vc999 ST2 Installation instructions

ORIGINAL OPERATING MANUAL
Art. no. 593.767
Shrink Tunnel
ST2/ST2 D
VC999 VERPACKUNGSSYSTEME AG Tel. ++41 (0) 71 35 35 900
Melonenstrasse 2 Fax ++41 (0) 71 35 35 901
CH-9100 Herisau / Switzerland E-Mail [email protected]

EC Declaration of Conformity
In accordance with Machinery Directive 2006/42/EC, Appendix II A
In accordance with EMC Directive 2004/108/EC
In accordance with Low Voltage Directive 2006/95/EC
Manufacturer Authorized Representative in the Community
VC999 VERPACKUNGSSYSTEME AG ............................................................
Melonenstrasse 2 ............................................................
CH-9100 Herisau ............................................................
We hereby declare that the following
product
Product name: Shrink Tunnel VC999 ST2/ST2 D
is in conformity with the relevant-
provisions of the above referenced
directives – including any valid
amendments at the time of the
declaration.
The following harmonized standards
have been applied:
EN ISO 12100-1 / -2 Safety of machinery, devices and systems
DIN EN 60 204-1 Electrical equipment for industrial machinery
Place: Date:
Herisau 12.02.2009
Document Custodian:
Uriel Inauen
VC999 VERPACKUNGSSYSTEME AG
Melonenstrasse 2
CH-9100 Herisau

Shrink Tunnel VC999 ST2/ST2 D
Handover declaration
2009-11-12 Art. no. 593.767 Page 3/96
NOTICE
The following handover declaration has to be completed by the owner. The owner is obliged to
return the original, completed handover declaration to us. The owner hereby certifies that
he/she has understood and taken full note of the operator manual. By signing this document
the owner certifies that he/she shall observe the safety instructions contained in the operator
manual and shall inform each and every machine user or persons working at the machine of the
relevant safety instructions.
The operator shall be liable for any personal injuries or damage to property resulting from non-
observance of the safety instructions.

Shrink Tunnel VC999 ST2/ST2 D
Contents
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Contents
1Introduction ......................................................................................9
1.1 General information............................................................................9
1.2 Terms...............................................................................................10
1.3 Copyright protection.........................................................................10
2Safety and warranty.......................................................................11
2.1 Explanation of the safety instructions ..............................................11
2.1.1 Warning safety signs at the machine...............................................11
2.2 Residual risks...................................................................................12
2.3 General safety instructions...............................................................12
2.4 Machine stability...............................................................................13
2.5 Intended use.....................................................................................13
2.6 Requirements for operators .............................................................14
2.7 Warranty and liability........................................................................14
3Description of the machine...........................................................15
3.1 Operating principle...........................................................................15
3.2 Structure of the machine..................................................................16
3.2.1 Operator tasks..................................................................................19
3.3 Technical data..................................................................................19
3.3.1 Dimensions.......................................................................................20
3.3.2 Weight..............................................................................................21
3.3.3 Products...........................................................................................21
3.3.4 Belt cartridge....................................................................................21
3.3.5 Water system ...................................................................................21
3.3.6 Steam extraction ..............................................................................21
3.3.7 Steam heater (VC999 ST2 D)..........................................................22
3.3.8 Decalcifying system (optional) .........................................................22
3.3.9 Electrical data...................................................................................22
3.3.9.1 Power supply....................................................................................22
3.3.9.2 Output and Fuse protection..............................................................22
3.3.9.3 Controller..........................................................................................23
3.3.10 Noise emission.................................................................................23
4Packaging and transport...............................................................24
4.1 Packing the machine........................................................................24
4.2 Transporting the machine ...............................................................24
4.3 Unpacking the machine....................................................................24

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5Setting up the machine..................................................................25
5.1 Site requirements .............................................................................25
5.2 Foundations......................................................................................25
5.3 Safety clearances.............................................................................25
5.4 Leveling the machine........................................................................26
6Machine connections.....................................................................27
6.1 Electrical connection.........................................................................27
6.2 Water connection..............................................................................27
6.3 Steam heater connection (VC999 ST2 D)........................................27
7Installation of the machine............................................................28
7.1 Electrical installation.........................................................................28
7.2 Installation of the water supply line ..................................................29
7.3 Installation of the water discharge....................................................30
7.4 Installation of the steam supply line (VC999 ST2 D)........................31
7.5 Installation of the steam extraction system ......................................31
7.6 Installation of the protective rollers...................................................32
7.7 Cleaning the machine.......................................................................32
8Start-up............................................................................................33
8.1 Initial start-up....................................................................................33
8.1.1 Installation check..............................................................................33
8.1.2 Switching on the machine ................................................................34
9Operation.........................................................................................35
9.1 General instructions..........................................................................35
9.2 Requirements for operation..............................................................35
9.3 Operation..........................................................................................36
9.3.1 Control panel....................................................................................36
9.3.2 Switching on.....................................................................................37
9.3.2.1 Switching on after an EMERGENCY STOP.....................................37
9.3.3 Operation via the display..................................................................38
9.3.4 Access rights....................................................................................40
9.4 Main menu page 1............................................................................42
9.4.1 Program parameters.........................................................................42
9.4.1.1 Water temperature............................................................................43
9.4.1.2 Infeed belt.........................................................................................43
9.4.1.3 Internal conveyor belt.......................................................................43
9.4.1.4 Outfeed belt......................................................................................44
9.4.1.5 Shower .............................................................................................44
9.4.1.6 Programs..........................................................................................44
9.4.2 Operating hours meter .....................................................................45
9.4.3 Alarm list...........................................................................................46
9.5 Main menu page 2............................................................................47
9.5.1 LOG IN .............................................................................................47
9.5.2 LOG OUT .........................................................................................48
9.5.3 Information........................................................................................48
9.5.3.1 Machine status .................................................................................48

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9.5.3.2 Analog value.....................................................................................49
9.5.3.3 Safety level.......................................................................................49
9.6 Main menu page 3 ...........................................................................50
9.6.1 Autostart...........................................................................................50
9.6.1.1 Automatic warm-up ..........................................................................51
9.6.1.2 Automatic decalcification (optional)..................................................51
9.6.2 Manual decalcification......................................................................53
9.6.3 Emptying the water tank...................................................................54
9.7 Main menu page 4 ...........................................................................55
9.7.1 Machine settings ..............................................................................55
9.7.1.1 Machine data....................................................................................55
9.7.1.2 Language, time and weekday..........................................................56
9.7.1.3 Temperature.....................................................................................56
9.7.1.4 Further functions ..............................................................................57
9.7.2 Inputs / Outputs................................................................................59
9.8 Starting production...........................................................................60
9.9 Cancelling production.......................................................................60
9.10 Stopping production.........................................................................60
9.11 Changing the program .....................................................................61
9.12 Continuous operation.......................................................................61
9.13 Decalcification mode........................................................................61
9.14 Switching off the machine................................................................62
10 Operating messages and faults....................................................63
10.1 Info text.............................................................................................63
10.2 Malfunctions.....................................................................................63
10.2.1 Troubleshooting................................................................................64
10.3 Error messages................................................................................66
11 Operating supplies.........................................................................68
12 Maintenance....................................................................................69
12.1 Cleaning...........................................................................................69
12.1.1 Cleaning agents ...............................................................................69
12.1.2 Cleaning work...................................................................................70
12.1.3 Cleaning the water supply line filter sieve........................................71
12.1.4 Cleaning the steam supply line filter sieve (VC999 ST2 D).............71
12.1.5 Cleaning the belt cartridge and sieve...............................................72
12.2 Checks .............................................................................................74
12.2.1 Checking the belt tension.................................................................74
12.3 Maintenance work............................................................................75
12.3.1 Regular maintenance work ..............................................................75
12.3.1.1 Changing the standard decalcifier canister (optional)......................76
13 Repairs............................................................................................77
13.1 Repairs to electronics or control system..........................................77
13.1.1.1 Replace fuses...................................................................................77
13.1.2 Replacing the display.......................................................................78
13.1.3 Replace buffer battery of PLC control system .................................78

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14 Spare parts......................................................................................79
14.1 Ordering spare parts.........................................................................79
15 Disposal...........................................................................................80
16 Circuit diagrams.............................................................................81
17 Index ................................................................................................95

Shrink Tunnel VC999 ST2/ST2 D
Introduction
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1 Introduction
1.1 General information
• This operator manual is an integral part of your machine. The information and safety instructions
contained herein have to be carefully read and adhered to by members of staff authorized to oper-
ate the machine. Superiors who are responsible for machine operation shall be liable for damages
and their consequences resulting from incorrect handling of the machine. It is therefore in the inter-
est of the operator that this operator manual is strictly adhered to.
• The manufacturer shall not be liable for any damages which occur due to non-observance of this
operator manual in its entirety.
• Only the information contained in this operator manual can prevent faults during operation and
guarantee trouble-free operation. It is therefore imperative that this operator manual is actually read
und understood by members of staff authorized to operate the machine
• This machine is a state-of-the-art device at the time of delivery. It complies with CE regulations and
the latest version of machinery directive 2006/42/EC at the time of delivery.
• In the unlikely event that problems should occur, or if questions arise, please do not hesitate to con-
tact our Customer Service.
• Due to technical changes and improvements to the machine some of the diagrams contained in this
operator manual may not be exact. However, the diagrams are fully understandable in order to ex-
plain processes or a course of action.
• We reserve the right to change dimensions and construction of the machine.
Customer Service Dept. Switzerland
The manufacturer’s address is displayed on the name plate. Always state the type of machine and the
machine’s serial number, which are also displayed on the name plate, when contacting us.
Manufacturer: VC999 VERPACKUNGSSYSTEME AG
Address: Melonenstrasse 2
CH-9100 Herisau / Switzerland
Phone: ++41 (0)71 35 35 900
Fax: ++41 (0)71 35 35 901
E-mail: [email protected]
Website: www.vc999.ch
Represented by:

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Introduction
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1.2 Terms
The following terms are used in this operator manual to describe people who work at or who are in
some way involved with the machine:
Buyer
The buyer is the person who purchases the machine from the manufacturer or its representative, even if
he/she always allows a third party to use the machine. The buyer is also the manufacturer’s customer
and is the owner as defined by law.
Owner
The owner is the person who operates or uses the machine, even if he/she is not the actual owner as
defined by law. The owner also becomes liable for the legal risk resulting from operation or connected to
operation of the machine when operating the machine.
Operator, operating personnel
Operators or operating personnel are the people responsible and authorized to operate the machine.
These people should possess sufficient know-how in order to handle and operate the machine correctly.
Usually, one or several people are given responsibility for the machine and provided with the operator
manual for future reference.
It is expected that these people have been briefed about the machine and the operator manual on-site
and are especially aware of the safety regulations for correct handling of the machine and have been
expressly informed about compliance with the aforesaid regulations.
Specialist, specialist personnel
Specialists are specially trained people who, due to their vocational training, are qualified to carry out
special tasks at the machine.
These people are, e.g., electricians, mechanics, specialist engineers and appropriately qualified clean-
ing staff. These people also have to be familiar with the contents of the operating manual.
1.3 Copyright protection
This operator manual is confidential. All data and details contained herein are protected by copyright.
Violation is expressly prohibited by law, and may result in severe civil and criminal penalties.
This documentation contains information protected by copyright. Any reproduction, copying, scanning or
forwarding to third parties is expressly prohibited without the express prior permission of VC999
VERPACKUNGSSYSTEME AG. Violation is expressly prohibited by law, and may result in severe civil
and criminal penalties.

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Safety and warranty
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2 Safety and warranty
2.1 Explanation of the safety instructions
All the safety instructions in this operating manual provide the operator with early warning of possible
dangers, possible damage to the machine and peripheral equipment and of flawed, productive work.
Any sections which are of particular importance to the operator are marked by a warning symbol. The
operator must read and comply with this information.
Meanings:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury!
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury!
CAUTION
Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury!
NOTICE
Indicates a situation which, if not avoided, may result in considerable damage to equipment or
environmental harm!
2.1.1 Warning safety signs at the machine
All possible areas of danger are described in this operator manual and additionally indicated at the ma-
chine via warning safety signs. Please always pay attention to this safety information and act with the
respective caution.
WARNING: POTENTIAL DANGER ZONE
This warning safety sign displays potential danger zones at the machine. Always observe safety
information to prevent injuries. These danger zones are described in detail in the operating
manual.
WARNING: ELECTRICAL HAZARD
This area contains an electrical appliance; danger of death! Risk of electric shock when coming
into direct contact with live parts! Only fully qualified electricians should carry out work on
electrical appliances.

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Safety and warranty
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WARNING: FINGER TRAP
This warning safety sign displays a potential risk of fingers being trapped in this area! Non-
observance and reaching into the machine may result in serious physical injuries.
WARNING: HOT SURFACE
This warning safety sign displays a hot surface. Great caution is recommended. Contact can
result in burns. Always switch off the machine and allow the relevant components to cool down
before carrying out any tasks.
2.2 Residual risks
Despite taking all precautions residual risks remain. Residual risks are potential, not obvious risks.
Pay particular attention to:
• Risk of burns when touching hot surfaces and due to hot steam*.
• Trapping fingers and general injuries from uncoordinated operation.
• Risk of injury from unskilled transport or movement of the machine.
• Risks from working on the electric equipment.
* only machine type ST2 D
2.3 General safety instructions
Pay particular attention to the following instructions:
• Everybody involved with the installation, start-up, operation and servicing (inspection, maintenance,
repair work) of the machine at the owner’s company has to have carefully read and understood the
entire operating manual and especially the chapter entitled "Safety and warranty".
• This machine is a state-of-the-art device at the time of delivery. The respective safety regulations for
machine operation have been observed.
• All parts, whether self-manufactured or purchased from a component firm, comply with technical
standards and EU regulations in accordance with machinery directive 2006/42/EC.
• A continuous quality control of our own and third party parts is carried out prior to assembly at our
production plant.
• All safety and protective equipment is included in this safety concept which is geared towards pro-
tecting all the people who are employed to work on or with this machine against dangers.
NOTICE
Technical intervention in the functioning and effectiveness of the safety devices, safety switch-
es and covers or casing is expressly prohibited. If any of the safety and protective devices are
either entirely or partially put out of service, claims for recourse against the manufacturer shall
not be accepted.
The machine is then considered unsafe for operation as defined by law and should neither be
operated nor provided to third parties for operation.

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Safety and warranty
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WARNING
Electrical hazard! Danger of death - electric shock!
If the operator manual expressly states that the power supply has to be disconnected for cer-
tain tasks at the machine, these tasks should only be carried out after it has been ensured that
accidental reconnection of the power supply cannot occur directly or via a third party. This
means:
• The power supply has to be disconnected either by disconnecting the machine from the
mains or by disconnecting the plug,
or:
• The main switch has to be secured accordingly, i.e. using a padlock or placing a seal
through the provided holes in the switch.
NOTICE
The owner is solely responsible for workplace safety and adherence to statutory regulations
regarding machine handling.
• This operator manual is part of the machine. If it is lost or damaged, immediately order a replace-
ment copy via our Customer Service. Always state the type of machine and the machine number
(according to the data on the name plate).
2.4 Machine stability
Machine stability is guaranteed on a flat surface during normal operation if the machine is standing cor-
rectly on all 4 machine feet and is leveled horizontally according to the description in this operating ma-
nual.
Stability must be guaranteed during the full life of the machine, in particular during transport, assembly,
operation, inoperative periods, disassembly, inspections, and foreseeable faults.
In these situations, the machine must be sufficiently secured against moving, tilting and falling to pre-
vent personal injuries and damage to the machine and the environment.
The owner is solely responsible for adherence to these requirements.
2.5 Intended use
This machine is a technical tool which is solely intended for packaging suitable products at your work-
place. It should only be used to shrink hermetically sealed shrink bags containing food (e.g. meat, cold
cuts, cheese, etc.). Any other use is strictly prohibited!
NOTICE
Do not place objects or living things inside the machine for whatever purpose (e.g. cleaning,
heating up, etc.)!

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Safety and warranty
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The owner is responsible for the suitability, condition and characteristics of the shrink packaging. The
machine manufacturer is not responsible for the content of the packages.
NOTICE
This machine can be dangerous if it is not used correctly and/or for its intended purpose. Cor-
rect usage also includes observance of the installation, operation and repair work regulations
specified by the manufacturer.
2.6 Requirements for operators
The machine should only be operated, serviced, and repaired by authorized and fully trained and quali-
fied personnel. It is the responsibility of the owner to inform operators of possible dangers.
Ensure that responsibilities with regard to assembly, operation, and repairs are clearly defined and
communicated by the owner to guarantee that health and safety regulations are observed.
Operators are obliged to make sure the machine is in efficient working order prior to operation and to in-
form superiors immediately about any changes which constitute a risk to human safety or device func-
tioning.
The operator must ensure that only authorized personnel work at the machine.
2.7 Warranty and liability
The agreements and written consent in the contract of sale apply.
All warranty claims refer to the replacement of defective materials. Further claims are not accepted.
Warranty refers to normal operation during a shift/day.
The warranty periods are reduced accordingly for multiple shift operation.
Warranty claims against the manufacturer are excluded if any modifications or changes which have not
been expressly authorized by the manufacturer or agreed with the manufacturer are carried out at the
machine or to its components. The same applies for commissioning without prior written acceptance.

Shrink Tunnel VC999 ST2/ST2 D
Description of the machine
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3 Description of the machine
3.1 Operating principle
The machine is operated via the control panel with interactive touch screen display.
Products hermetically sealed in shrink bags are fed into the machine either manually or via a conveyor
belt, e.g. from a VC999 packaging machine.
When the infeed photocell detects an incoming product, the control unit activates the conveyor belt (wire
mesh conveyor belt) integrated in the machine. The products are then conveyed through the machine
on this belt.
An economic shower process is switched on as soon as the conveyor belt is activated. This spray tun-
nel consists of nozzles that generate a hot water cascade inside the machine. The products on the belt
travel through this spray tunnel. This process shrinks the bag tightly around the product, in particular the
bag excess, creating a tight, completely sealed end product. The shrink-wrapped packages are then
discharged from the machine.
Various belt or roller conveyors are optionally available for feeding products into and out of the machine.

Shrink Tunnel VC999 ST2/ST2 D
Description of the machine
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3.2 Structure of the machine
Fig. 3/1
Legend
1 Name plate 15 Service door, swing door
2 Main switch 16 Reflector
3 Outfeed roller conveyor (optional) 17 Strip curtain
4 Electrical connection for peripheral devices 18 Decalcifying system (optional)
5 Water discharge 19 Infeed roller conveyor (optional)
6 Height-adjustable machine feet 20 Photoel. sensor
7 Control panel with touch screen display 21 Electrical connection for peripheral devices
8 EMERGENCY STOP button 22 Access cover
9 Water tank 23 Solenoid valve water supply
Electric heater (VC999 ST2) 24 Water filter
10 Steam distributor (VC999 ST2 D) 25 Steam extraction fan
11 Belt cartridge (internal conveyor belt) 26 Electric cabinet
with wire mesh conveyor belt and 2 protec- 27 Water connection
tive rollers 28 Power cord feedthrough
12 Sieves 29 Steam extraction connection
13 Star knob 30 Steam heater connection (VC999 ST2 D)
14 Bar handle

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Description of the machine
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Casing
The casing consists of a robust, stainless steel structure. The machine stands on four height-adjustable
feet (6). It is fitted at the front with an upward opening service door (15). The belt cartridge (11) with the
internal conveyor belt is located behind the service door. The product infeed and outfeed openings are
equipped with a strip curtain (17).
The electric cabinet (26) is accessible from the rear of the machine. The access cover (22), to the left of
the electric cabinet, can be removed for maintenance tasks.
The name plate (1) is attached to the rear of the machine.
Water tank and heater
The water tank is accessible from the left-hand side. The spray water is warmed up in the water tank (9)
and enters the machine via a pump and spray nozzles. As regards the heating technology, two machine
versions are available:
• With electric heater (VC999 ST2)
• With steam heater (VC999 ST2 D)
Electric heater:
Four electric heating elements are integrated in the water tank for warming up the spray water.
Steam heater:
The machine is connected to a central steam generation unit. The spray water is warmed up using hot
steam that enters the water tank via a steam distributor.
The water level in the water tank is monitored by three electronic sensors in both versions. The water
can only be warmed up when the heating element (VC999 ST2) or the steam distributor (VC999 ST2 D)
are completely submerged in water, thus guaranteeing dry run security.
If the water level falls below the minimum permissible level, the water tank is filled with water via a
valve. This supply of water is switched off once the maximum water level has been reached.
Interfaces
Electrical connection:
The power cord can be routed into the electric cabinet (26) from the top or the bottom (28).
Water supply:
The connection point for the water supply (27) is located on top of the machine.
Water discharge:
The water discharge connection is equipped with an electrically operated ball valve.
Steam heater connection:
The machine (VC999 ST2 D) must be connected to a steam generation unit for steam heating. The
steam line is fed to the machine from the top.
Steam extraction connection:
The connection for the steam extraction (29) is located on top of the machine.

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Description of the machine
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Control panel with touch screen display
Operation occurs via the control panel at the front of the machine. Individual parameters can be dis-
played and their values edited on the touch screen. A keyboard appears on the screen to enter data.
The START button, STOP button and the indicator lamp for the heater are located below the display.
Electric cabinet
The electric cabinet (26) is accessible from the rear of the machine. The power cord is routed into the
electric cabinet from either the top or the bottom.
Safety devices
The machine is equipped with various safety devices. These safety devices help to protect operators
against potential machine dangers. The safety devices include:
- Lockable main switch (2)
- EMERGENCY STOP button (8)
Belt cartridge
The belt cartridge (11) is the internal product transport unit. The belt cartridge can be accessed after
opening the service door (15). The belt cartridge is fitted with a wire mesh belt and equipped with a pro-
tective roller at the both ends. The protective rollers provide finger pinch protection at the transition point
to an optional infeed / outfeed roller conveyor.
When the belt cartridge is installed, it is connected to the drive motor via a mechanical coupler. The wire
mesh belt then rotates around the belt cartridge, conveying the products through the machine.
The lower spray nozzles are integrated in the belt cartridge. Sieves (12) in and below the belt cartridge
prevent contamination of the spray water. The sieves can be removed individually for cleaning.
Infeed roller conveyor (optional)
The infeed roller conveyor (19) is optionally available. It can be installed and de-installed without tools at
both sides of the machine.
The outfeed roller conveyor (optional)
The outfeed roller conveyor (3) is optionally available. It can be installed and de-installed without tools at
both sides of the machine.
Steam extraction fan
The steam extraction fan is accessible from the rear of the machine after removing the access cover
(22).

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Description of the machine
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3.2.1 Operator tasks
One operator is required at the machine during production to carry out the following tasks:
• To monitor and support the functional efficiency of the machine.
• To actuate the EMERGENCY STOP button in an emergency situation.
3.3 Technical data
Standard scope of supply:
• Machine on 4 machine feet
• Triangular socket key
• Square socket key
• Electric or steam heater
• Dry run security
• Steam extraction, controlled via water temperature
• Automatic temperature control
• Automatic level control
• Digital error display
• Automatic and continuous operation
• Programmable water warm-up time (timer)
• 1x original operating manual
Options:
• Outfeed roller conveyor
• Infeed roller conveyor
• Infeed conveyor
• Outfeed conveyor
• Decalcifying system

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Description of the machine
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3.3.1 Dimensions
Fig. 3/2
1 Power cord feedthrough (top) 5 Water discharge
2 Power cord feedthrough (bottom) 6 Steam extraction connection
3 Electrical connection peripheral devices 7 Steam heater connection
4 Water supply connection 8 Operator position