Henkelman Jumbo series User manual

Vacuum Packaging Machine
Jumbo
User Manual
Art No. 0894622
Original Instructions for Use
©Henkelman 2017-2018

• 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 42.
• 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 9 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 2017-2018
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................................................................................................................................. 5
1 Preamble....................................................................................................................................... 6
1.1 List of the Symbols Used in this Manual...............................................................................6
1.2 Qualified personnel................................................................................................................ 6
1.3 Storing the manual.................................................................................................................7
1.4 Regulatory information...........................................................................................................7
1.5 Terms of Warranty.................................................................................................................7
1.6 Liability....................................................................................................................................7
1.7 Terms and abbreviations........................................................................................................8
2 Safety.............................................................................................................................................9
2.1 Pictograms on the Machine...................................................................................................9
2.2 General Warnings.................................................................................................................. 9
2.3 Warnings During Use...........................................................................................................10
2.4 Warnings for Operating Personnel.......................................................................................11
3 Introduction.................................................................................................................................12
4 Description of the Machine.......................................................................................................13
4.1 Jumbo series........................................................................................................................13
4.1.1 Overview of the Main Components..............................................................................14
4.2 Description of the Packaging Process/Machine Functions..................................................15
4.2.1 Packaging Process/Machine Functions........................................................................15
4.2.2 General Functions........................................................................................................15
4.3 Sealing System.................................................................................................................... 16
5 Installation...................................................................................................................................17
5.1 Transportation and Installation.............................................................................................17
5.2 Connecting the Machine...................................................................................................... 17
5.3 Prior to the First Use........................................................................................................... 18
6 Operation.....................................................................................................................................19
6.1 1-Programme Control System (1-PCS)................................................................................19
6.1.1 Operating Elements......................................................................................................19
6.1.2 Starting the Machine....................................................................................................20
6.1.3 Starting the Packaging Cycle.......................................................................................20
6.1.4 Proceeding to the Next Step in the Cycle....................................................................20
6.1.5 Terminating a Programme............................................................................................20
6.1.6 Changing the Programme Settings..............................................................................21
6.1.6.1 Vacuum.................................................................................................................21
6.1.6.2 Vacuum+ time (only for sensor control)...............................................................21
6.1.6.3 Seal.......................................................................................................................22
6.1.6.4 External Vacuum (optional)..................................................................................22
Contents 3

6.1.7 Guideline for Function Values......................................................................................23
7 Maintenance................................................................................................................................24
7.1 Running the Pump Cleaning Programme............................................................................24
7.2 Maintenance Schedule.........................................................................................................24
7.3 Cleaning the Machine.......................................................................................................... 25
7.4 Replacing the Sealing Wire................................................................................................. 25
7.5 Replacing the Silicone Rubber of the Silicone Holders....................................................... 27
7.6 Replacing the Lid Gasket.....................................................................................................27
7.7 Inspecting the Lid Springs................................................................................................... 28
7.8 Vacuum Pump maintenance................................................................................................28
7.8.1 Overview.......................................................................................................................28
7.8.1.1 Pump 4 m3/h........................................................................................................ 29
7.8.1.2 Pump 8 m3/h........................................................................................................ 29
7.8.1.3 Pump 16 - 21 m3/h...............................................................................................30
7.8.2 Removing Oil, Refilling Oil...........................................................................................30
7.8.3 Replacing the Oil Exhaust Filter.................................................................................. 31
7.8.3.1 Pump 4 m3/h........................................................................................................ 31
7.8.3.2 Pump 8 m3/h........................................................................................................ 32
7.8.3.3 Pump 16 - 21 m3/h...............................................................................................32
7.8.4 Running the Pump Cleaning Programme.................................................................... 33
8 Troubleshooting and Error Codes........................................................................................... 34
9 Terms of Warranty.....................................................................................................................36
10 Disposal.....................................................................................................................................37
11 Appendices............................................................................................................................... 38
11.1 Technical Data................................................................................................................... 38
11.1.1 Jumbo series..............................................................................................................38
11.2 Electrical Installation...........................................................................................................40
11.3 Vapour Pressure Curve of Water.......................................................................................41
11.4 Logbook..............................................................................................................................42
Contents 4

List of Figures
Figure 1: Overview of the Main Components.................................................................................14
Figure 2: Overview of the Sealing System.....................................................................................16
Figure 3: Control Panel of the 1-PCS.............................................................................................19
Figure 4: External Vacuum Adapter Set (1-PCS)...........................................................................22
Figure 5: Removing the Sealing Bar...............................................................................................26
Figure 6: Replacing the Sealing Wire.............................................................................................26
Figure 7: Replacing the Silicone Rubber of the Silicone Holders...................................................27
Figure 8: Replacing the Lid Gasket................................................................................................28
Figure 9: Overview of the Pump.....................................................................................................29
Figure 10: Overview of the Pump...................................................................................................29
Figure 11: Overview of the Pump...................................................................................................30
Figure 12: Replacing the Oil Exhaust Filter....................................................................................31
Figure 13: Replacing the Oil Exhaust Filter....................................................................................32
Figure 14: Replacing the Oil Exhaust Filter....................................................................................32
Figure 15: Overview of the Electrical Installation............................................................................40
Figure 16: Vapour Pressure Curve of Water..................................................................................41
List of Figures 5

1 Preamble
This is the manual for your Henkelman vacuum packaging machine series: Jumbo.
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 6

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 Jumbo 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 7

• With the exception of the applicable legal regulations of public order and good faith, we are
not liable to pay for any damage of any sort whatsoever to the counterparty or to third parties,
directly or indirectly, including lost profits, damage to movable or immovable property or
personal injury.
• We are in no way liable for damages arising from or resulting from the use of the product used,
or the unsuitability thereof for the purpose for which the other party decided to purchase the
product.
1.7 Terms and abbreviations
1-PCS 1-Programme Control System
Machine Vacuum packaging machine
Pump Vacuum pump
Preamble 8

2 Safety
Your vacuum packaging machine has been carefully designed and expertly built to be operated
safely. This is corroborated by the EC Declaration of Conformity. However, there are always
dangers and safety risks that cannot be eliminated. These dangers and risks are the result of the
use functions of the machine and operation of the machine by the user. This section discusses
safety instructions and precautions, how they will be pointed out to you and the requirements
the user must meet. It is essential that you are well aware of these safety instructions and
requirements and observe them at all times!
2.1 Pictograms on the Machine
Pictograms and warnings have been fitted on the machine to warn users of the possible risks.
Warning sign "High Voltage"
• Is located on the back of the machine
Warning sign "Heat"
• Is located on the sealing bars and on the vacuum pump
Machine plate
• Is located on the back of the machine
Regularly check whether the pictograms and markings are still clearly recognisable and
legible. Replace them if this is not the case.
2.2 General Warnings
• All persons responsible for the operation of this machine must at least fully read and
understand the chapters Safety on page 9 and Operation on page 19.
• Failure to follow or disregard of the safety instructions may result in serious injury.
• Never pack products that can be damaged by vacuum.
• Never vacuum live animals.
• Warranty and/or liability is void if any damage is caused by repairs and/or modifications
that are not authorised by the supplier or any of its distributors.
• In case of malfunction, contact the supplier.
• High pressure cleaning is not allowed. This may cause damage to the electronics and
other components.
Safety 9

• Prevent water from entering the ventilation inlet of the chamber or the exhaust of the
pump. This causes irreversible damage to the pump.
• The work space around the machine must be safe. The owner of the machine must take
the necessary precautions to operate the machine safely.
• It is forbidden to start the machine in an explosive environment.
• The machine has been designed in such a way that production is safe under normal
ambient conditions.
• The owner of the machine must ensure that the instructions in this manual are actually
complied with.
• The available safety devices may not be removed.
• The correct operation and safety of the system can only be guaranteed if the
recommended maintenance is performed on time and properly.
• If work must be carried out on the machine, it must be disconnected and blocked from
the power supply.
• Only a technical expert may perform work on the electrical installation.
• Internal procedures and monitoring must be in place to ensure that all relevant power
supplies are disconnected.
• The machine may not be used during cleaning, inspection, repair or maintenance and
must be disconnected from the power supply by disconnecting the plug.
• Never perform welding work on the machine without first disconnecting the cable
connection to the electrical components.
• Never use the power supply of the control unit to connect other machines.
• All electrical connections must be connected to the terminal strips according to the
wiring diagram.
2.3 Warnings During Use
• Before starting the machine, make sure no work is being performed on the installation
and that the machine is ready for use.
• The machine may not be operated by unauthorised persons. This should be monitored
by the machine operator(s).
• Immediately contact the service technician of your technical department or dealer if
something does not seem right, such as unusual vibrations or unusual noise.
• Components of the sealing system can become very hot. Contact with these
components may cause injuries.
• Improper use, such as switching off the machine while it is creating a vacuum, is
strongly discouraged. Such actions may cause oil leaking back to the vacuum chamber.
Safety 10

2.4 Warnings for Operating Personnel
• Operating personnel must be 18 years or older.
• Only authorised persons are allowed to perform work on or with the machine.
• Personnel may only perform work for which it was trained. This applies to both
maintenance and normal use.
• The machine may only be operated by trained personnel.
• Operating personnel must be familiar with all circumstances, so quick and effective
action can be taken in case of an emergency.
• If an operator notices errors or risks or disagrees with safety measures, he or she
should report this to the owner or manager.
• Safety shoes are mandatory.
• Appropriate work clothing is mandatory.
• All personnel must obey the safety regulations to avoid danger to themselves and
others. Always strictly follow the work instructions.
Safety 11

3 Introduction
Henkelman BV is a supplier of ultra-modern vacuum packaging machines. Our machines are
developed and manufactured to meet the highest standards. They combine a sleekly built and
functional design with optimal ease of use and a long service life. After mounting the plug, it is just
a matter of "plug & pack". The clever design ensures compliance with the hygiene standards at all
times.
The Jumbo series are professional table top models, use-friendly and low-maintenance.
Introduction 12

4 Description of the Machine
This section provides an short introduction to the machine and an overview of it's main
components and functions. If detailed information is available in this manual, you will be referred to
the specific sections.
4.1 Jumbo series
Basic vacuum packaging machines for basic packaging needs. The Jumbo series represent a
range of compact table-top models.
All Jumbo models are equipped:
• Standard with 1 program memory
• Standard with double seal
• Free options: Cut-off and Wide seal
Description of the Machine 13

4.1.1 Overview of the Main Components
The figure below shows the main components of the Jumbo series. The model shown may differ
from your machine.
Figure 1: Overview of the Main Components
1. Lid
The lid closes the vacuum chamber during the application of the vacuum. A rubber is mounted
in the lid to ensure proper closing. Silicone holders are mounted in the lid as counter beams of
the sealing bar(s).
2. Vacuum chamber
The products to be packaged are placed on the work surface with the openings of the vacuum
bags on the sealing position.
3. Seal system
Depending on the model, one or two sealing bars are mounted in the vacuum chamber. These
close the vacuum bag.
4. Control panel
This serves to operate the available control functions.
5. Machine housing
The machine housing contains all the components necessary for the functioning of the
machine.
6. Vacuum pump
The vacuum pump creates the vacuum.
7. Power connection
This serves to connect the machine to the power supply.
Description of the Machine 14

4.2 Description of the Packaging Process/Machine Functions
This section provides an overview of the packaging process and available machine functions.
4.2.1 Packaging Process/Machine Functions
This section describes the packaging process and the machine functions. See Operation on page
19 for the realization of the specific steps of the procedure.
Step Process phase Operation
1. Preparation The operator puts the product in a vacuum bag and places it
on the work surface with the opening on the sealing position.
2. Applying vacuum The vacuum process is initiated by closing the lid.
During the cycle, the air will be removed from the chamber
until the set vacuum percentage or time has been reached.
3. Sealing The sealing bars are pressed against the vacuum bag and
melt the bag closed.
During the sealing process, the material of the vacuum bag
is heated and pressed together to create a hermetic seal.
The programming of this function takes place in seconds.
Optionally, the second sealing wire can be replaced by a cut-
off wire. The purpose of the cut-off wire is to remove the ex-
cess foil from the remaining flap.
4. Decompressing The vacuum is removed from the vacuum chamber by letting
air into the chamber.
5. Opening the vacu-
um chamber The lid opens.
6. Removing the
product The operator can remove the packaged product from the work surface.
4.2.2 General Functions
Function Pictogram Operation
Cleaning of the
oil pump The pump cleaning programme ensures that the pump is thor- oughly rinsed. During the programme, the pump and oil reach
the operating temperature, so the oil and moisture are separated
and any contamination is filtered. The high temperature causes
any moisture in the pump to evaporate, thus minimising the risk
of corrosion.
Description of the Machine 15

Function Pictogram Operation
External Vacu-
um This function allows special food containers to be vacuumed out-
side the machine.
The options to set the vacuum value are the same as for stand-
ard vacuuming (see External Vacuum (optional) on page 22).
4.3 Sealing System
The sealing system closes the opening(s) of the bag to retain the vacuum and/or gas in the bag.
The end of the bag can optionally be cut off by the sealing bar.
Figure 2: Overview of the Sealing System
1. Sealing bar
The sealing bar consists of the following components:
• Sealing wires: during the sealing process, the sealing wires are heated for a certain time
causing the edges of the vacuum bag to melt together.
• Cut-off wires (optional): A cut-off wire is heated in such a way that the foil of the bag
partially melts, allowing the excess foil of the vacuum bag to be removed easily.
• Teflon tape: sealing and cut-off wires are covered with Teflon tape to prevent the bag from
sticking to the sealing bar.
Consult Replacing the Sealing Wire on page 25 for more detailed information about
maintenance.
2. Silicone holder
Opposite the sealing bar is a silicone holder which provides counter pressure on the cylinders
(Replacing the Silicone Rubber of the Silicone Holders on page 27).
3. Sealing mechanism
The sealing bars are pressed onto the vacuum bag by cylinders. By connecting the inlet of the
cylinders with the atmospheric pressure outside, they press the sealing bar onto the bag.
Description of the Machine 16

5 Installation
Consult Technical Data on page 38 for the specifications of the machine.
Before installing the machine, carefully read the safety instructions in Safety on page 9.
Failure to follow or disregard of the safety instructions may result in serious injury.
5.1 Transportation and Installation
The machine must be moved and transported in an upright position.
1. Place the machine on a flat, level surface. This is essential to ensure a trouble-free operation
of the machine.
Do not position machines with plastic covers in the vicinity of a heat source.
Make sure there is sufficient space (at least 15 cm) around the machine to ensure a
proper ventilation.
2. Verify that the machine housing is present and correctly fitted.
5.2 Connecting the Machine
Only a technical expert may perform work on the electrical installation.
Make sure the power supply for this machine matches to the voltage and amperage stated on the
machine plate.
Specified amperage: 16 /fuse
20 C Description
16 Nominal amperage
Fuse 20 Minimum fuse value with the recommended type of fuse
C C characteristic
1. Fit the connecting cable to the machine. See Technical Data on page 38 for the correct
electrical connection.
2. Connect the machine to a grounded wall outlet to avoid fire or electric shock.
Installation 17

• The power cable must be free at all times, and nothing may be placed on it.
• Immediately replace the power cable if damaged.
5.3 Prior to the First Use
See Vacuum Pump maintenance on page 28 for more information how to perform these steps.
Prior to the first use, the following steps must be performed:
Failure to do so may result in unrepairable damage to the machine.
1. Check the oil sight glass to see if the amount of oil in the pump is sufficient.
2. Optional: If the amount of oil in the pump is insufficient, refill it.
3. Start up the machine. See Operation on page 19 for more information.
4. Run the pump cleaning programme before using the machine for the first time.
Installation 18

6 Operation
Depending on the configuration of the vacuum packaging machine it is equipped with one of the
following control systems:
• 1-Programme Control System (1-PCS)
Read the appropriate section how to operate the vacuum packaging machine.
• All persons responsible for the operation of this machine must at least fully read and
understand the chapters Safety on page 9 and Operation on page 19.
• Failure to follow or disregard of the safety instructions may result in serious injury.
6.1 1-Programme Control System (1-PCS)
6.1.1 Operating Elements
The 1-PCS allows the machine to be operated and programmes to be changed.
Figure 3: Control Panel of the 1-PCS
1. On/Off button
Serves to turn the control panel on or off.
Depending on the model, the on/off button is located on the left side of the control panel or on
the rear of the machine near the power cord.
2. Cursor key
This key is used to operate the functions of the parameter display and function display.
3. Pump cleaning programme button
This is used to activate the pump cleaning programme. Moisture can condensate in the oil
when the pump is running only short cycles or when you are packaging moisture-containing
products. This programme removes moisture from the oil of the vacuum pump. See Running
the Pump Cleaning Programme on page 24 for instructions.
4. Parameter display
This display shows the current value of the active function during the programme cycle or the
set value of the selected function when the machine is inactive.
Operation 19

5. Function display
The LED light in front of the function lights up if the function is active during the programme
cycle or if the function is selected in the programming mode.
6. – / STOP button
This is used to interrupt the entire cycle during a packaging cycle. All functions are skipped
and the cycle is terminated. In the programming mode, the value of the selected parameter
can be lowered using this button.
7. + / VACUUM STOP button
This stops the active function and proceeds to the next programme step. In the programming
mode, the value of the selected parameter can be increased using this button.
8. Vacuum meter
Shows the pressure in the vacuum chamber. A value of -1 bar corresponds to 99% vacuum.
6.1.2 Starting the Machine
1. Plug in the machine.
2. Turn the main switch to the ON position (see Electrical Installation on page 40) to turn on
the machine.
3. Press the on/off button on the control panel or on the rear of the machine to enable the
operation.
Two dashes may be shown on the display during the first start-up or ventilation. This means that
the machine needs to be decompressed. In this case, open the lid to decompress the machine.
6.1.3 Starting the Packaging Cycle
The machine must be started in accordance with Starting the Machine on page 20 before
starting a packaging cycle.
1. Select the desired programme.
Press the ▲▼ button
2. Put the product/products in place.
a. Put the product/products in the vacuum bag.
b. Place the vacuum bag in/on the vacuum chamber. Make sure the opening(s) is/are
correctly placed with regard to the seal position(s).
3. Close the lid.
The packaging cycle will start.
6.1.4 Proceeding to the Next Step in the Cycle
For some products, it may be necessary to proceed to the next step in the packaging cycle before
the vacuum time or the vacuum level has been reached.
1. Proceed to the next step in the cycle.
Press the + / VACUUM STOP button.
The next step will be started.
6.1.5 Terminating a Programme
Programmes such as the packaging programme or the pump cleaning programme can be
terminated at any time.
Operation 20