11 10 DIG EN 41 BOXER MARLIN FALCON POLAR SERIES USER MANUAL 4 H EXTERNAL VACUUMING OF FOOD CONTAINERS if applicable The BOXER and MARLIN series can be equipped with an option for externally vacuuming special food containers This system can vacuum special containers for longer storage life of the food products in the dish The container has a special lid with valve Contact the supplier or Henkelman BV for more information about the containers The system for the machine consists of a hose with vacuum applicator Operation External Vacuuming Food Containers 1 Start the machine 2 Place the hose connector over the extraction opening of the vacuum chamber of the machine 3 Check that the sliding valve on the vacuum applicator is on the side of the hose closed position Y E 4 Press the PROG 0 9 Key until E External Vacuuming appears on the small display 5 Place the vacuum applicator over the valve of the container and slide th
20. 50 80 80 30 after gas flush Sealing time 25 25 25 25 25 Soft air time OFF OFF 2 OFF OFF Only applicable if the machine is equipped with the options question If the machine is not equipped with the gassing system and or soft air ventilating then these options will not be available on the operating panel id Program 0 cannot be modified CUSTOMER SETTINGS TO BE FILLED IN Program 0 Vacuum time 99 Final vacuum pressure Vacuum plus time 15 Gas flush time Final vacuum pressure after gassing Sealing time Soft air time Version 11 10 DIG EN 40 REMARKS ON SPECIAL APPLICATIONS MACHINE WITH GAS FLUSH SYSTEM if applicable If the machine is equipped with the gassing system then the following remarks are important NEVER USE GAS MIXTURES WITH MORE THAN 20 OXYGEN AND OR OTHER EXPLOSIVE GASSES THIS COULD CAUSE FATAL EXPLOSIONS NEVER USE SEPARATE GAS BOTTLES WITH A MIXER WHEREBY ONE OF THE BOTTLES IS ONLY FILLED WITH OXYGEN MALFUNCTIONING OF THE MIXER OR IF THE OTHER BOTTLE WERE TO BE EMPTY COULD CAUSE FATAL EXPLOSIONS All guarantees and or liability expire in the case of accidents and or damage caused by using oxygen or other explosive gasses The maximum gas pressure that can be set in the packaging is 35 0 35 bar on the vacuum meter This means that there is 65 gas and 35 vacuum under pressure in the packaging If a higher gas pressure results in insufficient seal quality contact
21. E AND DURING MAINTENANCE The machine must always be completely voltage free before any maintenance is carried out on it Remove the plug from the wall socket or put the master switch in the O position the machine is not functioning properly or if it produces strange noises turn it off immediately with the ON OFF switch and contact the supplier or Henkelman BV machine is equipped with a gas flush system then always close the main crane during standard maintenance activities Always note that the pressure on the pressure reducing valve on the gas bottle is never higher than 1 atmosphere ATO before during and after the maintenance activities A higher pressure may cause irreparable damage to the machine NEVER use flammable gasses or gas mixtures containing oxygen When cleaning transparent lids if applicable NEVER use cleaning agents containing solvents Check at least once a week if there are cracks in the lid In case of cracks turn off the machine immediately and contact the supplier or Henkelman BV High pressure cleaning is not permitted for cleaning the machine High pressure cleaning can cause considerable damage to electronic and other parts of the machine Water may never be permitted to enter either the extraction nozzle of the chamber or the blow off opening of the pump This would cause irreparable damage to the pump Larger services must always be carried out by an authorised supplier The BOXER se
22. LIN FALCON POLAR SERIES USER MANUAL PRIOR STARTING TO USE THE MACHINE MACHINE REGISTRATION TO BE COMPLETED BY THE USER Register the machine using the following data This information is necessary if the supplier or Henkelman BV is contacted concerning questions or references about the specific machine DATA ON MACHINE TAG Relevant data for answering questions can be found on the machine tag The machine tag is located at the rear of the machine Note down the following data 1 MACHINE TYPE vacuum IE Conformit Europ enne Telephone 31 0 73 621 3671 nce 2 MACHINE NUMBER MACHINE NO PO rnet http www henkelman com 3 VOLTAGE TENSION CONTROL PANEL DATA When starting the machine two codes appear on the display consecutively before the control switches to user mode The first code indicates the software version of the control software and the second code indicates the active options Please write down the codes below 4 CODE 1 5 CODE2 Version 11 10 DIG EN 4 IMPORTANT FOR INSTALLATION READ THIS FIRST GENERAL First read this manual carefully before the machine is put into operation This manual contains relevant information and instructions for starting up maintenance and applications If problems arise with the machine that could have been avoided by referring to this manual then the guarantee expires Henkelman BV wish
23. Stainless steel 450x525x385 016 99 80 42 Stainless steel Transparent Stainless steel 490x525x430 021 99 80 42 XL Stainless steel Transparent Stainless steel 490x610x445 021 99 80 42 XL Bi active Stainless steel Transparent Stainless steel 490x610x420 021 99 80 MARLIN SERIES 46 Stainless steel Transparent Stainless steel 780x660x970 040 99 98 52 Stainless steel Transparent Stainless steel 700x690x1030 063 99 98 90 Stainless steel Transparent Stainless steel 1065x480x960 063 99 98 FALCON SERIES 52 Aluminium Aluminium Sight glass Stainless steel 700x690x1070 063 99 98 80 Aluminium Aluminium Sight glass Stainless steel 900x820x1070 100 99 98 2 60 Aluminium Aluminium Sight glass Stainless steel 1060 880 1070 063 99 98 2 70 Aluminium Aluminium Sight glass Stainless steel 1260x1010x1070 100 99 98 POLAR SERIES 52 Stainless steel Stainless steel Stainless steel 700x730x1100 063 99 98 80 Stainless steel Stainless steel Stainless steel 920x790x1125 100 99 98 2 40 Stainless steel Stainless steel Stainless steel 1480x790x1090 063 99 98 2 50 Stainless steel Stainless steel Stainless steel 1480x970x1120 100 99 98 2 75 Stainless steel Stainless steel Stainless steel 1545x1150x1150 160 99 99 2 85 Stainless steel Stainless steel Stainless steel 1900x1300x1150 300 99 99 2 95 Stainless steel Stainless steel Stainless steel 2420x1210x1130 300 99 99 Specifications can deviate from optional models Standard ambient temperature 05 C 30 C Fo
24. XER and MARLIN 42 42 XL 13 mm POLAR 2 85 and 2 95 and 8 mm for other machines The connector is at the rear of the machine For more information about the use of gas bottles please consult an authorised gas supplier CONNECTING COMPRESSED AIR FOR EXTERNAL SEALING PRESSURE if applicable The pressure from the compressor may NEVER be set to more than 1 atmosphere ATO A higher pressure may damage the machine Only dry compressed air may be used for the external seal pressure The diameter of the hose nipple connector the compressor is 6 mm rear machine For more information about the use of compressed air please consult an authorised gas supplier Version 11 10 DIG EN 6 IMPORTANT FOR OPERATION READ THIS FIRST GENERAL Never pack products that can be damaged during or after vacuum packaging Live oats may never be vacuumed Refer to this manual if in doubt as to the operation and or functioning of the machine If the manual does not offer a solution consult the supplier or Henkelman BV The guarantee and or liability expires if damage is caused by repairs and or changes made by you In the case of malfunctions contact the supplier or Henkelman BV In the case of malfunctions always stop the machine and remove the power cable from the wall socket GENERAL MAINTENANCE It is essential that the machine is serviced regularly to guarantee operation and to keep the machine in optimal condition The maintenance sched
25. and the lid opens All lights are off in front of the functions Large Display lines going up and down until the lid is open The vacuum meter runs back to the right to zero and the lid opens automatically 10 The product is packed and ready to remove Version 11 10 DIG EN Description of the program cycle for digital Quick Stop 20 sensor control 1 Select the program number with the PROG key and the small display The foundation for the Quick Stop 2 function is a very sensitive sensor control system The option can be activated in each program separately if H2O is shown in the display it indicates that the function is active To activate the Quick Stop 20 sensor Press the REPROG button program number will start to blink Then press the Program selection key H2O will appears in the display Press the REPROG button to get back to the operating mode The Program number will stop blinking to indicate the machine is ready for operation 2 Close the lid 3 Vacuum function 4 VACUUM PLUS function if installed 5 Gas flush Function if installed 6 Gas flush Plus Function if activated 7 Seal function 7 8 Soft air ventilation function if installed eae Cr 9 Ventilation function The machine starts to vacuum the chamber The light in front of VACUUM is burning Large Display 20 will be shown Vacuum meter starts increasing counter clock wise The machine continues vacuu
26. ch the pump runs continuously The 3 phase pumps need more time to warm up and turning them on and off has a detrimental effect on their lifespan If the machine is turned on but it is not used the pump will automatically turn off after 10 minutes This to prevent overheating from the oil and reduce unnecessary pollution from exhaust filters We call this function Sleeper function SLEEPER FUNCTION On the models Marlin Falcon and Polar the sleeper function is by default switched on This means if the machine is switched on but not used the pump automatically switches of after 10 minutes By closing the lid the cycle and the pump will start simultaneously Contact your supplier for more information on the sleeper function STARTING THE MACHINE After the machine is connected and the master switch is switched to 1 if applicable the machine can be turned on by using the ON OFF switch When starting the machine two codes appear consecutively on the display before the control panel switches to operation mode The first code indicates the model of the machine The second code indicates the control software version Please note down both codes on page 4 as they are important for the supplier or Henkelman BV when making enquiries and or if any problems arise After switching to operation mode the machine is ready for use If the machine is new or has not been used for a long period of time we advise to run the pump conditioning program
27. ck data of the sensor are not correct F2 is shown on the display This message will be shown directly after the sensor controls are started RP This message will be shown when due to circumstances the controls are unable to retrieve the programme values The word circumstances means peak tensions or a tension drop during starting When such a situation occurs the print will start with this message and go no further Two options exist now the machine can be switched off and on again to see if the problem repeats itself or the reprog key can be pressed By operating the reprog key the controls will use the factory settings to start The programme values set by the client will be cancelled as a result This message will be shown directly after the controls are started If one or more of the above messages occur regularly we advise you to contact your supplier Version 11 10 DIG EN 36 BOXER MARLIN FALCON POLAR SERIES USER MANUAL PNEUMATIC DIAGRAMS BOXER series MARLIN series gt ME 12 gt e Mi 3 Y4 07777 j a X 3 c S yes RWI Seal cylinder Vacuumpump Vacuumgauge Gas valve Coptional Seal valve Softair valve Coptionab Devac
28. d viscosity numbering If the machine is used outside normal specifications regarding ambient temperature contact the supplier or Henkelman BV Version 11 10 DIG EN 25 E ALVE ERA I RAR A FA HF AAR IBAI AR LIMEFR A I B YXYED MAD NI ICON AR SE DI CED AIAN LDVALI IV FL FT VLAN VIULN WV AINU RA Ambient Temperature Machine Type Pump Filling Standard Cold Hot Capacity litres Cil Type Oil Type Type 10 30 5 10 C 30 40 35 016 0 4 Viscosity VG 32 VM 32 VS 32 BOXER 42 42 XL 021 0 4 Viscosity VG 32 VM 32 VS 32 MARLIN 46 040 m3 h 1 0 Viscosity VG 32 VM 32 VS 32 MARLIN 52 90 FALCON 52 2 60 POLAR 52 2 40 063 1 0 Viscosity VG 100 VM 100 VS 100 FALCON 2 60 POLAR 2 50 100 m3 h 2 0 Viscosity VG 100 00 VS 100 POLAR 2 75 160 m3 h 5 0 Viscosity VG 100 VM 100 VS 100 POLAR 2 85 2 95 300 m3 h 7 0 Viscosity VG 100 00 VS 100 Machines are supplied with standard type oll The capacity of models with a 063 m3 h pump and 60 2 voltage is 2 0 litre instead of 1 0 litre Changing the oil filter The pumps of all floor models have oil filters When replacing the oil the filters must also be replaced The oil filter is screwed to the rear of the oil exhaust filter housing When replacing the oil it is first drained off The old
29. e oil in the pump If there is too little oil or the quality of the oil is bad turbid replace or top up the oil before operating the machine see page 23 Let the pump conditioning program run at least one full cycle before replacing the oil see page 22 Use the right type of oil for the pump when replacing or filling up see page 24 Use the conditioning program at least once a week to enhance correct and long lasting pump operation see page 22 USE OF GAS FLUSH SYSTEM if applicable NEVER use flammable gasses or gas mixtures containing too much oxygen Use thereof can cause risk of explosions Accidents and or damage caused by using abovementioned gasses voids all liability on the part of Henkelman BV as well as the guarantee The gas bottles must always be correctly secured If the gassing function and or the machine is not in use then the main cock of the gas bottle must always be closed The pressure of the pressure reducing valve on the gas bottle may NEVER be set to more than 1 atmosphere ATO A higher pressure may damage the machine For more information about the use of gas bottles consult an authorised gas supplier WARNING SIGNS ON THE MACHINE ONLY use the prescribed power supply voltage SHOCK HAZARD Insert the plug firmly into the mains wall socket E i ae nds a Always connect the machine to an earthed wall socket acme 8 99 Always remove the plug during ma
30. e sliding valve towards the lid to open the valve lt Y 6 Pres the Key The vacuum pump starts to run and the container is vacuumed j SS 7 When the vacuum meter reaches 1 then the container is fully vacuumed EE STOP 8 Press the Key to stop the vacuum pump 9 The vacuum applicator can now be removed from the lid by sliding back the sliding valve 10 The container is now ready for storage and or stock 11 Ifthe machine needs to be used for normal applications then the hose can be removed from the extraction opening and the required program chosen using the PROG 0 9 Key Version 11 10 DIG EN 42 EEC DECLARATION OF CONFIRMITY Concept of an EEC Declaration of Conformity Henkelman B V Titaniumlaan 10 5221 CK s Hertogenbosch Netherlands Declare that the machine complies with the machine directive 2006 42 EC the low voltage directive 2006 95 EEG and the EMC directive 2004 108 EG Machine Type Machine number Year of construction of the machine The machine and the belonging documentation is in accordance with the following standards or other normative documents NEN EN 60204 1 NEN EN IEC 61558 1 NEN EN IEC 61558 2 6 NEN 5509 NEN EN ISO 12100 1 NEN EN ISO 12100 2 NEN EN ISO 13732 1 NEN EN ISO 13857 RoHS 2002 95 EG If modifications are made to this machine without written permission these modifications fall entirely
31. e the rubber silicone holder The silicone holder must be inspected weekly for irregularities on the silicone rubber mainly caused by burning by the sealing wire If irregularities appear then the silicone rubber must be replaced Average maintenance cycle for silicone rubber is at least once every 6 months This indication refers to regular use of the machine with standard products No rights can be derived from this indication 1 Remove the old silicone rubber from the holder 2 Cut new piece of silicone rubber the same size as the old one The same size is very important too short or too long will cause problems with sealing Place the new piece in the silicone holder Ensure that the silicone rubber is completely and evenly placed in the groove It is also important that the surface of the silicone rubber is smooth after it is in place and is shows no signs of tension Appearance may differ per model but principle remains the same Replace lid gasket The lid gasket ensures that the vacuum chamber is completely sealed during the machine cycle This is essential for achieving a maximum vacuum The lid gasket wears due to the extreme pressure differences and must be replaced regularly Inspect the lid gasket weekly for tears or damage Average maintenance cycle for lid gasket is at least once every 6 months This indication refers to regular use of the machine on average 8 hours a day and with standard products No right
32. efer to the specifications of the relevant component for the correct types and values of fuses for replacement or contact your supplier Caution to avoid fire and or other irreparable damage to the machine replacement fuses must always be of the same type with the same value as the fuses being replaced Voltage Caution the maximum allowable voltage fluctuation is 10 of the official voltage stated on the machine tag Version 11 10 DIG EN 35 ERROR CODES The controls are programmed with a number of error codes These error codes are intended to give the user dealer a clear indication of what the possible cause might be why starting or packaging is not working as expected F1 This code indicates that the cycle cover switch will be interrupted prematurely Example the cover of the machine closes after starting but before sufficient vacuum is present to keep the cover closed the operator lets go of the cover The F1 code will now be shown on the display In a time controlled machine the time for gassing is set in such a way that the entire chamber is gassed and the cover opened without sealing taking place Here too the F1 code will immediately be shown on the display This message will never be shown directly after the controls are started but during the course of the cycle F2 This code indicates that the sensor is not working properly When the controls are started the condition of the sensor is checked If the feedba
33. es the customer lots of pleasure for an extended period from the purchase of the machine If there are any problems or questions then the customer can always approach the supplier or Henkelman BV ENVIRONMENT The machine must be moved or transported in an upright position The machine may NOT be tilted as this can cause damage to the pump Place the machine on a flat level floor This is essential for problem free operation of the machine Enough space must be left around the machine for good ventilation The space must be at least 5 centimetres The ambient temperature in which the machine is operated must be between 10 C and 30 C When operating the machine in other ambient temperatures the user must contact the supplier or Henkelman BV for advice NEVER place the machine directly next to a heat source or a steaming device for example a combi steamer dishwasher or stove POWER EARTH Check that the voltage stated on the machine tag is the same as the mains voltage Check the direction in which the pump is running when the machine is connected to a three phase power source Always connect the machine correctly to an earthed socket to avoid danger for fire or electrical shocks earth connection is green yellow The power cable must always be free and nothing may be placed on it Replace the power cable immediately if damaged Always disconnect the power if there are problems with the machine or during maintenance prior to starti
34. f this warranty then the replaced parts become our property 6 Ifthe other party does not sufficiently or not in an acceptable period of time fulfils the obligations to the agreement between the parties we are not obliged to provide this warranty as long as the situation is occurring The stipulations of the warranty and liability are part of the general terms and conditions of sales which we can send to you if requested Version 11 10 DIG EN 2 CONTENT USER MANUAL INTRODUCTION LIABILITY GUARANTEE _ _ _ _ _ _ _ a CONTENTS INSTRUCTION MANUAL meme nnn nnn nnn nnn nnn nnn nnn nns MACHINE REGISTRATION IMPORTANT FOR INSTALLATION READ THIS FIRST sss IMPORTANT FOR USE READ THIS FIRST 5999 WARNING LABELS gt IMPORTANT MACHINE PARTS 3 O nennen nnn nnn nnn nnn nnn nnn nnn n STARTING UP AND OPERATING 0 enm nnn nnn nnn nnn nnn nnn nnn nnn ON OFF switch Master switch 11 Sleeper function 11 Start machine 11 Standard operating steps 12 MACHINE CONTROL PANEL Control panel versions 13 Control panel layout 14 Operation mode 15 Program mode 19 Other modes 19 Operation Hours Counter 19 PROGRAMMING ___
35. for the relationship between the vacuum meter and the percentage vacuum Position Vacuum vacuum meter percentage 11 ON OFF Switch The ON OFF switch is used to turn the machine on and off before and after operation The switch turns on all units in the machine Caution the switch does not completely remove all power from the machine OPERATION MODE When the machine is turned on the machine switches to operation mode after displaying two START codes Please note START codes in user manual which has been delivered with machine The operation mode is the standard setting of the control panel for packaging products Set values cannot be modified in operation mode With the PROG key and function selection keys the set values within the various programs can be viewed If the machine is ready to package a product the product is already in the chamber then all that needs to be done is to choose the program PROG key and close the lid The program cycle starts automatically running through the set functions in the program Version 11 10 DIG EN 15 Description of the program cycle for digital time control 1 Select the program number with the PROG key and the small display If the selected programme is programmed with the active gas flush function then a dot appears in the lower right hand corner of the small display 2 Close the lid 3 Vacuum function 4 Gas flush function if installed 5 Gas flush Plus Function if ac
36. g system the remaining flap on the vacuum bag can be torn off SAFETY and PRODUCT PROTECTION The packing process can be partially or fully interrupted at all times Stop active function press VACUUM STOP key Stop full machine cycle press STOP key OPTIMAL AND EFFICIENT PACKAGING RESULT Use the correct size and good quality vacuum bags Maximum 75 product filling in vacuum bag Place vacuum bag fold free over sealing bar silicone holder use correct number insertplates in chamber Pull vacuum bag far enough over gas nozzles for gas flush so that no gas is lost and the bag does move during gas flushing Version 11 10 DIG EN 12 MACHINE CONTROL PANEL CONTROL PANEL VERSIONS General Digital Time Control Sensor Control Quick Stop 2 Control Version 11 10 DIG EN The digital control panels are implemented with 9 pre select programs that can be individually set with different function values to be able to pack different products Program 0 cannot be set and is used for servicing and testing A program cycle is the complete program of set functions that the machine runs through to pack a product The control panel is designed with an operation mode and a program mode The operation mode is used during operational activities for selecting the program number with the required program cycle The set values of the function program can also be seen in the operation mode but not changed The program
37. ic order and good faith we are not liable to pay for any damage of any sort whatsoever directly or indirectly including business losses to movable or immovable property or to persons either at the opposing party as at third parties 4 Weare in any case not liable for damages arising from or cause by the use of the product supplied or by the unsuitability of it for the goal for which the other party purchased it WARRANTY oubject to the following limitations the warranty period for products supplied by Henkelman is at least 12 months as of the date indicated on the purchase document This warranty is limited to manufacturing and machining defects and does therefore not cover breakdowns involving any part of the product that is exposed to any form of wear and tear Normal wear and tear that can be expected with the use of this product is therefore hereby excluded 1 Henkelman s responsibility is limited to replacing parts found to be defective we shall not acknowledge claims for any other kind of damage or costs 2 The warranty does not apply if the defect is the result of incorrect or negligent use or maintenance that is contrary to the instructions given in this manual 3 The warranty lapses if repairs or modifications on the product have been carried out by third parties 4 Defects due to damage or accidents deriving from outside factors are excluded from the warranty 5 If we replace parts in compliance with the obligations o
38. il in the vacuum pump The extraction hole at the back of the vacuum chamber is partially covered by the vacuum bag during vacuuming The lid gasket is worn The oil is contaminated The oil exhaust filter is saturated The pump s extraction filter is blocked The oil exhaust filter is saturated Plug the plug into the wall socket Replace the fuse Ensure the correct value Disassemble the front panel and replace the fuse Check this and if necessary replace it The micro switch must be properly adjusted or replaced Consult supplier Consult the supplier Extend the vacuum time Check the oil level and fill up if necessary Note the type and quantity Place the vacuum bag closer to the sealing bar Replace the lid gasket Replace the oil Note the type amp amount Replace the oil exhaust filter Consult the supplier Consult the supplier Replace the oil exhaust filter Consult the supplier 38 The vacuum bag is The vacuum bag is being placed e Place the vacuum bag neatly and not properly and or correctly on the sealing bar smoothly on the sealing bar Ensure that correctly sealed the opening of the bag is always within The sealing time is too long or too short the vacuum chamber The silicone rubber in on the silicone Adjust the sealing time longer or shorter holder is damaged or worn Replace the silicone rubber The teflon tape is damaged Replace the teflon tape The inside of the vacuum bag
39. intenance or when the machine is not in use for extended periods BY QUALIFIED PERSON WARNING IT iS STRICTLY FORBIDDEN TO USE OXYGEN Oz NEVER use flammable gasses or gas mixtures containing too much oxygen Use thereof can cause risk of explosions Accidents and or damage caused by using abovementioned gasses void s all liability on the part of Henkelman BV as well as the guarantee PRESSURE NOT HIGHER THEN 1 ATO 15 UU Version 11 10 DIG EN 8 BOXER MARLIN FALCON POLAR SERIES USER MANUAL Ed H N ELMA N IMPORTANT MACHINE PARTS BOXER SERIES MARLIN SERIES Vacuum chamber Sealing bar s in vacuum chamber Silicone holder s Gas flush nozzles if applicable Lid rubber in lid for hermetic seal Gas springs for opening lid after machine cycle Vacuum Ventilation opening Control panel Vacuum pressure meter ON OFF Switch 10 Master switch only MARLIN series 11 Oil drain plug 12 Oil fill plug 13 Oil inspection window 14 Power cable 15 Fuse holder with fuse 16 Gas bottle connector if applicable caution max 1 Bar 17 Machine tag 18 Warning stickers Od N gt Appearance of parts and machines can deviate from illustrations Version 11 10 DIG EN 9 BOXER MARLIN FALCON POLAR SERIES USER MANUAL Ed H NKEI Mi N FALCON SERIES Sealing bar s in lids Silicone holder s on holders in vacuum chamber Gas flush nozzles mounted o
40. ioning program and close the lid The program runs automatically During the program the large display will display moving lines The program can be interrupted at any time using the STOP key It is however important for the sake of good maintenance that the program completes a full 15 minute cycle and therefore advisable only to interrupt the cycle for something urgent It is also advisable to run the program before using the machine for the first time after the machine has been stationary for a lengthy period of time and especially prior to changing oil Version 11 10 DIG EN 24 FAVED MADI IN TAI DAIL AD IICED SSS ORIGINAL BOXER MARLIN FALCON POLAR SERIES USER MANUAL y 5 EE Changing Oil Filling Up The oil level and oil quality must be checked at least once a week The oil inspection window serves this purpose Fill up the oil level if it is too low Replace the oil if it is turbid Oil must be replaced at least once every 6 months BOXER series Oil fill plug Take care to use the correct type Oil drain plug of oil for the pump Oil inspection window Oil level indicator sticker Beware of hot oil fumes during drainage Draining oil If the oil is white or turbid when checked then it must be replaced Before draining off the oil let the conditioning pr
41. l Display Displays active program in operating and program modes 2 Large Display Displays the current value of the active function during the program cycle or the set value of the selected function in operation or program mode 3 PROG 0 9 Keys Selects program number in operation or program mode 4 REPROG Key Switch from operation mode to program mode for setting function values and vice versa After setting new function value s within a selected program in program mode this key must always be used to store the new values for the program in memory 5 FUNCTION SELECT Key Selects function within selected program in operation and program mode The function is selected if the function light is on in front of the function description under the large display 6 CONDITIONING PROGRAM Key Start the conditioning program for pump duration 15 minutes For instructions on the program see page 22 7 FUNCTION Lights A light in front of the function indicates that the function is active during the program cycle or that the function is selected during the operation or program modes Special Remark There is an additional time operated vacuum function available at digital sensor control the VACUUM PLUS function This function is not displayed on the panel The VACUUM PLUS function can only be activated if the standard vacuum function is set to 99 VACUUM PLUS function display during the cycle if activated The vacuum indicator light
42. lation function starts ventilating the chamber to 1 atmosphere ATO and the lid opens All lights are off in front of the functions Large Display lines going up and down until the lid is open The vacuum meter runs back to the right to zero and the lid opens automatically 10 The product is packed and ready to remove Version 11 10 DIG EN PROGRAM MODE The program mode is used to change the function values within the programs See page 18 20 for instructions on programming OTHER MODES The control panel also includes a service mode The conditioning program see page 22 for the pump and the operation hours counter are the functions most used in this mode Operation Hours Counter One of the service functions is the operation hours counter in order to be able to automatically indicate regular service requirements This functions sets the number of hours that the pump runs per 10 hours Note that for BOXER series the pump does not run continuously Once the number of hours set has been exceeded the message OIL appears on the display see page 11 The machine can still be used as usual but the message will keep reappearing on the display The factory setting for the program operation hours counter is OFF turned off The following steps can be followed to activate the operation hours counter or to reset it per 10 hours will be displayed for about 2 seconds After 2 seconds the originally set number of hours will be displayed
43. lly switches back to operation mode and the machine is ready for use The newly set values are now the new default values Version 11 10 DIG EN 20 AUTOMATIC PROGRAMMING starting situation machine is in normal operating mode and the lid is open select the correct programme with the PROG 0 9 Key for setting function values The programme number is displayed on the small display Then press the REPROG key to switch into programme mode The programme number now starts to blink on the small display VACUUM FUNCTION C ERE Digital Time Control Time is increasing As soon as the vacuum meter gets to 1 press the STOP VACUUM Key The machine cycle automatically switches to the following function Remark Digital Time Control Let the vacuum function run 2 to 4 seconds longer after reaching 1 on the vacuum meter so that trapped air in the packaging is also extracted Digital Sensor Control The percentage vacuum increases As soon as the value 99 is reached press the STOP VACUUM Key The machine cycle automatically switches to the following function Remark If full vacuum is not required press the STOP VACUUM Key when the required value has been reached VACUUM PLUS FUNCTION Digital Sensor Control Quick Stop H20 Control Time is increasing Press the STOP VACUUM Key at the required time The machine cycle automatically switches to the following function Remarks The VACUUM PLUS function can only be de activated OFF by
44. manual programming The VACUUM PLUS function will only run when VACUUM FUNCTION has been set at 99 GAS FLUSH FUNCTION optional Digital Time Operation Time is increasing As soon as the vacuum meter gets to the required under pressure press the STOP VACUUM Key The machine cycle automatically switches to the following function Digital Sensor Control The percentage vacuum decreases As soon as the required value is reached press the STOP VACUUM Key The machine cycle automatically switches to the following function Remarks The minimal under pressure advised is 0 5 bar or 50 vacuum The minimum under pressure that can be set is 0 3 bar or 30 GAS FLUSH function can only be de activated OFF by manual programming F SEAL AND SOFT AIR FUNCTION Both options can only be programmed manually After the cycle is finished the used settings will be stored automatically Version 11 10 DIG EN 21 SPECIAL REMARKS ON PROGRAMMING For Digital Sensor Control The value which is set for the gas flush function is the final vacuum percentage in the vacuum chamber after flushing gas For example the vacuum function is set to 99 and gas flush function is set to 60 This means that after the vacuum function the chamber will be flushed with gas until there is 60 vacuum and 40 actually 39 gas in de vacuum chamber For automatic programming Ensure that all functions are activated in the selected program Activation means that the functio
45. ming when the trigger point of the H2O has been reached or the full 99 has been reached The light in front of VACUUM is burning Large Display decrementing time per second starting at the time set max 5 sec and a dot in the lower right hand corner The vacuum meter will very slowly increment counter clock wise hardly noticeable Once the vacuum function has completed then the gas flush function starts to flush gas into the vacuum chamber The light in front of GAS is burning Large Display decrementing percentage vacuum until the set percentage min 30 Vacuum meter starts decreasing clock wise Once the normal gas flush phase is finished it is possible to add time for additional gas flushing With this option extra gas can be inserted while the sealing system is closing When the vacuum function or gas flush function if installed ends the seal function starts to seal the vacuum bag s The light in front of SEAL is burning Large Display decrementing time per second starting at the time set max 6 0 sec The reading on the vacuum meter stays the same After ending the seal function the soft air function starts to slowly ventilate the vacuum chamber The light in front of SOFT AIR is burning Large Display decrementing time per second starting at the time set max 99 sec Vacuum meter starts slowly decreasing clock wise After ending the seal function or the soft air function if installed the venti
46. n if installed the ventilation function starts ventilating the chamber to 1 atmosphere ATO and the lid opens All lights are off in front of the functions Large Display lines going up and down until the lid is opened The vacuum meter runs back to the right to zero and the lid opens automatically 9 The product is packed and ready to remove Version 11 10 DIG EN Description of the program cycle for digital sensor control 1 Select the program number with the PROG key and the small display If the selected program is programmed with the active gas flush function then a dot appears in the lower right hand corner of the small display If the selected program is programmed with the active VACUUM PLUS function then a dot appears in the lower right hand corner of the large display 2 Close the lid 3 Vacuum function 4 Vacuum Plus function if installed 5 Gas flush Function if installed 6 Gas flush Plus Function if activated 7 Seal function 7 8 Soft air ventilation function if installed PE 2 9 Ventilation function The machine starts to vacuum the chamber The light in front of VACUUM is burning Large Display incrementing percentage vacuum until the percentage set max 99 Vacuum meter starts increasing counter clock wise The machine continues vacuuming the chamber after 99 value is reached The light in front of VACUUM is burning Large Display decrementing
47. n in the program is assigned a value If the value is OFF then that means that the function is not activated and will not be included in the automatic programming cycle For machines with optional gas flush function If a program is setup with the active gas flush function then this is indicated by a dot in the lower right hand corner of the small display when selecting the program in the operation mode For machines with optional sensor control If a program is setup with the active VACUUM PLUS function then this is indicated by a dot in the lower right hand corner of the large display when selecting the program in the operation mode If the function s value is OFF then it can only be activated using manual programming Contact the supplier for more information about programming Version 11 10 DIG EN 22 MACHINE MAINTENANCE GENERAL A regular and complete maintenance is required for long usage of the machine to avoid malfunctioning and to achieve an optimal packaging result If the machine is used intensively more than 5 hours per day we recommend professional servicing every 6 months For normal use of the machine complete servicing once a year should be sufficient depending on location environment and products However there are small maintenance activities that must be carried out regularly These maintenance activities can be done by the user The following page contains an overview of these activities A IMPORTANT BEFOR
48. n silicone holders if applicable Lid rubber in lid for hermetic seal Vacuum Decompression Suction pipe Control panel ON OFF switch Vacuum pressure meter Master switch 10 Oil drain plug elbow 11 Oil filler cap 12 Oil inspection window 13 Oil spray filter housing 14 Power cable 15 Gas bottle connector if applicable caution max 1 Bar 16 Seal pressure connector if applicable caution max 1 Bar 17 Machine tag 18 Warning stickers fo oo X4 O0 OT ON rt Appearance of parts and machines can deviate from illustrations Version 11 10 DIG EN 10 STARTING AND OPERATING THE MACHINE e ON OFF SWITCH The ON OFF switch is used to turn the machine on and off before and after operation MASTER SWITCH CAUTION The ON OFF switch does not completely turn off all power to the machine With the BOXER series and other models which run on 1 phase power it is necessary to unplug the power cable from the wall socket before the machine is completely without power With the MARLIN FALCON POLAR series and other models which run on 3 phase power it is necessary to turn off the master switch before the machine is completely without power Ensure that the machine is completely without power during maintenance and repair activities BOXER series When the machine is turned on with the ON OFF switch the pump only runs during the vacuum cycle MARLIN FALCON POLAR series When the machine is turned on with the ON OFF swit
49. nd teflon tape Remove teflon tape Unscrew and remove sealing wires Replace the teflon tape Screw down new wires onto clamping plate Pull wires taught using a pair of pliers and a vice and screw the wires down on the clamping plate Version 11 10 DIG EN 10 11 12 13 Remove the sealing bar s from the holders in the chamber or lid by releasing the click system or by unscrewing the screws Remove the teflon tape from the sealing bar The old sealing wires and cut off wires if applicable can be removed by unscrewing the clamp see illustration and pulling the wires from the grooves Remove the teflon tape that is attached to the top of the sealing bar and stick a new piece of teflon tape to the bar of the same length after having degreased and cleaned the bar with a dust free cloth Cut a new peace of sealing wire or cut off wire to the size of the sealing beam plus about 15 cm 6 inches If 2 sealing wires or an extra cut off wire is on the sealing beam then a second sealing wire or cut off wire must of course be cut Place the end of the wire or wires through the groove s on the side of the sealing beam and screw the wires to the bottom Place the sealing bar top down in a vice and pull the sealing wire or wires through the other side of the groove s on the sealing beam Pull the wires tight with a pair of pliers and screw them down at the same time Ensure that the wire wires
50. ng work on the machine If the machine is stationary for long periods then the power should always be disconnected Version 11 10 DIG EN 5 VACUUM PUMP Check before starting the machine if there is oil in the pump see page 23 NEVER start the machine without oil in the pump Use the right type of oil for the pump see page 24 After moving and or transporting the machine always first check the oil level before re starting operation When starting the machine for the first time or after a lengthy idle period first run the conditioning program before operating the machine see page 22 Always change the oil before a long period of inactivity of the machine and make sure the pump is clean and free of moisture CONNECTING THE GAS FLUSH SYSTEM if applicable NEVER use flammable gasses or gas mixtures containing too much oxygen There is a danger of explosion when using the aforementioned gasses Accidents and or damage caused by using abovementioned gasses void all liability on the part of Henkelman BV as well as the guarantee The gas bottles must always be correctly secured If the gas flush function and or the machine is not in use then the main cock of the gas bottle must always be closed The pressure of the pressure reducing valve on the gas bottle may NEVER be set to more than 1 atmosphere ATO A higher pressure may damage the machine The diameter of the hose nipple connector for the gas bottle is 6 mm BO
51. ogram run a full cycle The dirt and moisture is absorbed by the oil and the oil becomes thinner making draining easier After the program has ended the drainage plug can be removed CAUTION when unscrewing hot oil fumes can escape The oil now drains from the drain hole an oil pan must be placed underneath For the BOXER series when the oil has drained tilt the machine slightly so that all residual oil can drain off After draining the oil drain plug is replaced Location at rear or side of machine View can differ per model Filling up oil After draining or if the oil level has dropped oil needs to be filled up The oil fill plug must be removed with the correct size spanner The pump can now be filled with oil Make sure that you add the correct amount see table on page 24 TAKE CARE to fill with small amounts at intervals Fill the oil level to the top of the oil level indicator sticker TAKE CARE to replace the oil filter before adding the new oil see page 24 Oil types and amounts It is important to use the correct type and quantity of oil for the pump The wrong type or too much oil could damage the pump The ambient temperature where the machine is operated is also important for the type of oil See amounts and types with related ambient temperatures in the table on the next page Examples of supplier brands for the standard types of oil are Shell Vitrea Aral Motanol GM BP Energol CS or Texaco Regal with relate
52. outside our responsibility and this declaration will be considered dissolved s Hertogenbosch S C H Fliervoet Maas Version 11 10 DIG EN 43 MAINTENANCE SCHEDULE NOTES Ganon Operations pany Maintenance Version 11 10 DIG EN 44 REMOVAL TOOLS FRONT PANEL With every machine we enclose two special tools to remove the front panel You can slide the tools into the slots at the bottom side of the front panel Lift them a little and pull them towards you Version 11 10 DIG EN 45
53. r deviating ambient temperatures see page 24 for special oil specifications Maximum use per day BOXER series 5 hours per day Other machines 8 hours per day Electricity Voltage see machine tag Frequency see machine tag Power see machine tag Electrical connection Maximum fluctuation 10 of the official registered voltage Gas bottle connector diameter BOXER series diameter 6 mm if applicable POLAR 2 85 2 95 diameter 13 mm OTHER MODELS diameter 8 mm Maximum pressure gas bottle connector 1 ATO if applicable External seal pressure connection diameter 6 mm if applicable sound level 70 DB Version 11 10 DIG EN 32 ELECTRICAL DIAGRAMS Control Current Diagram BOXER TOUCAN series 12 13 14 15 INPUT INPUT COM MICROSWITCH MIC NITCH PUMP GAS SEAL SEAL SOFTAIR DECOMP INPUT INPUT 24 VOLT VOLT 51 COM CONTACTOR VALVE VALVE CONTACTOR VALVE VALVE 9_VOLT O VOLT FUSE F9 Y2 YS K2 Y4 YS FUSE FS 5 05 6 05 7 0 8 05 9 02 10 0 11 0 12 0 13 02 14 05 15 0 24 Volt 0 Volt 9 Volt 0 Volt Keyboard 1 etal nore Date Name Description Connection Diagram Digital Panel
54. rie machines are designed for a maximum of 5 hours operation per day Other machines are designed for a maximum of 8 hours per day The supplier or Henkelman BV cannot be held responsible for any malfunctions or defects if these operation time limits are clearly exceeded without consultation The machine must be moved or transported in an upright position The machine may NOT be tilted as it can cause damage to the pump The supplier or Henkelman BV cannot be held responsible for any malfunctions or defects if the maintenance instructions in this manual are not followed Contact the supplier or Henkelman BV if there are any doubts or questions about maintenance or malfunctions Version 11 10 DIG EN 23 STANDARD MAINTENANCE SCHEDULE FOR THE MACHINE Daily Clean the vacuum chamber lid and housing after use with a damp cloth Make sure that no cleaning agents containing solvents are used Make sure that no high pressure cleaner is used Weekly Check the oil level and replace or fill up oil when the oil is turbid or the oil level is too low For instructions see page 23 Activate the conditioning program for the pump at least once a week Inspect the sealing bar for damage Replace Teflon tape sealing wire if the seal quality is no longer sufficient or if the Teflon tape sealing wire is no longer tight and straight on the sealing bar For instructions see page 26 Inspect the lid gasket and replace it when the gasket is
55. s can be derived from this indication De length of the new lid gasket is determined by using the old gasket If the lid rubber is too short or too long can cause problems closing the lid or leak rubber connect up closely The rubber must be placed evenly and without tension in the holder The ends must be cut straight and must be laid tightly against each other to avoid leakage Version 11 10 DIG EN 29 LIST OF SERVICE PARTS VACUUM PUMP PARTS BUSCH VACUUM PUMPS HENKELMAN MODELS 016 m3 h BOXER 35 021 m h BOXER 42 42 XL 42 XL 040 m3 h MARLIN 46 063 m3 h MARLIN 52 90 FALCON 52 2 60 POLAR 52 2 40 100 m3 h FALCON 80 2 70 POLAR 80 2 50 160 m3 h POLAR 2 75 300 m3 h POLAR 2 85 2 95 BUSCH STANDARD OIL OIL FILTER OIL MIST FILTER Henkelman Henkelman Henkelman Type Reference Type Reference Type Reference Amount 016 m3 h 0439510 50 60Hz 0939163 1 021 m3 h 0439510 50 60 2 0939165 1 040 m3 h 0439520 040 063 100 0939090 50 60Hz 0939171 1 063 m3 h 50 2 0439520 040 063 100 0939090 50Hz 0939171 1 063 m3 h 60 2 0439520 040 063 100 0939090 60Hz 0939170 2 100 m3 h 0439520 040 063 100 0939090 50 60Hz 0939170 2 160 m3 h 0439520 160 300 0939091 50 60Hz 0939175 2 300 m3 h 0439520 160 300 0939091 50 60Hz 0939175 3 SEAL SYSTEMS HENKELMAN PARTS SPECIFICATIONS REFERENCE QUANTITY Teflon tape 46 mm wide teflon tape 0305515 length sealing bar 5 cm Double Seal x 3 5 mm round
56. t type of filter is used for the pump type see page 29 for the correct type of filter for the type of pump It is advisable to have the suppler do this service SEAL SYSTEM MAINTENANCE All or some of the following sealing systems are possible in the BOXER MARLIN FALCON POLAR series It is essential to know which sealing system is applicable to the relevant machine mE Gp GT OU DOUBLE SEAL CUT OFFSEAL 1 2 CUT OFFSEAL WIDE SEAL BI ACTIVE SEAL 2 x 3 5 mm seal 1 x 3 5 mm seal 1 x 3 5 mm seal 1 x 8 0 mm seal 1 x 5 0 mm seal x 1 1 mm cut 1 x 1 1 mm cut above and below single time setting individual time settings servicing the sealing bar is almost identical for all systems The seal quality is partially dependent on the maintenance of the sealing bar and contra bar silicone holder The main maintenance activities are the daily cleaning of the sealing bar and the silicone holder with a damp cloth and a weekly inspection of the bars with replacement of the sealing wire teflon tape or silicone rubber if irregularities appear on top of the bar or the seal quality is insufficient The average maintenance cycle of the sealing bar teflon tape sealing wire is at least once every 3 months This indication refers to regular use of the machine on average 8 hours per day and packaging standard products with standard vacuum packaging materials No rights can be derived from this indication Version 11 10 DIG EN 27 Replace sealing wire a
57. the supplier or Henkelman BV for more information about connecting external seal pressure Henkelman recommends checking the pressure and amount of gas in the gas bottles regularly Ensure that the gas bottle s is are correctly anchored Always turn off the main cock on the gas bottle if the machine is in operation or if the gas flush function is not active PACKAGING LIQUID PRODUCTS The machines can be also used for packaging liquid products like soups or sauces In this process the vacuum process must be carefully monitored only possible with transparent lid or lid with inspection window The STOP VACUUM key must be pressed as soon as bubbles appear in the product the saturation point same as boiling point has then been reached Settings for programs for packaging liquid products can best be programmed using automatic programming see page 19 20 The saturation point of liquids is reached at a certain ratio line of low pressures and high temperatures see the example table for water below The saturation point will be reached sooner in the vacuum process when packaging liquids with a high temperature the amount of vacuum will therefore be less Henkelman recommends therefore to first cool liquid products before packaging In this way an optimal vacuum of the product can be achieved Saturation point of water relation between the pressure and temperature of the water Vacuum pressure 1000 800 600 400 200 100 50
58. tivated 6 Seal function 7 7 Soft air ventilation function if installed 8 Ventilation function The machine starts to vacuum the chamber The light in front of VACUUM is burning Large Display decrementing time per second starting at the time set max 99 sec Vacuum meter starts increasing counter clock wise Once the vacuum function has completed then the gas flush function starts to flush gas into the vacuum chamber The light in front of GAS is burning Large Display decrementing time per second starting at the time set max 99 sec Vacuum meter starts decreasing to the clock wise Once the normal gas flush phase is finished it is possible to add time for additional gas flushing With this option extra gas can be inserted while the sealing system is closing When the vacuum function or gas flush function if installed ends the seal function starts to seal the vacuum bag s The light in front of SEAL is burning Large Display decrementing time per 0 1 second starting at the time set max 6 0 sec The reading on the vacuum meter stays the same After ending the seal function the soft air function starts to slowly ventilate the vacuum chamber The light in front of SOFT AIR is burning Large Display decrementing time per second starting at the time set max 99 sec Vacuum meter starts slowly decreasing clock wise After ending the seal function or the soft air functio
59. ule is clearly defined on page 22 The guarantee automatically expires due to overdue or sloppy maintenance Always remove the power cable from the wall socket for maintenance work the machine must be completely disconnected If there are doubts about the maintenance activities or if the machine fails to work correctly always contact the supplier or Henkelman BV TRANSPARENT LID if applicable Never locate the machine near a heat source This can cause damage to the lid cracks Never place hot sharp or heavy objects on the lid These can cause damage to the lid cracks in the long run Always clean the lid with solvent free cleaning agents Solvents can damage the lid Check at least once a week if there are cracks in the lid If cracks are visible in the lid then the machine must IMMEDIATELY be turned off and not used again until the lid has been replaced Continuing to work with a cracked lid can cause the lid to implode All guarantees and or liability expire in the case of accidents and or damage caused by working with a cracked lid Replace the transparent lid every 4 years as a precautionary measure as a standard maintenance interval Version 11 10 DIG EN 7 DAVED INI FAI BAI AD uL ER BOXER MARLIN FALCON POLAR SERIES USER MANUAL NKEI y 5 VACUUM PUMP Regularly check the level and quality of th
60. valve H Jatum Naam Benaming Boxer Series G Getek 5 04 MD F Geco Pneumatic diagram Mat D Afm B 8 G 8 A 60 09 nummer Nabet E lid HENKELMAN vacuum systems A Tolera op v ma Revisie Datum Ini volge FALCON series POLAR series Diagrams are shown for standard configurations Version 11 10 DIG EN Si aa Geter Soran D ELI l Tolerontie vrije malen Um me volgany Seal bag V cuumpump Vacuungouge Vacuum valve hos valve faptional Seol valve Sof tair valve faptional Devac valve lt Lt Tu H 89 9 Falcon 52 Falcon 80 Pneumatic diagram DOOOODO Vervol voor PROBLEM SOLVING Machine does not work Machine does not work Control panel is on Transparent lid does not open automatically Final vacuum is insufficient The machine builds up a vacuum slowly Version 11 10 DIG EN The plug is not plugged into the wall socket The main fuse is burnt The circuit board fuse is burnt The control transformer fuse is burnt The micro switch which is activated when the lid is closed needs adjustment or is faulty There is an internal malfunction The gas spring is faulty The set vacuum time is too short There is too little o
61. wire 0305000 2 wires length of sealing bar 15 cm 1 x 3 5 mm round wire 0305000 1x1 1 mm round wire 0305010 1 x 3 5 mm round wire 0305000 1x1 1 mm round wire 0305010 1 x 8 0 mm flat wire 0305025 Cut off seal 1 wire length of sealing bar 15 cm 1 wire length of sealing bar 15 cm 1 wire length of sealing bar 15 cm 1 wire length of sealing bar 15 cm 1 wire length of sealing bar 15 cm 1 2 Cut off seal Broad Seal 1x5 0 mm flat wire 0305020 1x8 0 mm flat wire 0305025 Silicone 17 x 8 0320200 Bi Active Seal 1 wire length of sealing bar 15 cm 1 wire length of sealing bar 15 cm length silicone holder Silicone Rubber Bi active Seal Single chambers uses 2 x 5 0 mm Double chambers 1 x 5 0 mm and 1 x 8 0 mm Version 11 10 DIG EN LID GASKET HENKELMAN MODELS REFERENCE LENGTHS PER MODEL in cm BOXER SERIES 0320215 BOXER 35 BOXER 42 BOXER 42 XL BOXER 42 XL BA MARLIN 46 52 90 0320210 MARLIN 46 FALCON SERIES MARLIN 52 FALCON 52 POLAR 52 POLAR 52 80 2 40 2 50 MARLIN 90 FALCON 80 POLAR 80 FALCON 2 60 2 70 POLAR 2 40 2 50 POLAR 2 75 2 85 2 95 0320212 POLAR 2 75 2 85 2 95 Lengths specified are always a little longer and must be cut to the correct length Version 11 10 DIG EN 280 300 350 390 440 31 TECHNICAL SPECIFICATIONS MODEL VACUUM CHAMBER LID HOUSING DIMENSIONS PUMP FINAL WORKING PLATE VACUUM mm m3 h BOXER SERIES 35 Stainless steel Transparent

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