Henkelman Boxer 35 User manual

USER MANUAL
Vacuum Packing Machine
Boxer
Lynx
Toucan
Part no 0895001

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© Copyright 2014
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form
or by any electronic or mechanical means, or by photocopying, recording, or otherwise without the
prior written consent of Henkelman BV.

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INTRODUCTION
Henkelman BV is a supplier of ultra-modern vacuum packing machines.
Our machines are designed and manufactured to the highest standards. And that's clear. They
combine a sleek built and functional design with ease of use and durability. Installation is just a matter
of 'plug & pack' and the clever design ensures that the hygiene standards are maintained at all times.
This manual contains relevant information and instructions for installation, operation and maintenance
of the machine.
The machine is not suitable for the packaging of toxic, corrosive, irritant or
hazardous materials
All persons responsible for the operation must at least fully read and understand
the chapters on operation and safety of these operating instructions
All persons responsible for assembly, installation, maintenance and/or repair
should read and understand all of these instructions
The user is responsible for the interpretation and use of this manual in any
circumstances. Please contact the owner or the manager in case of questions or
doubts about the correct interpretation
This manual should be kept near the machine and should be within reach for
users
All major maintenance, adjustments to the machine and observations should be
recorded in a log, see Appendix 10.1
Changes to the installation/machine are not permitted without prior written
approval of the supplier
Please contact the vendor for special servicing that is not included in this manual
Comply at all times with the safety requirements, as specified in Chapter 3
The proper functioning and safety of the system can only be guaranteed if the
recommended maintenance is executed on time and correctly
Illustrations may differ from your machine

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TABLE OF CONTENTS
LIST OF FIGURES.................................................................................................................................. 6
EC DECLARATION OF CONFORMITY (COPY) ................................................................................... 7
LIST OF SYMBOLS................................................................................................................................ 8
ICONS ..................................................................................................................................................... 9
1. TECHNICAL INFORMATION........................................................................................................ 10
2. DESCRIPTION OF THE MACHINE............................................................................................... 13
2.1. DESCRIPTION OF THE PACKAGING PROCESS /MACHINE FUNCTIONS ....................................... 14
2.1.1. THE PACKAGING PROCESS /MACHINE FUNCTIONS................................................................. 15
2.1.2. GENERAL FUNCTIONS.......................................................................................................... 18
2.2. THE SEAL SYSTEM............................................................................................................... 19
2.3. THE VACUUM PUMP ............................................................................................................. 20
2.4. GAS FLUSHING (OPTIONAL).................................................................................................. 22
2.5. ELECTRICAL INSTALLATION.................................................................................................. 22
2.6. MULTI PROGRAM DIGITAL CONTROL (MPDC)...................................................................... 24
2.7. ADVANCED CONTROL SYSTEM (ACS).................................................................................. 26
2.7.1. SETTINGS ACS GENERAL.................................................................................................... 27
2.7.2. IMPORT /EXPORT DATA ....................................................................................................... 29
2.7.3. HAZARD ANALYSIS AND CRITICAL CONTROL POINTS (HACCP).............................................. 29
2.7.3.1. SET UP AND USE HACCP.................................................................................................... 29
2.7.3.2. EXPORT THE HACCP DATA LOG.......................................................................................... 30
3. SAFETY ......................................................................................................................................... 32
3.1. GENERAL............................................................................................................................ 32
3.2. DURING NORMAL OPERATION............................................................................................... 33
3.3. OPERATIONAL STAFF........................................................................................................... 33
4. INSTALLATION............................................................................................................................. 34
4.1. TRANSPORT AND PLACEMENT.............................................................................................. 34
4.2. CONNECTING THE MACHINE ................................................................................................. 34
4.3. START THE MACHINE FOR THE FIRST TIME............................................................................. 34
5. OPERATION.................................................................................................................................. 35
5.1. STARTUP ............................................................................................................................ 35
5.2. PRODUCTION ...................................................................................................................... 35
5.3. CONTINUE TO THE NEXT STEP OF THE CYCLE ........................................................................ 36
5.4. STOP PROGRAM .................................................................................................................. 36
5.5. CHANGING THE PROGRAM SETTINGS .................................................................................... 37
5.5.1. MULTI PROGRAM DIGITAL CONTROL (MPDC)...................................................................... 37
5.5.1.1. VACUUM+OPTION (MPDC) ................................................................................................. 38
5.5.1.2. GAS+OPTION (MPDC)........................................................................................................ 39
5.5.1.3. LIQUID SENSOR CONTROL (MPDC)...................................................................................... 39
5.5.1.4. RED MEAT OPTION (MPDC) ................................................................................................ 40
5.5.1.5. MULTI CYCLE OPTION (MPDC)............................................................................................. 40
5.5.1.6. EXTERNAL VACUUM OPTION (MPDC)................................................................................... 42
5.5.2. ADVANCED CONTROL SYSTEM (ADC).................................................................................. 43
5.5.2.1. PROGRAMMING THE ACS CONTROL ON YOUR PC................................................................. 44
5.5.2.2. OPTIONS (ACS).................................................................................................................. 45
5.5.2.3. EXTERN VACUÜM OPTIE (ACS)............................................................................................ 46
5.6. DIRECTIVE FOR FUNCTION VALUES ....................................................................................... 47

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6. MAINTENANCE............................................................................................................................. 49
6.1. MAINTENANCE DIAGRAM...................................................................................................... 49
6.2. CLEANING THE MACHINE...................................................................................................... 50
6.3. OIL CLEANING PROGRAM ..................................................................................................... 51
6.4. ADD OIL /CHANGE OIL ......................................................................................................... 51
6.5. REPLACING THE EXHAUST FILTER (MAINTENANCE OF VACUUM PUMP).................................... 53
6.6. REPLACING THE SEALING WIRE ............................................................................................ 54
6.7. REPLACING THE SILICONE RUBBER ON THE SILICONE HOLDERS ............................................. 56
6.8. REPLACING THE LID GASKET................................................................................................ 57
7. TROUBLESHOOTING................................................................................................................... 59
8. WARRANTY CONDITIONS........................................................................................................... 61
8.1. LIABILITY ............................................................................................................................ 61
8.2. WARRANTY......................................................................................................................... 61
9. DISPOSE AS WASTE ................................................................................................................... 62
10. APPENDIX..................................................................................................................................... 63
10.1. LOG.................................................................................................................................... 63

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LIST OF FIGURES
FIGURE 1: OVERVIEW OF THE MAIN COMPONENTS...................................................................................... 13
FIGURE 2: OVERVIEW OF THE SEAL SYSTEM .............................................................................................. 19
FIGURE 3: OVERVIEW OF THE PUMP (FILTER COVER REMOVED) .................................................................. 21
FIGURE 4: OVERVIEW OF THE ELECTRICAL INSTALLATION ........................................................................... 23
FIGURE 5: CONTROL PANEL DIGITAL CONTROL (MPDC)............................................................................ 24
FIGURE 6: CONTROL PANEL ADVANCED CONTROL SYSTEM (ACS)............................................................. 26
FIGURE 7: FOUR POSSIBLE DISPLAY MODES............................................................................................... 27
FIGURE 8: OVERVIEW SETTINGS ............................................................................................................... 28
FIGURE 9: EXAMPLE OF AN EXPORTED LOG ............................................................................................... 31
FIGURE 10: CHANGING PARAMETERS (MPDC).......................................................................................... 37
FIGURE 11: EXTERNAL VACUUM ADAPTER KIT (MPDC).............................................................................. 42
FIGURE 12: PROGRAM DISPLAY AND CONTROLS ACS................................................................................ 43
FIGURE 13: EXTERNAL VACUUM ADAPTER KIT (ACS) ................................................................................. 46
FIGURE 14:WATER VAPOUR LINE ............................................................................................................. 48
FIGURE 15: MOUNTING PLATE BOXER 52 .................................................................................................. 52
FIGURE 16: REPLACING THE EXHAUST FILTER............................................................................................ 53
FIGURE 17: REMOVING THE SEAL BAR....................................................................................................... 54
FIGURE 18: REPLACING THE SEALING WIRE ............................................................................................... 55
FIGURE 19: REPLACING THE SILICONE RUBBER OF THE SILICONE HOLDERS ................................................. 56
FIGURE 20: REPLACING THE LID GASKET................................................................................................... 57

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EC DECLARATION OF CONFORMITY (COPY)
We,
Henkelman BV
Titaniumlaan 10
5221 CK, ‘s Hertogenbosch
Nederland
declare under our sole responsibility that the product;
Machine type: Boxer / Lynx / Toucan serie
fulfils all the relevant provisions of the directives
2006/42/EG Machinery Directive
2004/108/EG EMC-Directive
and is in conformity with the following standard(s) or other normative document(s);
NEN-EN-ISO 12100 Safety of machinery - general principles for design –Risk assessment and risk
reduction
NEN-EN 13857 Safety of machinery –Safety distances to prevent hazard zones being reached by
upper and lower limbs
NEN-EN 349 Safety of machinery –Minimum gaps to avoid crushing of parts of the human body
NEN-EN 953 Safety of machinery –Guards - General requirements for the design and construction of
fixed and movable guards
NEN-EN 13849-1 Safety of machinery –Safety-related parts of control systems - Part 1: General
principles for design
NEN-EN 60204-1 Safety of machinery –Electrical equipment of machines - Part 1: General requirements
The undersigned is authorized to compile the technical file
Netherlands, 's-Hertogenbosch, 28 februari 2014 Stephan Harleman
Director

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LIST OF SYMBOLS
For all operations in which the safety of the operator and/or technician is at stake and where caution
should be exercised, the following symbols are used.
Caution!
Danger:
High Voltage!
Tip:
Provides a quick overview or offers tips to make it easier to perform certain actions

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ICONS
Some icons and warnings are included on the machine among others to indicate the possible risks
involved to the users.
ICON
DESCRIPTION
LOCATION
Nameplate
At the rear of the machine
Warning sign "HIGH VOLTAGE"
At the rear of the machine, on the cover
of the electrical cabinet
Warning sign "HEAT"
On the sealbar(s)
On the vacuum pump
Warning sign “GAS CONNECTION “
(optional)
Prohibited to connect oxygen
At the rear of the machine
Warning sign “GAS CONNECTION “
(optional)
Maximum gas pressure at gas connection
At the rear of the machine
Warning sign “SEAL PRESSURE
CONNECTION“ (optional)
Maximum pressure at external seal
pressure connection
At the rear of the machine
CAUTION!
Regularly check that the icons and markings are still clearly recognizable and
legible. Replace them if this is no longer the case

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1. TECHNICAL INFORMATION
Boxer
35
42
42XL
42XL
BA
52
General
Ambient temperature
5 tot 30
5 tot 30
5 tot 30
5 tot 30
5 tot 30
˚C
Noise production
< 70
< 70
< 70
< 70
< 70
dB(A)
Maximum daily production
5
5
5
5
5
h/day
Dimensions of the machine
Width
450
493
493
403
698
mm
Length
554
528
616
616
528
mm
Height
405
440
470
420
440
mm
Weight
49
62
67
67
66
kg
Maximum product height
150
180
180
120
185
mm
Gas flush (optional)
Connection size
6
6
6
6
6
mm
Gas flow
60-100
60-100
60-100
60-100
60-100
l/min
Maximum pressure
1
1
1
1
1
bar
Electrical connection
Tension
*
*
*
*
*
V
Power
*
*
*
*
*
kVA
Vacuum pump
Capacity
16
21
21
21
21
m3/h-
Oil
0.3
0.5
0.5
0.5
0.5
liter
Oil type
(Ambient temperature 5-40°C)
VM32
VM32
VM32
VM32
VM32
* See the nameplate

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Lynx
32
42
General
Ambient temperature
5 tot 30
5 tot 30
˚C
Noise production
< 70
< 70
dB(A)
Maximum daily production
5
5
h/day
Dimensions of the machine
Width
534
534
mm
Length
400
491
mm
Height
385
396
mm
Weight
35
46
kg
Maximum product height
103
114
mm
Gas flush (optional)
Connection size
6
6
mm
Gas flow
60-100
60-100
l/min
Maximum pressure
1
1
bar
Electrical connection
Tension
*
*
V
Power
*
*
kVA
Vacuum pump
Capacity
8
16
m3/h-
Oil
0.5
0.5
liter
Oil type
(Ambient temperature 5-40°C)
VM32
VM32
* See the nameplate

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Toucan
regular
square
General
Ambient temperature
5 tot 30
5 tot 30
˚C
Noise production
< 70
< 70
dB(A)
Maximum daily production
5
5
h/day
Dimensions of the machine
Width
480
480
mm
Length
581
581
mm
Height
795
795
mm
Weight
kg
Maximum product height
275
330
mm
Gas flush (optional)
Connection size
6
6
mm
Gas flow
60-100
60-100
l/min
Maximum pressure
1
1
bar
Electrical connection
Tension
*
*
V
Power
*
*
kVA
Vacuum pump
Capacity
21
21
m3/h-
Oil
0.5
0.5
liter
Oil type
(Ambient temperature 5-40°C)
VM32
VM32
* See the nameplate

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2. DESCRIPTION OF THE MACHINE
FUNCTION
This chapter provides an overview of the main components and functions
If detailed information is available in this guide, you will be redirected to the
specific sections
The performance of your machine may differ from the figure below
The figure below shows the main components of the system:
Figure 1: Overview of the main components
NO.
PART
DESCRIPTION
SECTION
1
Lid
The function of the lid is to close the chamber
during the vacuum cycle
The lid has a lid gasket fitted, which makes sure the
machine does not leak during the vacuum cycle
In the lid, silicone holder(s) are mounted as the
opposite of the sealing bar(s)
6.8
2.2, 6.7
2
Work plate / Chamber
The products to be packed will be placed on the
worktable / in the chamber with the opening of the
vacuum seal bag on the seal position
3
Seal bar
In the chamber, depending on the version, 1 or 2
seal bars are mounted. With this/these the vacuum
bag is closed
2.2, 6.6
4
Controlpanel
See section
2.6, 2.7
8
7
6
5
4
3
2
1

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NO.
PART
DESCRIPTION
SECTION
5
Machine housing
The machine frame contains all necessary parts for
the correct functioning of the machine
6
Vacuum pump
See section
2.3
7
Power connection
See section
2.5
8
Gas flush (optional)
See section
1, 2.4
2.1. Description of the packaging process / machine functions
FUNTION
This chapter provides an overview of the process and the available machine
functions
For the functions H2O (H2O+), Gas (Gas+) and Seal 1-2 Cut-off, specific
components must be installed in your machine before they can be activated.
Please contact your supplier for more details
In chapter 5.5 you will find information on how to set the parameters to the correct
values
EXPLANATION (Only applicable to the Toucan series)
The External Vacuum option does not apply
On a Toucan Regular the vacuum bag is placed on the plateau in an upright
position. The height of this plateau needs to be set in such a way that the seal is
placed on the correct position of the vacuum bag
A Toucan Square features a mold for block bags. In this mold only the specific
size of the bags can be used, for which the mold is designed
In a Toucan square you should first place the vacuum bag in the mold before
filling it. Make sure the bag is filled sufficiently

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2.1.1. The packaging process / machine functions
The following steps are taken during the process. For the detailed procedure, see Chapter 5.
STEP
PROCESS PHASE
OPERATION
1
Preparations
The operator puts the product in a vacuum bag and
places it on the work top with the opening on the
seal or contra bar
2
Extracting vacuum
The vacuum process is started by closing the lid
Depending on the options you have chosen for your
machine and the product you are packaging, the
following functions are available
FUNCTION
ICON
Vacuum
During the cycle, the air will be removed from the
chamber until the set time has been reached
Extracting vacuum to a set value is only possible
with a sensor control (optional for Digital Control
(DC). This value can be set in %. The percentage
indicates the depth of the vacuum. The pressure of
the outside air hereby is 0%. In the Advanced
Control System (ACS), the value(s) indicated in
mbar, hPa or %
Vacuum+
Available if the vacuum percentage is set to
maximum
Vacuum+ is an option that adds additional time to
the vacuum to create the possibility to let any air
escape that is still within the product
Vacuum+ is only possible in combination with
sensor control
Gas
(optional)
After extracting the vacuum, a gas is injected into
the chamber and the vacuum bag. This is to create
a modified atmosphere to protect the shape or to
increase the shelf life of the product. The value of
the gas function can, depending on the control type,
be set in %, mbar or hPa
Gas+
(optional)
Gas+ is an option that adds additional time to the
gassing to increase the amount of gas in the
package (see 5.5.1.2)

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STEP
PROCESS PHASE
OPERATION
FUNCTION
ICON
Liquid Control
(optional)
Available with the optional Liquid Control Sensor
The principle of the Liquid Control function is that it
is a system that is controlled by a highly sensitive
sensor. The sensor is able to detect the moment
that liquids from the product or the product itself
begin to vaporize (boil). At that time, the system will
switch to the next step in the process. This will
prevent the product from drying out, lose weight
and/or splash out of the vacuum bag and thus
contaminating the seal, the chamber and the oil in
the pump (see 5.5.1.3)
Liquid Control+
(optional)
Available with the Liquid Control option
The Liquid Control+ function allows you to proceed
with the vacuum process for a certain time, after the
evaporation phase has been reached
Red Meat
(optional)
This function is specifically designed for packaging
of fresh meat. It is added to the normal vacuum
function to prevent degasification of the product
during the sealing phase. This degassing can
cause bubbles and causes droplet formation in the
package. (see 0)
Sequential
vacuum
(optional)
Sequential vacuum makes it possible to exchange
the vacuum process with pauses, so that the
trapped air in a product will have the opportunity to
escape. In total, up to 5 steps can be programmed.
This function is available in machines with
Advanced Control System (ACS)
Multi-cycle
vacuum
(optional)
With multi-cycle it is possible to gradually extract
vacuum and use gas. With this the oxygen content
is reduced as well
This function is available in machines with Multi
Program Digital Control (MPDC) (see 5.5.1.5)

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STEP
PROCESS PHASE
OPERATION
3
Sealing
The seal bars are pressed against the contra bars,
with the vacuum bag in between and melt the bag
to be closed
FUNCTION
ICON
Seal
During the sealing, the material of the vacuum bag
is heated and compressed to form a hermetic
sealing. The function is programmed in seconds
As an option, a cutting wire is available. The
purpose of this wire is to remove the remaining foil
from the excess flap. Depending on the chosen
model, the cutting wire is controlled simultaneously,
or independent from the normal seal wire (Seal 1-2
cut-off)
4
Releasing vacuum
The vacuum is released, by letting air back into the
chamber
FUNCTION
ICON
Soft air
(optional on
Falcon)
This makes it possible to let air flow back into the
chamber slowly, so that the vacuum bag slowly
forms itself around the product. This prevents sharp
edges on the product to damage the foil and
possibly cause leaks
5
Open vacuum chamber
The lid opens
6
Remove the product
The operator can remove the packed product from
the worktable

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2.1.2. General Functions
FUNCTION
ICON
OPERATION
Cleaning the pump
The pump cleaning program allows for a proper flushing of the
pump. During the program, the pump and the oil will reach the
operating temperature, so that the oil and the fluid will be
separated and that any contamination is filtered. The high
temperature takes care of evaporation of moisture in the pump,
which reduces the risk of corrosion
Menu
This feature is available on machines with Advanced Control
System (ACS)
Menu is used to change the machine settings, such as language
and printing options
Print
This feature is available on machines with Advanced Control
System (ACS)
With this function one or more labels can be created per cycle
which can be stuck on the bag
The following information may be listed on the label: name of the
manufacturer, product name, production date, shelf life, used
gas, vacuum reached, the initials of the user and the
recommended storage temperature
External vacuum
This feature is available as an option depending on the machine
type
With this function vacuum can be applied to special food
packaging gastronorm containers outside the machine
The possibilities for adjusting the vacuum value are equal to the
standard vacuum (see 5.5.1.6 MPDC of 5.5.2.3 ACS control)

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2.2. The seal system
FUNCTION
The seal system closes the opening(s) of the bag(s) to maintain the vacuum
and/or gas inside
The remaining flap can optionally be cut off by the seal bar
Figure 2: Overview of the seal system
NO.
PART
DESCRIPTION
SECTION
1
Seal bar
The seal bar consists of the following components
Seal wires: the sealing wires are heated for a
certain period of time so that the open side of the
vacuum bag will melt together during the sealing
Cutting wire (optional): a cutting wire is heated in
such a way that the foil of the bag partially melts
so that the top flap of the vacuum bag can be
torn off easily
Teflon-tape: sealing and cutting wires are coated
with Teflon tape to prevent the bag to stick to the
seal bar
Refer to the indicated section for detailed information
on maintenance
6.6
2
Silicon holder
Opposite to each seal bar a silicone holder is mounted,
which provides counter-pressure on the cylinders / seal
bag
6.7
3
Seal mechanism
The seal bars are pressed on the vacuum bag by
using cylinders or seal bags
By connecting the outside atmospheric pressure to
the inlet of the seal bags / cylinders, they will press
the seal bar on the bag
2.2
3
2
1

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2.3. The vacuum pump
FUNCTION
The vacuum pump creates a vacuum in the chamber
8 m3
5
4
3
2
1