VEMAG HP10E User manual

Vacuum ller
HP10E - Dairy design (from 168.1004)
HP12E - Dairy design (from 168.5003)
HP15E - Dairy design (from 168.2010)
HP20E - Dairy design (from 168.3009)
Operating instructions

The copying, distribution and utilization of this document as well as the
communication of its contents to others without expressed authorization
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or
ornamental design registration.
We reserve the right to make technical modications
Issue: 04/13
Version: 2.4 EN (Original operating instructions)
Software Version:
00.03.505
© VEMAG Maschinenbau GmbH • Postfach 1620 • D-27266 Verden
Phone: [phone] • Fax: [phone]
E-Mail: [email protected]
http://www.vemag.de

HP10E / HP12E / HP15E / HP20E - Dairy design Index
i© VEMAG 2013
Index
Declaration of conformity
0. Foreword 0-1
1. Safety instructions 1-1
1.1 Sphere of application 1-1
1.2 Use in accordance with purpose 1-1
1.3 Explanation of symbols 1-2
1.4 General safety instructions 1-3
1.5 Special safety instructions 1-4
2. Description 2-1
2.1 Overview HP10E / HP12E / HP15E / HP20E 2-1
2.2 Brief description 2-1
2.2.1 Hopper 2-1
2.2.2 Feed screw 2-2
2.2.3 Double screws 2-2
2.2.4 Filling horn holder 2-3
2.2.5 Controls 2-4
2.2.6 Knee lever 2-6
2.2.7 Step 2-6
2.2.8 Adjustable feet 2-6
2.2.9 Front door 2-6
3. Installation and commissioning 3-1
3.1 Transporting the machine 3-1
3.2 Setting up the machine 3-3
3.3 Electrical connection 3-4
3.4 Checking direction of rotation 3-5
4. Setting up 4-1
4.1 General information 4-1
4.2 Fitting the double screw housing 4-1
4.3 Fitting the double screws 4-3
4.4 Fitting the lling horn holder 4-4
4.5 Setting the vacuum 4-5
4.5.1 Filling liquid products 4-5
4.6 Fitting the scraper 4-6
4.7 Adjusting the knee lever 4-7
5. Operation 5-1
5.1 Working with the machine 5-1
5.2 Working with provisional drive 5-3
6. Graphical control 6-1
6.1 Control panel 6-3
6.2 Screen 6-5
6.2.1 Header 6-5
6.2.2 Program and mode 6-5
6.2.3 Basic parameters 6-5
6.2.4 Supplementary parameters 6-5
6.2.5 Footer 6-5
6.3 Keypad 6-7
6.3.1 Numerical keypad 6-7
6.3.2 Key C (Cancel) 6-7
6.3.3 Screen up/down keys 6-7
6.3.4 Padlock key 6-7
6.3.5 Plus/minus keys 6-7
6.3.6 Cursor keys 6-7
6.3.7 Enter key 6-7
6.4 Status and error messages 6-8
6.5 Principles of operation 6-9
6.5.1 Select and edit programs 6-11
6.5.2 Importing and exporting programs using a USB stick 6-13
6.5.3 Select mode group, mode and view 6-15
6.5.4 Select start/stop method 6-17
6.5.5 Make settings (language, date/time, password) 6-19
6.5.6 Set up userkey 6-21
6.6. Mode groups, modes, start/stop methods and parameters 6-23
6.6.1 Mode groups, modes and views 6-24

HP10E / HP12E / HP15E / HP20E - Dairy designIndex
ii © VEMAG 2013
6.6.2 Start/stop methods 6-24
6.6.2.1 Knee I 6-24
6.6.2.2 Knee II 6-24
6.6.2.3 Remote end 6-24
6.6.2.4 Remote stop 6-24
6.6.2.5 Remote II 6-24
6.6.3 Basic parameters 6-25
6.6.3.1 Weight 6-25
6.6.3.2 First portion 6-26
6.6.3.3 Total weight (only for weight groups) 6-26
6.6.3.4 Pause 6-27
6.6.3.5 Linking/clip time/knife/output signal 6-27
6.6.3.6 Speed 6-28
6.6.3.7 Individual speed 6-29
6.6.3.8 Back suction 6-29
6.6.3.9 LPG belt speed 6-29
6.6.3.10 Portions per minute 6-30
6.6.3.11 Pressure control 6-30
6.6.4 Supplementary parameters 6-31
General applications 6-31
6.6.4.1 Speed of feed unit screw 6-31
6.6.4.2 Feed unit run-on 6-31
6.6.4.3 First link 6-31
6.6.4.4 Link offset/clip offset/knife offset (minced meat line) 6-32
6.6.4.5 Select double screw (HP series only) 6-32
6.6.4.6 Select pumping system 6-33
6.6.4.7 Stop counter 6-33
6.6.4.8 Soft start-up 6-33
6.6.4.9 Metal detection 6-34
6.6.4.10 Vacuum control 6-34
6.6.4.11 Synchronizing the machine using an external signal 6-35
6.6.4.12 Linking support 6-35
Working with sausage lines 6-36
6.6.4.13 Product type 6-36
6.6.4.14 Last portion 6-36
6.6.4.15 Split casing tolerance 6-36
6.6.4.16 Remaining portions 6-37
6.6.4.17 Run-on 6-37
6.6.4.18 Calibre and sausage length 6-38
6.6.4.19 Portion length/rst portion length 6-38
6.6.4.20 Gap length 6-38
6.6.4.21 Conveyor belt calibre/discharge conveyor calibre 6-39
6.6.4.22 Cut quantity 6-39
6.6.4.23 Link point stretch/cut distance 6-39
Working with the hanging machine 6-40
6.6.4.24 Calibre and sausage length 6-40
6.6.4.25 Distance from LPV 802 6-40
6.6.4.26 Sausages before rst hook 6-40
6.6.4.27 Sausages on last hook 6-41
6.6.4.28 Sausages per hook 6-41
6.6.4.29 Hooks per stick 6-42
6.6.4.30 Sausages per stick 6-42
6.6.4.31 Catch position 6-42
6.6.4.32 End of stick 6-43
6.6.4.33 Stick restart 6-43
6.6.4.34 End of portioning (LPV 802 and DHV 841 only) 6-44
6.6.4.35 Extra hook 6-44
6.6.4.36 Permitted deviation 6-44
6.6.4.37 Last hook later 6-45
Working with the automatic separation valve 6-46
6.6.4.38 Separation valve 6-46
6.6.4.39 Separation interval 6-46
6.6.4.40 Valve offset 6-46
6.6.4.41 Separation valve open 6-47
6.6.4.42 Separation valve closed 6-47

HP10E / HP12E / HP15E / HP20E - Dairy design Index
iii© VEMAG 2013
Working with the minced meat line and forming machine 6-48
6.6.4.43 Weight groups 6-48
6.6.4.44 Group position 6-48
6.6.4.45 Group portions 6-49
6.6.4.46 Group pause 6-49
6.6.4.47 Belt control (analog output 1) 6-50
6.6.4.48 Belt control (analog output 2) 6-50
Working with the scale 6-51
6.6.4.49 Number of samples (VEMAG Scale 877) 6-51
6.6.4.50 Sample interval (VEMAG Waage 877) 6-51
6.6.4.51 Tendency control (e.g. Process Check) 6-51
Working with special devices 6-52
6.6.4.52 Casing pusher 6-52
6.6.4.53 Pushback 6-52
6.6.4.54 Type of special control 6-53
6.6.4.55 Portion delay 6-53
6.6.4.56 Knife (cutter) 6-54
6.6.4.57 Maximum lling pressure (pressure monitoring
on grinding system) 6-54
6.6.4.58 Maximum temperature (temperature monitoring
for the grinding system) 6-55
6.6.4.59 Hopper mode 6-55
6.6.4.60 Hopper vacuum 6-56
6.6.4.61 Hopper level 6-56
6.6.4.62 Hopper level (optional) 6-57
6.6.4.63 Speed limit 6-58
6.6.4.64 External portioning 6-58
6.7 Congurations (operating mode settings) 6-61
6.8 Service 6-63
6.8.1 Service pages 6-63
6.9 Messages 6-64
6.9.1 List of messages 6-64
7. Cleaning 7-1
7.1 General information 7-1
7.2 Removing parts to be cleaned 7-1
7.2.1 Filling horn holder 7-1
7.2.2 Double screws 7-2
7.2.3 Double screw housing 7-2
7.2.4 Hopper 7-5
7.2.5 Scraper 7-8
7.2.6 Vacuum system 7-9
7.3 Cleaning the machine 7-11
7.4 Cleaning schedule 7-12
7.4.1 General recommendations 7-12
7.4.2 Chlorine-free alkaline cleaning agents 7-12
7.4.3 Chlorine-containing alkaline cleaning agents 7-14
7.4.4 Specialist cleaning agent for machine interior 7-15
7.5 Lubrication and assembly 7-16
7.5.1 Hopper 7-16
8. Maintenance 8-1
8.1 General information 8-1
8.2 Grease gun 8-5
8.3 First-time maintenance work 8-6
8.4 Maintenance schedule 8-7
8.5 Daily maintenance 8-8
8.5.1 Feed unit seals (lubrication) 8-8
8.5.2 Sliding ring (wear) 8-10
8.6 Weekly maintenance 8-11
8.6.1 Feed unit drive (lubrication) 8-11
8.6.2 Intake (air lter) 8-12
8.6.3 Vacuum pump (air lter) 8-13
8.6.4 Vacuum pump 8-13
8.7 Monthly maintenance 8-14
8.7.1 Double screw drive (oil level and seals) 8-14
8.7.2 Vacuum pump 8-14

HP10E / HP12E / HP15E / HP20E - Dairy designIndex
iv © VEMAG 2013
8.8 Six-monthly maintenance 8-15
8.8.1 Feed unit seals 8-15
8.8.2 Vacuum pump 8-15
8.9 Annual maintenance 8-16
8.9.1 Feed unit drive and feed unit seals 8-16
8.9.2 Vacuum pump 8-16
8.10 Biennial maintenance 8-18
8.10.1 Double screw drive (oil change) 8-18
8.11 Three-yearly maintenance 8-19
8.11.1 Feed drive (oil change) 8-19
9. Troubleshooting 9-1
9.1 General information 9-1
9.2 Troubleshooting table 9-1
10. Appendix 10-1
10.1 General information 10-1
10.2 Technical data HP10E / HP12E / HP15E / HP20E 10-2
10.3 Dimensional drawings HP10E / HP12E / HP15E / HP20E 10-3
10.4 Lubricants 10-4
10.4.1 Double screw drive 10-4
10.4.2 Feed drive 10-4
10.4.3 Vacuum pump 10-4
10.4.4 Feed unit seals and feed unit drive 10-4
10.4.5 Individual parts 10-4
10.5 Accessories 10-5
10.5.1 Miscellaneous accessories 10-5
10.5.2 Tools 10-5
10.6 Disposal 10-6
10.6.1 General information 10-6
10.6.2 Proper disposal 10-6

HP10E / HP12E / HP15E / HP20E - Dairy design Declaration of conformity
© VEMAG 2013
Declaration of conformity
reecting the intention of EC Machinery Directive 2006/42/EC, Annex IIA
We
VEMAG Maschinenbau GmbH
Weserstraße 32
27283 Verden (Aller)
hereby declare that the
Continuous vacuum ller
HP10E type 168
HP12E type 168
HP15E type 168
HP20E type 168
Machine no. 168.xxxx
complies with all of the relevant provisions of the EC Machinery Directive 2006/42/EC.
Particular consideration was given to
the standard EN 12463:2004(D) Food Processing Machinery - Filling machines and auxiliary machines -
Safety and hygiene requirements
The notied German authority
Prüf- und Zertizierungsstelle im BG-PRÜFZERT
Fachausschuß Fleischwirtschaft
Lortzingstraße 2, 55127 Mainz
performed a prototype test for this series of llers. The number of the inspection document issued on
29.12.2009 is FW 09117.
Authorised documentation representative:
Dr. Michael Gerretz
Tel.: [phone]
Fax: [phone]
[email protected]

HP10E / HP12E / HP15E / HP20E - Dairy design 0. Foreword
0-1© VEMAG 2013
0. Foreword
These operating instructions cover all the information required to operate
the vacuum ller. The machine is available as:
• HP10E / HP12E / HP15E / HP20E in the form of a portioning machine
Operating and maintenance instructions for any attachments (optional)
can be found in the appropriate separate operating instructions.
If you have any questions which cannot be answered by this manual,
please contact VEMAG Customer Service at any time. Our staff will be
please to hear your suggestions.
Read the safety instructions (Section 1) rst, before starting up the ma-
chine. You must follow all safety instructions to prevent injury to people
and damage to the machine.
You must follow all instructions on cleaning (Section 7) and maintenance
(Section 8). This is the only way to ensure reliable operation, high perfor-
mance and a long service life of your machine.

HP10E / HP12E / HP15E / HP20E - Dairy design0. Foreword
0-2 © VEMAG 2013

HP10E / HP12E / HP15E / HP20E - Dairy design 1. Safety instructions
1-1© VEMAG 2013
1. Safety instructions
1.1 Sphere of application
The machine is available as:
• HP10E / HP12E / HP15E / HP20E in the form of a portioning machine
It can also be tted with special attachments (optional).
1.2 Use in accordance with purpose
The HP10E / HP12E / HP15E / HP20E continuous vacuum ller is desi-
gned and built for lling and portioning viscous products.Other products
may only be processed with the express agreement of VEMAG.
The vacuum ller is designed for industrial applications.
The vacuum ller may not be used in an explosive atmosphere.
Raw materials may be processed at a temperature of between -4 °C and
+ 50 °C.
The vacuum ller requires ambient temperatures between +0.5 °C and
+25 °C.
The vacuum ller is designed for one operator. The operator must have
been trained on site by VEMAG specialists or one of their representa-
tives.
The vacuum ller may only be cleaned by trained cleaning staff.
The vacuum ller may only be serviced by trained maintenance staff
(tters or electricians).
The manufacturer’s assembly, commissioning, operating and mainte-
nance instructions must be followed to satisfy the conditions of ”use in
accordance with purpose”.
The HP10E / HP12E / HP15E / HP20E continuous vacuum ller is built
in accordance with the state of the art and, in the condition in which it is
delivered, complies with machinery directive 2006/42/EC.
Nevertheless, the machine may present residual hazards if it:
• is not used in accordance with purpose
• is not used in accordance with these operating instructions,
• is used by untrained staff
• is not carefully cleaned and maintained to specication.

HP10E / HP12E / HP15E / HP20E - Dairy design1. Safety instructions
1-2 © VEMAG 2013
1.3 Explanation of symbols
The following symbols appear in these operating instructions, indicating
residual hazards when operating the machine or referring the reader to
other important information.
Danger!
This warning symbol refers to important instructions which must be follo-
wed to prevent faulty operation which could pose a threat to human life or
lead to injury.
Warning!
This warning symbol refers to important instructions which must be
followed to prevent faulty operation which could result in damage to the
machine or installation or which could jeopardise production.
This arrow symbol indicates additional information at another point in the
manual or in other documentation.

HP10E / HP12E / HP15E / HP20E - Dairy design 1. Safety instructions
1-3© VEMAG 2013
1.4 General safety instructions
• Any person working on or with the machine must have read and un-
derstood these operating instructions, in particular the safety instruc-
tions.
• The machine may be used only by trained and authorised staff.
• Responsibilities during operation must be clearly assigned and obser-
ved.
• The machine may only be serviced by trained staff authorized to do
so.
• The machine may only be used if it is in perfect working order. In the
event of changes, such as loss of oil or unusual noises starting, the
machine should be stopped immediately and your in-house mainte-
nance department or VEMAG Customer Service informed.
• The machine may not be operated without the housing cover.
• Route mains cables and data cables (e.g. remote control cable) so as
to avoid tripping hazards.
• Sockets which are not being used must be rmly sealed with the
appropriate protective cap to prevent the penetration of moisture.
Corrosion at the contacts can lead to switching errors.
• It is prohibited to remove, switch off or override safety devices. In the
event of damage to safety devices, inform VEMAG Customer Service
immediately.
• Warning signs on the machine may not be removed or painted over.
• Conversions, attachments and other modications to the machine not
approved by VEMAG are not permitted.
• In all cases, generally-applicable and in-house safety and accident
prevention regulations apply in addition to these safety instructions.

HP10E / HP12E / HP15E / HP20E - Dairy design1. Safety instructions
1-4 © VEMAG 2013
1.5 Special safety instructions
Danger!
To prevent injury, switch off the machine before any work (assembly, dis-
mantling, cleaning, maintenance, repair). Then switch off the main switch
to disconnect the machine from the mains.
Danger!
To prevent injury in the area of the double screws, switch off the machine
before undoing the locking nut. Then switch off the main switch to dis-
connect the machine from the mains. The lling horn holder may only be
tted or removed with the machine switched off.
Before starting up the machine, always perform the following steps:
• Check that the machine is in proper condition. Leaking oil indicates
leaks which must be eliminated immediately. In this case, inform your
in-house maintenance department or VEMAG Customer Service
immediately.
• Check that the safety devices on the hopper and lling horn holder are
working properly.
Section 5
If you notice any damage, inform VEMAG Customer Service immedi-
ately.
Danger!
To prevent injury, switch off the machine before doing any work on the
hopper. Then switch off the main switch to disconnect the machine from
the mains. Do not climb onto the machine to check the hopper/hopper
contents, use only the step provided. Under no circumstances use a lad-
der or other aid to get at the hopper of the machine.

HP10E / HP12E / HP15E / HP20E - Dairy design 2. Description
2-1© VEMAG 2013
2. Description
2.1 Overview HP10E / HP12E / HP15E / HP20E
1 Hopper
2 Vacuum pot
3 Vacuum display
4 Vacuum control valve
5 Control panel
6 Adjustable feet
7 Step
8 Knee lever
9 Locking nut
10
Hopper release mechanism
11 Cover
Fig. 2-1
Machine with lling horn
holder
1
2
4
3
5
7
8
6
9
10
11
2.2 Brief description
2.2.1 Hopper
The ller is equipped with a hopper for pouring in product for lling. The
hopper is tted with a safety device which switches off the machine when
the hopper is open.
Danger!
To prevent injury, switch off the machine before doing any work on the
hopper. Then switch off the main switch to disconnect the machine from
the mains. Do not climb onto the machine to check the hopper/hopper
contents or for cleaning and maintenance purposes, use only the step
provided. Under no circumstances use a ladder or other aid to get at the
hopper of the machine.
The hopper is tted with cushioning as a partial counterweight to prevent
the hopper falling shut under its own weight.
Danger!
Proceed especially carefully when opening and closing the hopper to
prevent injury (risk of crushing). Grasp the hopper only at the ange to tip
it over carefully. Open the cover only after the hopper has been opened.

HP10E / HP12E / HP15E / HP20E - Dairy design2. Description
2-2 © VEMAG 2013
2.2.2 Feed screw
The product is compressed in the hopper by the feed screw (1) and fed to
the thread of the double screws with the aid of the vacuum. Spiral stopper
(2) improves product feed. The scraper (3) attached to the feed screw
completely empties the hopper. The scraper is easy to remove for clea-
ning.
1 Feed screw
2 Spiral stopper
3 Scraper
Fig. 2-2
Feed screw
1
2
3
2.2.3 Double screws
The double screws ensure that the product is conveyed gently and evenly
to the outlet. The same volume is conveyed with each rotation of the dou-
ble screws. In this process, the proportion of air in the product for lling is
reduced by the vacuum applied. The double screws feed until completely
empty. The speed of the double screws and thus the quantity of product
portioned can be innitely adjusted.
The product for lling can be portioned either continuously or in individual
portions. If portioning individually, the number of double screw rotations is
a measure of the weight of the individual portion. Individual portions can
be linked in the pauses between individual portions.
Fig. 2-3
Double screws

HP10E / HP12E / HP15E / HP20E - Dairy design 2. Description
2-3© VEMAG 2013
2.2.4 Filling horn holder
The machine is tted with a lling horn holder (1) at the outlet as standard
and this is locked at the outlet by the locking nut (2). Further attachments
(optional) can be connected to the lling horn holder. The product is
ejected through the lling horn holder by the double screws.
1 Filling horn holder
2 Locking nut
Fig. 2-4
Machine with lling horn
holder
1
2
Optional attachments are described separately
Operating instructions attachment (optional)

HP10E / HP12E / HP15E / HP20E - Dairy design2. Description
2-4 © VEMAG 2013
2.2.5 Controls
The controls on the rear of the machine are protected by a cover (1)
which is latched with the aid of a toggle (2).
1 Cover
2 Toggle
Fig. 2-5
Controls
1
2
Behind the cover is main switch (1) which is used to switch the power
supply to the machine on and off.
Attachments and additional devices (optional) can be connected to the
power supply of the machine via equipment socket (2). Instead of blind
covers, further sockets can be provided for supplementary equipment like
coextrusion systems (optional), for example.
1 Main switch
2 Equipment socket
3 Compressed air con-
nection for automatic
separation valve
(optional)
4 Pressure monitoring
for separation grinder
982 or separation
attachment 801
(optional)
Fig. 2-6
Controls
1
2
4
3
Warning!
Always seal off unused sockets with the appropriate protective cap to
prevent moisture and dirt penetrating. Corrosion on the contacts can lead
to switching faults.

HP10E / HP12E / HP15E / HP20E - Dairy design 2. Description
2-5© VEMAG 2013
The following controls are arranged on the control panel on the front of
the machine next to the portioning computer:
• ON switch (1)
• OFF switch (2)
• Vacuum display (3)
• Vacuum control valve (4)
1 ON switch
2 OFF switch
3 Vacuum display
4 Vacuum control valve
Fig. 2-7
Machine control panel
1
2
3
4
ON key
This key switches on the drive of the machine.
OFF key
This key switches off the drive of the machine.
Vacuum display
The vacuum set by the vacuum control valve can be read off in per cent
(0 - 100 %) at the vacuum display.
Vacuum control valve
The desired vacuum for evacuating the product can be set using the va-
cuum control valve. Turning clockwise (+) increases the vacuum, turning
anti-clockwise (-) reduces the vacuum.

HP10E / HP12E / HP15E / HP20E - Dairy design2. Description
2-6 © VEMAG 2013
2.2.6 Knee lever
The lling process is switched on and off using the knee lever. It can be
adjusted to suit the height and location of the operator.
Section 4.7
2.2.7 Step
At the front of the machine is a step which allows the operator to ll the
hopper or get at it for cleaning and maintenance purposes.
Danger!
There is a risk of crushing when folding the step in and out. Proceed with
extreme caution when folding the step in and out to prevent injury.
2.2.8 Adjustable feet
To compensate for uneven oors, the machine is tted with adjustable
feet. The height of the machine can be adjusted by up to 80 mm (outlet
height 1,000 mm to 1,080 mm).
Section 3.2
2.2.9 Front door
The front door of the machine can be swung right open for maintenance
work.