Henkelman Boxer Series User manual

Vacuum Packaging Machine
Boxer, Lynx, Neo, Toucan
User Manual
Art No. 0895001
Original Instructions for Use
©Henkelman 2017-2019

• The machine is not suitable for the packaging of toxic, corrosive, irritant or potentially
explosive materials.
• All persons responsible for the operation of this machine must at least fully read and
understand the chapters about the operation and safety provided in these operating
instructions.
• All persons responsible for the assembly, installation, maintenance and/or repairs must
fully read and understand these operating instructions.
• The user is at all times responsible for the interpretation and use of this manual.
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 its users.
• All major maintenance work, modifications to the machine and observations must be
kept in a logbook; see Logbook on page 105.
• Modifications to the installation/machine are not allowed without the prior written
consent of the supplier.
• For specific maintenance work not included in this manual, please contact the supplier.
• Comply with the safety requirements as set out in Safety on page 12 at all times.
• The correct operation and safety of the system can only be guaranteed if the
recommended maintenance is performed on time and properly.
• Illustrations shown may differ from your machine.
Copyright ©Henkelman BV 2017-2019
Henkelman BV reserves the right to change specifications and/or spare parts without prior notice.
The content of this user manual may also be changed without prior notice.
For information about settings, maintenance and repairs not provided for in this user manual, please contact the technical department of your supplier.
Henkelman BV accepts no liability for damage and/or problems arising from the use of spare parts not supplied by Henkelman BV.
This user manual has been compiled with all possible care. Henkelman BV assumes no responsibility for any errors in this manual and/or the
consequences of an erroneous interpretation of the instructions.
All rights reserved. No part of this publication may be reproduced, stored in computerised databases, or made public, in any form or by any means,
either electronic, mechanical, through photocopying, recording or otherwise, without the prior written consent of Henkelman BV. This also applies to the
associated drawings and diagrams.

Contents
List of Figures................................................................................................................................. 7
1 Preamble....................................................................................................................................... 9
1.1 List of the Symbols Used in this Manual...............................................................................9
1.2 Qualified personnel................................................................................................................ 9
1.3 Storing the manual...............................................................................................................10
1.4 Regulatory information......................................................................................................... 10
1.5 Terms of Warranty...............................................................................................................10
1.6 Liability..................................................................................................................................10
1.7 Terms and abbreviations......................................................................................................11
2 Safety...........................................................................................................................................12
2.1 Pictograms on the Machine.................................................................................................12
2.2 General Warnings................................................................................................................ 12
2.3 Warnings During Use...........................................................................................................13
2.4 Warnings for Operating Personnel.......................................................................................14
3 Introduction.................................................................................................................................15
4 Description of the Machine.......................................................................................................16
4.1 Boxer series......................................................................................................................... 16
4.1.1 Overview of the Main Components..............................................................................17
4.2 Lynx series...........................................................................................................................18
4.2.1 Overview of the Main Components..............................................................................18
4.3 Neo series............................................................................................................................19
4.3.1 Overview of the Main Components..............................................................................20
4.4 Toucan series.......................................................................................................................21
4.4.1 Overview of the Main Components..............................................................................22
4.5 Description of the Packaging Process/Machine Functions..................................................23
4.5.1 Packaging Process/Machine Functions........................................................................23
4.5.2 General Functions........................................................................................................27
4.6 Sealing System.................................................................................................................... 28
5 Installation...................................................................................................................................29
5.1 Transportation and Installation.............................................................................................29
5.2 Connecting the Machine...................................................................................................... 29
5.3 Prior to the First Use........................................................................................................... 30
6 Operation.....................................................................................................................................31
6.1 10-Programme Control System (10-PCS)............................................................................31
6.1.1 Operating Elements......................................................................................................31
6.1.2 Starting the Machine....................................................................................................32
6.1.3 Starting the Packaging Cycle.......................................................................................32
6.1.4 Proceeding to the Next Step in the Cycle....................................................................33
Contents 3

6.1.5 Terminating a Programme............................................................................................33
6.1.6 Changing the Programme Settings..............................................................................33
6.1.6.1 Vacuum.................................................................................................................33
6.1.6.2 Vacuum (automatic)............................................................................................. 34
6.1.6.3 Vacuum+ (optional).............................................................................................. 34
6.1.6.4 Gas (optional).......................................................................................................34
6.1.6.5 Gas+ (optional).....................................................................................................35
6.1.6.6 Liquid Control (optional).......................................................................................35
6.1.6.7 Liquid Control+ (optional).....................................................................................36
6.1.6.8 Red Meat (optional)..............................................................................................36
6.1.6.9 Multi-Cycle Vacuum (optional)..............................................................................36
6.1.6.10 Seal.....................................................................................................................37
6.1.6.11 Soft-Air................................................................................................................37
6.1.6.12 External Vacuum (optional)................................................................................38
6.1.7 Example programmes.................................................................................................. 38
6.1.8 Guideline for Function Values......................................................................................40
6.2 Advanced Control System (ACS).........................................................................................41
6.2.1 Operating Elements......................................................................................................42
6.2.1.1 Changing the ACS Settings................................................................................. 43
6.2.1.2 Importing/Exporting Data......................................................................................46
6.2.1.3 Data Log ID..........................................................................................................46
6.2.2 Starting the Machine....................................................................................................48
6.2.3 Starting the Packaging Cycle.......................................................................................48
6.2.4 Proceeding to the Next Step in the Cycle....................................................................48
6.2.5 Changing the Programme Settings..............................................................................49
6.2.5.1 Programming the ACS Control Using the PC......................................................50
6.2.5.2 Functions.............................................................................................................. 50
6.2.5.3 Vacuum.................................................................................................................50
6.2.5.4 Vacuum (automatic)............................................................................................. 51
6.2.5.5 Vacuum+ (optional).............................................................................................. 51
6.2.5.6 Gas (optional).......................................................................................................51
6.2.5.7 Gas+ (optional).....................................................................................................52
6.2.5.8 Liquid Control (optional).......................................................................................52
6.2.5.9 Liquid Control+ (optional).....................................................................................53
6.2.5.10 Red Meat (optional)............................................................................................53
6.2.5.11 Sequential Vacuum (optional)............................................................................ 53
6.2.5.12 Marinating (optional)...........................................................................................54
6.2.5.13 Tenderising (optional).........................................................................................55
6.2.5.14 Jars (optional).....................................................................................................55
6.2.5.15 Seal.....................................................................................................................55
6.2.5.16 Soft-Air................................................................................................................56
6.2.5.17 External Vacuum (optional)................................................................................56
6.2.5.18 Dealer Information..............................................................................................57
6.2.6 Terminating a Programme............................................................................................57
6.2.7 Printer...........................................................................................................................57
6.2.7.1 Connecting a Printer.............................................................................................57
6.2.7.2 Creating a Label...................................................................................................58
Contents 4

6.2.7.3 Replacing a Printer Roll....................................................................................... 58
6.2.7.4 Aligning the Printer...............................................................................................60
6.2.8 Example programmes.................................................................................................. 61
6.2.9 Guideline for Function Values......................................................................................62
6.3 Touch Control System (TCS)...............................................................................................64
6.3.1 Operating elements......................................................................................................65
6.3.2 Starting the machine....................................................................................................65
6.3.3 Selecting a programme................................................................................................66
6.3.4 Changing the programme............................................................................................ 66
6.3.4.1 Changing the vacuum settings (icon 16)..............................................................66
6.3.4.2 Changing the gas settings (icon 17).................................................................... 66
6.3.4.3 Changing the seal time (icon 18).........................................................................66
6.3.4.4 Changing the soft air time (icon 19).....................................................................66
6.3.5 Running the packaging cycle.......................................................................................66
6.3.6 Proceeding to the next cycle step................................................................................67
6.3.7 Cleaning the pump.......................................................................................................67
6.3.8 Selecting options on the machine in the option menu.................................................67
6.3.8.1 Liquid control (icon 4)...........................................................................................67
6.3.8.2 Red meat (icon 5)................................................................................................ 67
6.3.8.3 Step vacuum (icon 6)...........................................................................................67
6.3.8.4 Marinating (icon 7)................................................................................................68
6.3.9 Terminating a Programme............................................................................................68
6.3.10 Switching off the machine..........................................................................................68
6.3.11 Using the App.............................................................................................................68
6.3.11.1 Downloading the App.........................................................................................68
6.3.11.2 Programmes in the App..................................................................................... 69
6.3.12 Printer.........................................................................................................................71
6.3.12.1 Connecting a Printer...........................................................................................71
6.3.12.2 Creating a Label (App only)...............................................................................71
6.3.12.3 Replacing a Printer Roll..................................................................................... 73
6.3.12.4 Aligning the Printer.............................................................................................75
6.3.13 Data Log ID................................................................................................................76
6.3.14 Notifications................................................................................................................ 77
6.3.15 Example programmes................................................................................................ 78
6.3.16 Guideline for Function Values....................................................................................79
7 Maintenance................................................................................................................................82
7.1 Running the Pump Cleaning Programme............................................................................82
7.2 Maintenance Schedule.........................................................................................................82
7.3 Cleaning the Machine.......................................................................................................... 83
7.4 Replacing the Sealing Wire................................................................................................. 84
7.5 Replacing the Silicone Rubber of the Silicone Holders....................................................... 86
7.6 Replacing the Lid Gasket.....................................................................................................86
7.7 Inspecting the Lid Springs................................................................................................... 87
7.8 Vacuum Pump maintenance................................................................................................87
7.8.1 Overview.......................................................................................................................87
7.8.1.1 Pump 8 m3/h........................................................................................................ 88
Contents 5

7.8.1.2 Pump 16 - 21 m3/h...............................................................................................88
7.8.2 Removing Oil, Refilling Oil...........................................................................................89
7.8.3 Replacing the Oil Exhaust Filter.................................................................................. 90
7.8.3.1 Pump 8 m3/h........................................................................................................ 90
7.8.3.2 Pump 16 - 21 m3/h...............................................................................................91
7.8.4 Running the Pump Cleaning Programme.................................................................... 91
8 Troubleshooting and Error Codes........................................................................................... 93
9 Terms of Warranty.....................................................................................................................96
10 Disposal.....................................................................................................................................97
11 Appendices............................................................................................................................... 98
11.1 Technical Data................................................................................................................... 98
11.1.1 Boxer series............................................................................................................... 98
11.1.2 Lynx series............................................................................................................... 100
11.1.3 Neo series................................................................................................................ 101
11.1.4 Toucan series...........................................................................................................102
11.2 Electrical Installation.........................................................................................................103
11.3 Vapour Pressure Curve of Water.....................................................................................104
11.4 Logbook............................................................................................................................105
Contents 6

List of Figures
Figure 1: Overview of the Main Components.................................................................................17
Figure 2: Overview of the Main Components.................................................................................19
Figure 3: Overview of the Main Components.................................................................................20
Figure 4: Overview of the Main Components.................................................................................22
Figure 5: Overview of the Sealing System.....................................................................................28
Figure 6: Control Panel of the 10-Programme Control System......................................................31
Figure 7: External Vacuum Adapter Set (10-Programme Control System).....................................38
Figure 8: Control Panel of the Advanced Control System (ACS)...................................................42
Figure 9: Possible Display Modes.................................................................................................. 43
Figure 10: Possible Display Modes................................................................................................ 43
Figure 11: Overview of the Menus................................................................................................. 45
Figure 12: Example of an Exported Data Log................................................................................47
Figure 13: Screenshot of the navigation mode and the operating buttons of the ACS................... 49
Figure 14: External Vacuum Adapter Set (ACS)............................................................................57
Figure 15: Replacing the Printer Roll..............................................................................................59
Figure 16: Aligning the Printer........................................................................................................60
Figure 17: Printing the First Label..................................................................................................60
Figure 18: Neo control panel.......................................................................................................... 65
Figure 19: Replacing the Printer Roll..............................................................................................74
Figure 20: Aligning the Printer........................................................................................................75
Figure 21: Printing the First Label..................................................................................................75
Figure 22: Vapour Pressure Curve of Water..................................................................................81
Figure 23: Removing the Sealing Bar (Plastic Lid).........................................................................84
Figure 24: Removing the Sealing Bar (Metal Lid).......................................................................... 84
Figure 25: Replacing the Sealing Wire...........................................................................................85
Figure 26: Replacing the Silicone Rubber of the Silicone Holders.................................................86
Figure 27: Replacing the Lid Gasket..............................................................................................87
Figure 28: Overview of the Pump...................................................................................................88
Figure 29: Overview of the Pump...................................................................................................88
Figure 30: Mounting Plate Boxer 52...............................................................................................89
Figure 31: Replacing the Oil Exhaust Filter....................................................................................90
Figure 32: Replacing the Oil Exhaust Filter....................................................................................91
Figure 33: Overview of the Electrical Installation..........................................................................103
List of Figures 7

Figure 34: Vapour Pressure Curve of Water................................................................................104
List of Figures 8

1 Preamble
This is the manual for your Henkelman vacuum packaging machine series: Boxer, Lynx, Neo and
Toucan.
This manual is intended for anyone who works with or services the machine.
This manual contains information and instructions for installation, operation and maintenance
of the machine. We recommend that you carefully read this manual before use and follow the
procedures and instructions strictly. This will ensure that you get the best out of the machine and
prevents possible accidents and serious injury.
1.1 List of the Symbols Used in this Manual
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.
Indicates a hazardous situation that, if not avoided, could result in serious injury or death
and/or material damage if one does not obey the safety instructions.
Indicates a hazardous situation that, if not avoided, could result in minor or moderate
injury and/or material damage if one does not follow the safety instructions.
Provides additional information that is helpful to do a task or to avoid problems.
This symbol warns for high voltage.
1.2 Qualified personnel
This document is intended for qualified personnel.
The term "qualified personnel" is defined here as individuals who thoroughly understand
the equipment and its safe installation, operation or maintenance. Qualified personnel are
physically capable of performing the required tasks, are familiar with all relevant and local
safety rules and regulations and have been trained to safely install, operate or maintain the
equipment. It is the responsibility of the company installing, operating or maintaining this
equipment to ensure that its personnel meet these requirements.
Preamble 9

1.3 Storing the manual
This manual is a part of your product. Store the manual in the immediate vicinity of the product.
Always present a copy of the manual to operators and engineers working on the Vacuum
Packaging Machine.
1.4 Regulatory information
The Henkelman Boxer, Lynx, Neo and Toucan Vacuum Packaging Machine is designed to comply
with the following directives:
• 2006/42/EC: Machinery Directive
• 2014/30/EG: EMC Directive
• 2014/35/EC: Low Voltage Directive
The CE Declaration is available upon request. Please contact the manufacturer.
1.5 Terms of Warranty
The warranty is subject to the following limitations. The warranty period for products supplied by
Henkelman BV is 3 years from the date indicated on the purchase document. This warranty is
limited to manufacturing and machining defects and therefore does not cover breakdowns involving
any part of the product that is exposed to any form of wear and tear. Normal wear and tear that
may be expected with the use of this product is therefore hereby excluded.
• The responsibility of Henkelman BV is limited to replacing defective parts; we shall not
acknowledge claims for any other kind of damage or costs.
• The warranty automatically expires in case of overdue or poor maintenance.
• If there are doubts about the maintenance activities or if the machine fails to work correctly,
always contact the supplier.
• The warranty does not apply if the defect is the result of incorrect or negligent use, or
maintenance that was conducted contrary to the instructions given in this manual.
• The warranty is void in the event of repairs or modifications to the product by third parties.
• Defects due to damage or accidents caused by external factors are excluded from the warranty.
• If we replace parts in compliance with the obligations of this warranty, then the replaced parts
become our property.
The provisions regarding the warranty and liability are part of the general terms and conditions of
sale, which can be sent to you upon request.
1.6 Liability
• We exclude all liability insofar as far as it is not required by law.
• Our liability shall never exceed the total amount of the machine value in question.
Preamble 10