vc999 K7 User manual


Vacuum Packaging Machine VC999 K7
Handover declaration
2008-11-26 Art.-No. 592.016 Page 3/121
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.


Vacuum Packaging Machine VC999 K7
Contents
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Contents
1Introduction ......................................................................................8
1.1 General information............................................................................8
1.2 Terms.................................................................................................9
1.3 Copyright protection...........................................................................9
2Safety, warranty .............................................................................10
2.1 Explanation of the safety instructions ..............................................10
2.1.1 Warning safety signs at the machine...............................................10
2.2 General safety instructions...............................................................11
2.3 Intended Use....................................................................................12
2.4 Safety when vacuuming...................................................................13
2.4.1 Safety precautions and equipment ..................................................13
3Description of the machine...........................................................15
3.1 Operating principle...........................................................................15
3.2 Principle of operation .......................................................................19
3.3 Technical data..................................................................................20
3.3.1 Dimensions.......................................................................................20
3.3.2 Weight..............................................................................................20
3.3.3 Electrical data...................................................................................21
3.3.3.1 Control..............................................................................................21
3.3.4 Pneumatic data ................................................................................21
3.3.5 Performance data.............................................................................21
3.3.6 Noise emission.................................................................................22
3.4 Accessories......................................................................................22
3.4.1 Bag waste suction unit (VC999 K7A)...............................................22
3.4.2 Filling plate.......................................................................................23
4Packaging and transport...............................................................24
5Setting up the machine..................................................................25
5.1 Preparation.......................................................................................25
5.1.1 Site requirements.............................................................................25
5.1.2 Space requirement...........................................................................25
5.1.3 Base.................................................................................................26
6Installation of the machine............................................................27
6.1 Casing plates....................................................................................28
6.2 Connection.......................................................................................28
6.2.1 Connecting the electric power supply..............................................29
6.2.2 Connecting the compressed air supply............................................30

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6.3 Connecting the vacuum pump(s) .....................................................31
6.4 Periphery..........................................................................................31
7Initial start-up..................................................................................32
7.1 Installation inspection.......................................................................32
8Start-up............................................................................................33
8.1 Functional checks.............................................................................34
9Operation.........................................................................................35
9.1 Requirements for operation..............................................................35
9.2 Preparation.......................................................................................35
9.2.1 Preparing the product.......................................................................35
9.2.2 Preparing the packaging material.....................................................36
9.2.3 Adjusting the packaging machine to suit the product.......................36
9.2.3.1 Adjusting the height of the sealed seam..........................................36
9.2.3.2 Installing or removing the filling plate...............................................41
9.3 Switching on the machine ................................................................41
9.4 Operating display..............................................................................42
9.5 Step 0 ...............................................................................................47
9.5.1 Mask 00: Start-up.............................................................................47
9.5.2 Mask 10: Information........................................................................47
9.5.3 Mask 11: Counter.............................................................................48
9.5.4 Mask 12: Graph................................................................................48
9.5.5 Mask 13: Process monitoring...........................................................49
9.5.6 Mask 300: Programs ........................................................................50
9.5.7 Mask 990: Alarm list.........................................................................51
9.5.8 Mask 52: Test function .....................................................................52
9.5.9 Mask 53: Leak test air-cushion.........................................................53
9.5.10 Mask 54: Leak test vacuum chamber...............................................53
9.6 Step 1 ...............................................................................................54
9.6.1 Mask 55: Periphery...........................................................................54
9.7 Step 2 ...............................................................................................55
9.7.1 Mask 101/102: Parameters 1/2 and 2/2...........................................55
9.8 Step 3 ...............................................................................................60
9.8.1 Mask 151: Calibration......................................................................60
9.8.1.1 Mask 152: Calibration sealing bars..................................................60
9.8.1.2 Burn-in sealing bars..........................................................................61
9.8.1.3 Mask 153: Calibration vacuum system.............................................62
9.8.1.4 Initializing frequency converter.........................................................62
9.8.2 Mask 157: Defect Modes..................................................................63
9.8.3 Mask 156: Service parameter ..........................................................64
9.9 Step 4 ...............................................................................................65
9.10 Programming....................................................................................66
9.10.1 Define program.................................................................................66
9.10.2 Load program...................................................................................66
9.10.3 Edit program.....................................................................................67
9.10.4 Delete program.................................................................................67
9.11 Packaging cycle................................................................................68
9.11.1 Conveyor belt positioning.................................................................68
9.11.2 Start / terminate packaging cycle.....................................................68
9.12 Switch off..........................................................................................69

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9.13 Operating messages........................................................................70
10 Error display and troubleshooting...............................................71
10.1 Alarm messages...............................................................................71
10.2 Faults and their remedies.................................................................72
10.3 Other faults and their remedies........................................................78
11 Maintenance....................................................................................80
11.1 Servicing plan...................................................................................80
11.1.1 Cleaning work...................................................................................81
11.1.2 Inspection work ................................................................................82
11.2 Servicing work..................................................................................83
11.2.1 Compressed air maintenance unit ...................................................84
11.2.2 Maintenance sealing bars................................................................84
11.2.2.1 Replace Teflon tape and sealing wires............................................85
11.2.2.2 Calibration and burn-in sealing bars ................................................88
11.3 Maintenance vacuum pump(s).........................................................89
11.4 Tensioning the conveyor belt...........................................................89
11.5 Maintenance blades.........................................................................90
11.5.1 Checking cutter blade (VC999 K7A) /
perforation blade (VC999 K7B)........................................................90
11.5.2 Checking pre-perforation blade........................................................91
12 Repairs............................................................................................92
12.1 Replacing the conveyor belt.............................................................92
12.2 Repairs to electronics or control system..........................................93
12.2.1 Replace buffer battery of PLC control system .................................93
12.2.2 Replacing the buffer battery of the display.......................................93
12.2.3 Replace fuses...................................................................................94
13 Spare parts......................................................................................95
13.1 Ordering spare parts........................................................................95
14 De-commissioning / Interim storage / Disposal..........................96
14.1 De-commissioning and dismantling .................................................96
14.2 Interim storage .................................................................................96
14.3 Disposal............................................................................................97
15 Appendix.........................................................................................98
15.1 Program table...................................................................................98
15.2 Pneumatic diagram..........................................................................99
15.3 Wiring diagrams .............................................................................100
16 Index..............................................................................................119

Vacuum Packaging Machine VC999 K7
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 authorised to operate
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 interest 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 op-
erator manual in its entirety.
• Only the information contained in this operator manual can prevent faults during operation and guar-
antee trouble-free operation. It is therefore imperative that this operator manual is actually read und
understood by members of staff authorised 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 98/37/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: Inauen Maschinen 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.biz
Represented by:

Vacuum Packaging Machine VC999 K7
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 authorised 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 Inauen Ma-
schinen AG. Violation is expressly prohibited by law, and may result in severe civil and criminal penal-
ties.

Vacuum Packaging Machine VC999 K7
Safety, warranty
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2 Safety, 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 wich, if not avoided, will result in death or serious injury!
WARNING
indicates a hazardous situation wich, if not avoided, could result in death or serious injury!
CAUTION
indicates a hazardous situation wich, if not avoided, may result in minor or moderate injury!
NOTICE
indicates a situation wich, 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 OF A 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.

Vacuum Packaging Machine VC999 K7
Safety, warranty
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2.2 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".
• 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 98/37/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 swit-
ches 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.
NOTICE
Never place objects on the vacuum chamber lid (Fig. 3/1, pos. 15)!
NOTICE
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 switching on 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.

Vacuum Packaging Machine VC999 K7
Safety, warranty
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NOTICE
Before each intervention at pneumatic parts, ensure that the compressed air valves and cylin-
ders are depressurized.
• Always check all the safety devices prior to each start-up.
• Check the earth resistance at the electrical components after carrying out work at the ma-
chine
• Always observe local and regional safety regulations (e.g. electricity provider). This also
applies to the regulations of professional organizations.
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 replacement
copy via our Customer Service. Always state the type of machine and the machine number (according
to the data on the name plate).
2.3 Intended Use
The Vacuum Packaging Machine VC999 K7 is a technical appliance which should only be used for its
intended task. Use of the Vacuum Packaging Machine in accordance with its intended purpose consists
with provisions in vacuuming and sealing suitable products in sealable plastic bags.
Proper use in accordance with the intended purpose also includes compliance with all the instructions
and conditions for setting up, connection and the operation of the Vacuum Packaging Machine as speci-
fied by the manufacturer.
Suitable products
Suitable products for vacuum wrapping are goods which do not develop any explosive or toxic vapours
on introduction of a vacuum and which will not be damaged by the effect of the vacuum. Such products
may be from the foodstuffs sector (e.g. meat, sausage, etc.) or the non-food sector (medical equipment,
electrical or mechanical components, etc.).
The owner is responsible for the suitability, condition and characteristics of the products being pack-
aged. The machine manufacturer is not responsible for the content of the packages.
If in doubt, check the suitability of products with valueless samples or take advice from the Vacuum
Packaging Machine manufacturer.
Any use that deviates from the use in accordance without the written approval of the manufacturer is
deemed to be mis-use. The manufacturer cannot be held liable for any damage to the Vacuum Packag-
ing Machine or vacuum-packed products arising from this.

Vacuum Packaging Machine VC999 K7
Safety, warranty
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2.4 Safety when vacuuming
... DANGER
Vacuums kill living organisms! Do not vacuum-pack any living organisms and also ensure that
no living organisms are vacuum-packed by unauthorized persons or children!
Vacuum packaging systems use a vacuum pump to remove air from a hermetically sealed vacuum
chamber in which the product and the packaging has been placed. Therefore, access is not possible
during the sealing process. External air has to flow into the chamber before the two parts of the sealing
tool can be opened.
Never try to open the tool with force!
The vacuum is used to extract the air in the packaging. According to the laws of thermalphysics, mois-
ture in the air starts to evaporate at a relatively low vacuum. This means that products which contain a
large amount of uncombined moisture can be affected.
The vacuum pump has the reverse effect, like a compressor. Dust particles, but also moisture, are en-
trained by the vacuum current and can reach the vacuum pump unhindered. If products for which this
process can occur are to be packaged, it is recommended to install a dust or moisture separator in front
of the vacuum pump.
This especially applies for products which have a high sugar or starch content (sauces and breadcrumb
coating), since entrained particles become incrusted in valves and small bore holes in the tool and on
the lamellas of the vacuum pump where they crystallize or agglutinate. And since these locations can
hardly be cleaned, functioning of the entire system can be significantly affected if a filter and separator
are not installed.
It is also hazardous to package flammable or explosive products (icing sugar or dextrose, but also spray
or perfume bottles), since entrained parts or particles can react accordingly.
... DANGER
Spray bottles with a specified internal pressure should not be vacuum packed, since a reduc-
tion of the external pressure causes the high internal pressure to explode.
The standard version of the Vacuum Packaging Machine VC999 K7 is equipped with a vacuum pump
but without a filter or separator, if not ordered with the respective equipment.
2.4.1 Safety precautions and equipment
The following safety precautions and equipment are designed to ensure your safety:
• EMERGENCY STOP button on both sides of the cockpit
If an emergency or hazardous situation arises, use the EMERGENCY STOP buttons to immediately
stop the Vacuum Packaging Machine and to de-energize any hazardous components. Release of
the EMERGENCY STOP button does not automatically restart the machine. The machine has to be
actively re-started.

Vacuum Packaging Machine VC999 K7
Safety, warranty
Page 14/121 Art.-No. 592.016 2008-11-26
• Hand-guard at the vacuum chamber lid
A hand-guard is fitted around the edge of the vacuum chamber lid. This hand-guard must be com-
pletely lowered without hindrance in order to start the packaging cycle.

Vacuum Packaging Machine VC999 K7
Description of the machine
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3 Description of the machine
3.1 Operating principle
This section describes how the Vacuum Packaging Machine is structured. This will assist you in identify-
ing and naming the individual parts and sub-assemblies.
Fig. 3/1

Vacuum Packaging Machine VC999 K7
Description of the machine
Page 16/121 Art.-No. 592.016 2008-11-26
Legend
1 Cockpit with interactive display
2 Loading area limit mark
3 Conveyor belt joint (plastic wire)
4 Loading area limit mark
5 Conveyor belt
6 Tensioning lever for conveyor belt tension
7 Start button for automatic operation
8 Vacuum pump positions (vacuum pumps)
9 Height adjustable foot
10 Electrical cabinet with control unit
11 Right-hand bag waste suction tube (VC999 K7A)
12 To the bag waste suction unit (VC999 K7A)
13 Vacuum chamber bottom
14 Emergency stop buttons
15 Vacuum chamber lid
16 Terminal box with vacuum sensor
17 Outfeed roller conveyor
18 Lifting mechanism
19 Name plate
20 Cabinet for energy supply (electric / pneumatic)
21 Left-hand bag waste suction tube (VC999 K7A)
22 Electrical connection
23 Compressed air connection
24 Upper sealing bars, cutter blade (VC999 K7A), perforation blade (VC999 K7B), pre-perforation
25 Lower sealing bars
26 Main switch
Cockpit (1)
The cockpit is located directly above the conveyor belt and can be operated from either side of the ma-
chine. It includes all operating elements for operating the Vacuum Packaging Machine.
Programming of packaging cycles is done on the interactive display.
Here, you can also display the individual parameters and edit their values. A keyboard appears for en-
tering data.
Vacuum generation with vacuum chamber
The vacuum generation unit and vacuum chamber form the central sub-assembly of the Vacuum Pack-
aging Machine. One or more vacuum pumps can be provided for vacuum generation to meet customer
requirements.
The vacuum chamber consists of the vacuum chamber lid (15) and the vacuum chamber bottom (13). A
lifting mechanism lowers the vacuum chamber lid onto the vacuum chamber bottom and raises it again
after vacuuming.

Vacuum Packaging Machine VC999 K7
Description of the machine
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Pre-perforation (24)
The pre-perforation ensures that unusually long bags which protrude from the vacuum chamber lid can
be easily processed. Due to the spring-loaded mechanism on both sides of the vacuum chamber lid, the
bag is pressed together by hold-down clamps when closing the vacuum chamber. The perforation blade
is subsequently released and pressed down onto the bag in the vacuum chamber. This results in small
bag perforations via which vacuum can be created in the bag.
Sealing device (24) with cutter blade (VC999 K7A) or perforation blade (VC999 K7B)
The sealing device consists of two sealing bars in the vacuum chamber lid and two sealing bars in the
vacuum chamber bottom. When the vacuum chamber closes, the upper and lower sealing bars are po-
sitioned opposite each other and pressed together for sealing.
The bag waste is either cut off by a cutter blade (VC999 K7A) or perforated by a perforation blade
(VC999 K7B) during the sealing process. The blades are located in the vacuum chamber lid next to the
sealing bars.
The bags are perforated (VC999 K7B) to ensure that the bag waste can be removed manually once the
bag has left the machine.
Conveyor belt (5)
The conveyor belt runs through the entire Vacuum Packaging Machine. A short run-out roller track (17)
at the end of this belt enables optional conveyor devices to be added on as required by the customer.
The integral initiator ensures that within a packaging cycle the conveyor belt moves far enough for the
packaging product laid between the markings (2, 4) on the feed belt to come to a stop exactly in the va-
cuum chamber.
The conveyor belt can be slackened by means of the tension lever (6) for cleaning and opened for dis-
mantling by removing the plastic wire on the cord at the joint.
Power supply (20)
The electrical (22) and compressed air (23) connections are located inside the machine on the rear wall
of the power supply cabinet (20). The power cable and the compressed air line are fed into the cabinet
from below. The cabinet also contains the compressed air maintenance unit.

Vacuum Packaging Machine VC999 K7
Description of the machine
Page 18/121 Art.-No. 592.016 2008-11-26
Electrical cabinet with control unit (10)
Legend
1 Circuit breaker
2 Power supply unit 24V
3 Temperature control device
4 Contactor
5 Line filter
6 Frequency converter
7 Safety cutout
8 PLC converter
9 PLC control
10 Microfuse FST 6.3 AT
11 2 microsfuses FST 3.15 AT
12 Buffer battery PLC
Fig. 3/2
The control unit consists of the operating elements fitted in the cockpit and the electronic power element
in the electrical cabinet (Fig. 3/1, Pos. 10). The control unit also receives limit switch and vacuum mea-
surement inputs.
Bag waste suction unit (VC999 K7A)
The bag waste suction unit consists of the bag waste suction
tubes at the Vacuum Packaging Machine (Fig. 3/1, Pos. 12, 21)
as well as the suction blower (a) and the bag waste separator
(b).
Fig. 3/3

Vacuum Packaging Machine VC999 K7
Description of the machine
2008-11-26 Art.-No. 592.016 Page 19/121
3.2 Principle of operation
The product for packaging is put in a sealable plastic bag and fed in by conveyor belt from the work-
surface to the Vacuum Packaging Machine.
In the Vacuum Packaging Machine, the vacuum chamber lid lowers over the bag containing the product
for packaging and seals it with an airtight seal.
This produces a vacuum chamber. Unusually long bag parts which protrude from the vacuum chamber
are pre-perforated. The air is subsequently removed from the vacuum chamber and thus also from the
bag via the perforation. As soon as a preset vacuum has been achieved, the bag is sealed and the bag
waste in the vacuum chamber is either cut off by a cutter blade (VC999 K7A) or perforated by a perfora-
tion blade (VC999 K7B) outside the sealing zone.
When the vacuum chamber is then vented, the vacuum-pack bag clings closely to the product. The cut
off bag waste is automatically removed by the bag waste suction unit (VC999 K7A) when the vacuum
chamber is opened. If the Vacuum Packaging Machine is not equipped with a bag waste suction unit
(VC999 K7B), the perforated bag waste can be removed manually.
As vacuum generation and sealing of the bags take place, further bags can be placed on the conveyor
belt. This means that as the packed bags are ejected, new bags are being introduced into the machine
at the same time, so that the next packaging cycle can be started without any delay.
In order to make full use of the machine capabilities, the number of bags placed on the conveyor belt in
any one cycle should be the capacity between the markings (Fig. 3/1, pos. 2 and 4) on the work-
surface.

Vacuum Packaging Machine VC999 K7
Description of the machine
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3.3 Technical data
3.3.1 Dimensions
Fig. 3/4
A Operator position B Bag waste suction unit (VC999 K7A)
Vacuum chamber
Max. product height (standard), without filling plate 250 mm
Length 890 mm
Width (sealing bar distance) 630 mm
Sealing bar height (adjustable) 40 or 80 mm
Length 2 x 870 mm
3.3.2 Weight
Machine without pump approx. 850 kg
Weight of rotary slide vacuum pump (300) approx. 220 kg
Weight of roots vacuum pump (W500) approx. 110 kg
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