VEMAG ROBOT HP7C User manual

Vacuum filler
ROBOT HP7C (from 146.0132)
ROBOT HP10C (from 142.1543)
ROBOT HP15C (from 143.1549)
ROBOT HP17C (from 147.1552)
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 modifications
Issue: 02/06
Version: 1.2 EN
© VEMAG Maschinenbau GmbH • Postfach 1620 • D-27266 Verden
Phone: [phone] • Fax: [phone]
e-mail: [email protected]
http://www.vemag.de

Index
i
ROBOT HP7C / HP10C / HP15C / HP17C
© VEMAG 2004
Index
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 ROBOT HP7C / HP10C / HP15C / HP17C 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 Linking gear (optional) 2-3
2.2.6 Controls 2-4
2.2.7 Knee lever 2-7
2.2.8 Step 2-7
2.2.9 Adjustable feet 2-7
2.2.10 Lifting/tipping device (optional) 2-7
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
3.5 Levelling the lifting/tipping device (optional) 3-6
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 filling horn 4-4
4.5 Locking the linking gear (optional) 4-5
4.6 Fitting the linking horn (optional) 4-6
4.7 Setting the vacuum 4-8
4.7.1 Filling raw and cooked sausage 4-8
4.7.2 Filling liquid product (e.g. liver sausage) 4-8
4.8 Fitting the scraper 4-9
4.9 Adjusting the knee lever 4-10

Index
ii © VEMAG 2004
ROBOT HP7C / HP10C / HP15C / HP17C
5. Operation 5-1
5.1 Working with the machine 5-1
5.2 Working with provisional drive 5-4
6. Cleaning 6-1
6.1 General information 6-1
6.2 Removing parts to be cleaned 6-1
6.2.1 Filling horn and filling horn holder 6-1
6.2.2 Linking horn (optional) 6-2
6.2.3 Linking gear (optional) 6-2
6.2.4 Double screws 6-3
6.2.5 Double screw housing 6-3
6.2.6 Hopper 6-6
6.2.7 Scraper 6-7
6.2.8 Vacuum system 6-8
6.3 Cleaning the machine 6-10
6.4 Cleaning schedule 6-11
6.5 Lubrication and assembly 6-12
6.5.1 Hopper 6-12
7. Maintenance 7-1
7.1 General information 7-1
7.2 Grease gun 7-2
7.3 First-time maintenance work 7-2
7.4 Maintenance schedule 7-3
7.5 Daily maintenance 7-4
7.5.1 Feed unit seals (lubrication) 7-4
7.6 Weekly maintenance 7-6
7.6.1 Feed unit drive (lubrication) 7-6
7.6.2 Vacuum pump (air filter and oil level) 7-7
7.7 Monthly maintenance 7-9
7.7.1 Hydraulic drive (oil level) 7-9
7.7.2 Double screw drive (oil level and seals) 7-10
7.8 Quarterly maintenance 7-11
7.8.1 Vacuum pump
(oil change, screens, gas ballast valve) 7-11
7.9 Six-monthly maintenance 7-18
7.9.1 Feed unit seals 7-18
7.10 Annual maintenance 7-19
7.10.1 Hydraulic drive (oil change and filter cartridge) 7-19
7.10.2 Feed unit drive and feed unit seals 7-20
7.10.3 Vacuum pump (air de-oiling element) 7-21

Index
iii
ROBOT HP7C / HP10C / HP15C / HP17C
© VEMAG 2004
7.11 Biennial maintenance 7-22
7.11.1 Double screw drive (oil change) 7-22
8. Troubleshooting 8-1
8.1 General information 8-1
8.2 Troubleshooting table 8-1
9. Appendix 9-1
9.1 General information 9-1
9.2 Technical data ROBOT HP7C / HP10C /
HP15C / HP17C 9-2
9.3 ROBOT HP7C / HP10C / HP15C / HP17C
dimensional drawings 9-3
9.4 Vacuum system 9-4
9.5 Hydraulics plan 9-5
9.6 Electrical control panel 9-7
9.7 Power electronics 9-8
9.8 Lubricants 9-9
9.8.1 Double screw drive 9-9
9.8.2 Hydraulic drive 9-9
9.8.3 Vacuum pump 9-9
9.8.4 Feed unit seals and feed unit drive 9-9
9.8.5 Individual parts 9-9
9.9 Accessories 9-10
9.9.1 Double screw selection 9-10
9.9.2 Filling horn selection 9-11
9.9.3 Linking horns 9-11
9.9.4 Miscellaneous accessories 9-11
9.9.5 Tools 9-12

Index
iv © VEMAG 2004
ROBOT HP7C / HP10C / HP15C / HP17C

0. Foreword
0-1
ROBOT HP7C / HP10C / HP15C / HP17C
© VEMAG 2004
0. Foreword
These operating instructions cover all the information required to operate
the vacuum filler. Two versions of the machine are available:
• ROBOT HP7C / HP10C / HP15C / HP17C in the form of a portioning
machine
• ROBOT HP7C / HP10C / HP15C / HP17C in the form of a portioning
and linking machine
Operating and maintenance instructions for any attachments (optional)
can be found in the appropriate separate operating instructions.
Information on operating the portioning computer can be found in the
appropriate user guide.
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) first, before starting up the
machine. You must follow all safety instructions to prevent injury to people
and damage to the machine.
You must follow all instructions on cleaning (Section 6) and maintenance
(Section 7). This is the only way to ensure reliable operation, high
performance and a long service life of your machine.

0. Foreword
0-2 © VEMAG 2004
ROBOT HP7C / HP10C / HP15C / HP17C

1. Safety instructionsROBOT HP7C / HP10C / HP15C / HP17C
1-1© VEMAG 2004
1. Safety instructions
1.1 Sphere of application
Two versions of the continuous vacuum filler are available:
• ROBOT HP7C / HP10C / HP15C / HP17C in the form of a portioning
machine
• ROBOT HP7C / HP10C / HP15C / HP17C in the form of a portioning
and linking machine
It can also be fitted with special attachments (optional).
1.2 Use in accordance with purpose
The ROBOT HP7C / HP10C / HP15C / HP17C continuous vacuum filler is
designed and built for filling and portioning sausages in natural, collagen
and cellulose casings. Standard sausage meats are suitable as the pro-
duct for filling to make fresh sausage, salamis and boiled sausage. The
filler can also be used for grinding and separating meat for processing.
Other products may only be processed with the express agreement of
VEMAG.
The vacuum filler 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 filler requires ambient temperatures between +0.5 °C and
+25 °C.
The vacuum filler is designed for one operator. The operator must have
been trained on site by VEMAG specialists or one of their representatives.
The vacuum filler may only be cleaned by trained cleaning staff.
The vacuum filler may only be serviced by trained maintenance staff
(fitters or electricians).
The manufacturer’s assembly, commissioning, operating and
maintenance instructions must be followed to satisfy the conditions of
”use in accordance with purpose”.
The ROBOT HP7C / HP10C / HP15C / HP17C continuous vacuum filler is
built in accordance with the state of the art and in the condition in which it
is delivered complies with
• machinery directive 98/37/EC, Annex IIA
• low-voltage directive 79/23/EC
• EMC directive 89/336/EC.
European standard EN 12463 „Filling machines and attachments“, in
particular, was applied.
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 specification.

1. Safety instructions ROBOT HP7C / HP10C / HP15C / HP17C
1-2 © VEMAG 2004
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
followed 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.

1. Safety instructionsROBOT HP7C / HP10C / HP15C / HP17C
1-3© VEMAG 2004
1.4 General safety instructions
• Any person working on or with the machine must have read and
understood these operating instructions, in particular the safety
instructions.
• The machine may be used only by trained and authorised staff.
• Responsibilities during operation must be clearly assigned and
observed.
• 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
maintenance 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 firmly 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 modifications 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.

1. Safety instructions ROBOT HP7C / HP10C / HP15C / HP17C
1-4 © VEMAG 2004
1.5 Special safety instructions
Danger!
To prevent injury, switch off the machine before any work (assembly,
dismantling, 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 filling horn holder or linking
gear (optional) may only be fitted 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, step and filling horn
holder are working properly.
Section 5
If you notice any damage, inform VEMAG Customer Service
immediately.
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
ladder or other aid to get at the hopper of the machine.
Danger!
No-one may stand in the area of the lifting/tipping device (optional). Do
not put any objects in this area. Only trolleys to DIN 9797 with a capacity
of 200 l or 300 l are permitted.

2. DescriptionROBOT HP7C / HP10C / HP15C / HP17C
2-1© VEMAG 2004
2. Description
2.1 Overview ROBOT HP7C / HP10C / HP15C / HP17C
2.2 Brief description
2.2.1 Hopper
The filler is equipped with a hopper for pouring in product for filling. The
hopper is fitted with a safety device which switches off the machine when
the hopper is open. A mirror attached to the hopper allows the contents to
be checked.
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 fitted 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 flange to tip
it over carefully. Do not open the hopper as long as the lifting and tipping
device (optional) is in its top limit position.
1 Hopper
2 Vacuum pot
3 Vacuum display
4 Vacuum control valve
5 Trolley
6 Lifting/tipping device
(optional)
7 Control panel
8 Adjustable feet
9 Step
10 Knee lever
11 Filling horn
12 Locking nut
13 Hopper release
mechanism
14 Mirror
15 Stopper
Fig. 2-1
Machine with filling horn
1
2
3
5
4
6
7
8
9
10
11
12
13
14
15

2. Description ROBOT HP7C / HP10C / HP15C / HP17C
2-2 © VEMAG 2004
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
cleaning.
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
double screws, air being withdrawn from the product by the vacuum
system. The double screws feed until completely empty. The speed of the
double screws and thus the quantity of product portioned can be infinitely
adjusted.
The product for filling 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.
1 Feed screw
2 Spiral stopper
3 Scraper
Fig. 2-2
Feed screw
1
2
3
Fig. 2-3
Double screws

2. DescriptionROBOT HP7C / HP10C / HP15C / HP17C
2-3© VEMAG 2004
2.2.4 Filling horn holder
The machine is fitted with a filling horn holder (1) at the outlet as standard
and this is locked at the outlet by the locking nut (2). The filling horn (3) is
attached to the filling horn holder with the aid of the filling horn nut (4).
The product is ejected through the filling horn by the double screws.
2.2.5 Linking gear (optional)
The linking gear (1) is attached to the housing of the machine with the aid
of two bearing journals (2) and swivelled in front of the outlet. It is locked
in position at the outlet with the locking nut (3) like the filling horn holder.
The linking horn (4) is attached to the linking gear with the aid of linking
nut (5).
Danger!
To prevent injury, do not use linking horns with sprung heads. Use only
completely straight linking horns and check the selected linking horn with
the relevant test program before production starts.
Portioning computer user guide
1 Filling horn holder
2 Locking nut
3 Filling horn
4 Filling horn nut
Fig. 2-4
Machine with filling horn
holder
1
3
4
2
1 Linking gear
2 Bearing journals
3 Locking nut
4 Linking horn
5 Linking nut
Fig. 2-5
Machine with linking gear
(optional)
1
2
3
5
4

2. Description ROBOT HP7C / HP10C / HP15C / HP17C
2-4 © VEMAG 2004
2.2.6 Controls
The main switch (1) which switches the power supply to the machine on
and off can be found on the rear of the machine housing.
Attachments and additional devices (optional) can be connected to the
power supply of the machine via equipment socket (2). Instead of blind
covers (3), further sockets can be provided for supplementary equipment
like coextrusion systems (optional), for example.
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.
1 Main switch
2 Equipment socket
3 Blind cover
Fig. 2-6
Controls
1
2
3
3

2. DescriptionROBOT HP7C / HP10C / HP15C / HP17C
2-5© VEMAG 2004
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)
• UP key (3) for lifting/tipping device (optional)
• STOP key (4) for lifting/tipping device (optional)
• DOWN key (5) for lifting/tipping device (optional)
• Vacuum display (6)
• Vacuum control valve (7)
• Cleaning plug (8) for vacuum line
ON key
This key switches on the drive of the machine.
OFF key
This key switches off the drive of the machine.
UP key (optional)
This key raises the trolley hoist of the lifting/tipping device (optional). In the
top end position above the hopper, the trolley is automatically tipped and
emptied. After 30 seconds have elapsed, the trolley hoist can be lowered
again using the DOWN key. If it is to be lowered before that, the STOP key
has to be pressed first.
1 ON switch
2 OFF switch
3 UP key (optional)
4 STOP key (optional)
5 DOWN key (optional)
6 Vacuum display
7 Vacuum control valve
8 Cleaning plug
Fig. 2-7
Machine control panel
1
6
2
7
3
4
5
8

2. Description ROBOT HP7C / HP10C / HP15C / HP17C
2-6 © VEMAG 2004
STOP key (optional)
This key stops the trolley hoist of the lifting/tipping device (optional).
DOWN key (optional)
This key lowers the trolley hoist of the lifting/tipping device (optional). The
trolley hoist stops automatically as soon as the trolley is 500 mm above
the ground. To move it into its bottom end position, the key must be
pressed again and held down until the final position is reached.
Danger!
When lowering the lifting/tipping device, ensure that there is no-one in this
area. Do not deposit any objects in this area.
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
vacuum control valve. Turning clockwise (+) increases the vacuum,
turning anti-clockwise (-) reduces the vacuum.
The significance of the individual keys of the portioning computer is
described in the relevant user guide.
Portioning computer user guide

2. DescriptionROBOT HP7C / HP10C / HP15C / HP17C
2-7© VEMAG 2004
2.2.7 Knee lever
The filling process is switched on and off using the knee lever. It can be
adjusted to suit the height and location of the operator.
Section 4.9
2.2.8 Step
At the front of the machine is a step which allows the operator to fill the
hopper or get at it for cleaning and maintenance purposes. The step is
fitted with a safety device which switches off the filler as soon as the step
is folded out.
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.
2.2.9 Adjustable feet
To compensate for uneven floors, the machine is fitted 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
2.2.10 Lifting/tipping device (optional)
The lifting/tipping device is designed for trolleys with a capacity of 200 l or
300 l.

2. Description ROBOT HP7C / HP10C / HP15C / HP17C
2-8 © VEMAG 2004