Henkelman Marlin 52 Manual

Vacuum Packaging Machine

Marlin, Falcon, Polar

User Manual

Art No. 0895111

Original Instructions for Use

© Henkelman 2017-2018

• The machine is not suitable for the packaging of toxic, corrosive, irritant or potentially explosive materials.

•All persons responsible for the operation of this machine must at least fully read and understand the chapters about the operation and safety provided in these operating instructions.

•All persons responsible for the assembly, installation, maintenance and/or repairs must fully read and understand these operating instructions.

•The user is at all times responsible for the interpretation and use of this manual. Contact the owner or the manager in case of questions or doubts about the correct interpretation.

•This manual should be kept near the machine and should be within reach for its users.

•All major maintenance work, modifications to the machine and observations must be kept in a logbook; see Logbook on page 75.

•Modifications to the installation/machine are not allowed without the prior written consent of the supplier. Such modifications will invalidate the ETL Certification.

•For specific maintenance work not included in this manual, please contact the supplier.

•Comply with the safety requirements as set out in Safety at all times.

•The correct operation and safety of the system can only be guaranteed if the recommended maintenance is performed on time and properly.

•Illustrations shown may differ from your machine.

Copyright © Henkelman BV / Henkelman Inc. 2017-2018

Henkelman BV / Henkelman Inc. reserves the right to change specifications and/or spare parts without prior notice.

The content of this user manual may also be changed without prior notice.

For information about settings, maintenance and repairs not provided for in this user manual, please contact the technical department of your supplier.

Henkelman BV / Henkelman Inc. accepts no liability for damage and/or problems arising from the use of spare parts not supplied by Henkelman BV / Henkelman Inc..

This user manual has been compiled with all possible care. Henkelman BV / Henkelman Inc. assumes no responsibility for any errors in this manual and/or the consequences of an erroneous interpretation of the instructions.

All rights reserved. No part of this publication may be reproduced, stored in computerised databases, or made public, in any form or by any means, either electronic, mechanical, through photocopying, recording or otherwise, without the prior written consent of Henkelman BV / Henkelman Inc.. This also applies to the associated drawings and diagrams.

Contents
List of Figures.................................................................................................................................		6
1 Preamble.......................................................................................................................................		7
2 Safety.............................................................................................................................................		8
2.1	List of the Symbols Used in this Manual...............................................................................	8
2.2	Pictograms on the Machine...................................................................................................	8
2.3	General Warnings..................................................................................................................	9
2.4	Warnings During Use...........................................................................................................	10
2.5	Warnings for Operating Personnel.......................................................................................	11
3 Introduction.................................................................................................................................		12
4 Description of the Machine.......................................................................................................		13
4.1	Overview of the Main Components......................................................................................	13
4.2	Description of the Packaging Process/Machine Functions..................................................	14
4.2.1 Packaging Process/Machine Functions........................................................................		14
4.2.2 General Functions........................................................................................................		18
4.3	Sealing System....................................................................................................................	19
4.4	Vacuum Pump......................................................................................................................	20
4.5	Electrical Installation.............................................................................................................	20
5 Installation...................................................................................................................................		23
5.1	Transportation and Installation.............................................................................................	23
5.2	Connecting the Machine......................................................................................................	23
5.3	Prior to the First Use...........................................................................................................	24
6 Operation.....................................................................................................................................		26
6.1	Operating Elements of the 10-Programme Control System.................................................	26
6.2	Operating Elements of the Advanced Control System (ACS)..............................................	27
6.2.1 Changing the ACS Settings.........................................................................................		28
6.2.2 Importing/Exporting Data..............................................................................................		31
6.2.3 Data Log ID..................................................................................................................		31
	6.2.3.1 Setting and Using the Data Log ID......................................................................	31
	6.2.3.2 Exporting Data Log..............................................................................................	32
6.3	Starting the Machine............................................................................................................	33
6.4	Starting the Packaging Cycle...............................................................................................	33
6.5	Proceeding to the Next Step in the Cycle...........................................................................	33
6.6	Terminating a Programme....................................................................................................	34
6.7	Changing the Programme Settings......................................................................................	34
6.7.1 10-Programme Control System....................................................................................		34
	6.7.1.1 Vacuum.................................................................................................................	34
	6.7.1.2 Vacuum (automatic)..............................................................................................	35
	6.7.1.3 Vacuum+ (optional)...............................................................................................	35
	Contents	3

6.7.1.4 Gas (optional).......................................................................................................	35
6.7.1.5 Gas+ (optional).....................................................................................................	36
6.7.1.6 Liquid Control (optional).......................................................................................	36
6.7.1.7 Liquid Control+ (optional).....................................................................................	37
6.7.1.8 Red Meat (optional)..............................................................................................	37
6.7.1.9 Multi-Cycle Vacuum (optional)..............................................................................	37
6.7.1.10 Seal.....................................................................................................................	38
6.7.1.11 Soft-Air (optional for the Falcon)........................................................................	38
6.7.1.12 External Vacuum (optional)................................................................................	39
6.7.1.13 Sleeper Option....................................................................................................	39
6.7.2 Advanced Control System (ACS).................................................................................	40
6.7.2.1 Programming the ACS Control Using the PC......................................................	41
6.7.2.2 Functions..............................................................................................................	41
6.7.2.3 Vacuum.................................................................................................................	41
6.7.2.4 Vacuum (automatic)..............................................................................................	42
6.7.2.5 Vacuum+ (optional)...............................................................................................	42
6.7.2.6 Gas (optional).......................................................................................................	42
6.7.2.7 Gas+ (optional).....................................................................................................	43
6.7.2.8 Liquid Control (optional).......................................................................................	43
6.7.2.9 Liquid Control+ (optional).....................................................................................	44
6.7.2.10 Red Meat (optional)............................................................................................	44
6.7.2.11 Sequential Vacuum (optional).............................................................................	44
6.7.2.12 Marinating (optional)...........................................................................................	45
6.7.2.13 Tenderising (optional).........................................................................................	45
6.7.2.14 Seal.....................................................................................................................	46
6.7.2.15 Soft-Air (optional for the Falcon)........................................................................	46
6.7.2.16 External Vacuum (optional)................................................................................	47
6.7.2.17 Sleeper Option....................................................................................................	47
6.7.2.18 Dealer Information..............................................................................................	47
6.8 Guideline for Function Values..............................................................................................	48
6.9 Printer (ACS only)................................................................................................................	50
6.9.1 Connecting a Printer....................................................................................................	50
6.9.2 Creating a Label...........................................................................................................	51
6.10 Automatic lid (optional on Polar 2-85 and 2-95)................................................................	51
6.10.1 Operating the automatic lid........................................................................................	53
6.10.2 Restarting the automatic lid after an emergency.......................................................	53
7 Maintenance................................................................................................................................	54
7.1 Maintenance Schedule.........................................................................................................	54
7.2 Cleaning the Machine..........................................................................................................	55
7.3 Running the Pump Cleaning Programme............................................................................	55
7.4 Removing Oil, Replacing Oil Filter, Refilling Oil...................................................................	55
7.5 Replacing the Oil Exhaust Filter..........................................................................................	56
7.5.1 Pump 76 m3/2684 cf/h - 360 m3/12713 cf/h................................................................	57
7.6 Replacing the Sealing Wire.................................................................................................	57
7.7 Replacing the Silicone Rubber of the Silicone Holders.......................................................	59
7.8 Replacing the Lid Gasket.....................................................................................................	60

Contents 4

7.9 Inspecting the Lid Springs...................................................................................................		61
8 Troubleshooting.........................................................................................................................		62
9 Disposal.......................................................................................................................................		64
10 Appendices...............................................................................................................................		65
10.1	Technical Data....................................................................................................................	65
10.1.1 Technical Data Marlin.................................................................................................		65
10.1.2 Technical Data Falcon................................................................................................		66
10.1.3 Technical Data Polar..................................................................................................		68
10.2	Example Programmes........................................................................................................	72
10.3	Logbook..............................................................................................................................	75
10.4 EC Declaration of Conformity............................................................................................		77
10.5	Replacing a Printer Roll.....................................................................................................	78
10.6	Aligning the Printer.............................................................................................................	79

Contents 5

List of Figures
Figure 1: Overview of the Main Components.................................................................................	13
Figure 2: Overview of the Sealing System (Including Sealing Cylinder).........................................	19
Figure 3: Overview of the Sealing System (Including Seal Bag)....................................................	19
Figure 4: Overview of the Pump (75 m3/h / 2780 cf/h)...................................................................	20
Figure 5: Overview of the Electrical Installation..............................................................................	21
Figure 6: Direction of Rotation of the Vacuum Pump.....................................................................	24
Figure 7: Hose connection for compressed air...............................................................................	24
Figure 8: Control Panel of the 10-Programme Control System......................................................	26
Figure 9: Control Panel of the Advanced Control System (ACS)....................................................	27
Figure 10: Possible Display Modes.................................................................................................	28
Figure 11: Possible Display Modes.................................................................................................	28
Figure 12: Overview of the Menus..................................................................................................	30
Figure 13: Example of an Exported Data Log................................................................................	32
Figure 14: External Vacuum Adapter Set (10-Programme Control System)...................................	39
Figure 15: Screenshot of the navigation mode and the operating buttons of the ACS....................	40
Figure 16: External Vacuum Adapter Set (ACS)............................................................................	47
Figure 17: Vapour Pressure Curve of Water..................................................................................	50
Figure 18: Foot switch.....................................................................................................................	52
Figure 19: Emergency stop.............................................................................................................	52
Figure 20: Safety bumper................................................................................................................	52
Figure 21: Reset button..................................................................................................................	53
Figure 22: Automatic lid switch.......................................................................................................	53
Figure 23: Replacing the Oil Exhaust Filter (Pump 76 m3/2684 cf/h - 360 m3/12713 cf/h)............	57
Figure 24: Removing the Sealing Bar (Plastic Lid).........................................................................	58
Figure 25: Removing the Sealing Bar (Metal Lid)..........................................................................	58
Figure 26: Replacing the Sealing Wire...........................................................................................	58
Figure 27: Replacing the Silicone Rubber of the Silicone Holders.................................................	59
Figure 28: Replacing the Lid Gasket..............................................................................................	60
Figure 29: Replacing the Printer Roll.............................................................................................	78
Figure 30: Aligning the Printer........................................................................................................	79
Figure 31: Printing the First Label..................................................................................................	79

List of Figures 6

1 Preamble

This is the manual for your Henkelman vacuum packaging machine. This manual is intended for anyone who works with or services the machine.

This manual contains information and instructions for installation, operation and maintenance of the machine. We recommend that you carefully read this manual before use and follow the

procedures and instructions strictly. This will ensure that you get the best out of the machine and prevents possible accidents and serious injury.

Preamble 7

2 Safety

Your vacuum packaging machine has been carefully designed and expertly built to be operated safely. This is corroborated by the ETL Certification and the EC Declaration of Conformity. However, there are always dangers and safety risks that cannot be eliminated. These dangers and risks are the result of the use functions of the machine and operation of the machine by the user. This section discusses safety instructions and precautions, how they will be pointed out to

you and the requirements the user must meet. It is essential that you are well aware of these safety instructions and requirements and observe them at all times!

2.1List of the Symbols Used in this Manual

For all operations in which the safety of the operator and/or technician is at stake and where caution should be exercised, the following symbols are used.

This symbol provides insight or offers tips to help facilitate certain actions.

This symbol warns for dangerous situations that may lead to damage to the machine or personal injury.

This symbol warns for high voltage.

2.2Pictograms on the Machine

Pictograms and warnings have been fitted on the machine to warn users of the possible risks.

Warning sign 'Hazardous voltage'

• Is located on the back of the machine

Caution sign ‘Electric shock’

• Is located on the back of the machine

Safety 8

Caution sign ‘Hot surface’

• Is located on the housing of the machine

Warning sign ‘Gas Connection’ (optional)

Forbidden to connect oxygen

• Is located on the back of the machine

Warning sign ‘Gas Connection’ (optional)

Maximum allowed gas pressure of the gas flush system

• Is located on the back of the machine

Warning sign ‘Seal Pressure Connector’ (optional)

Maximum allowed gas pressure of the gas flush system

• Is located on the back of the machine

Machine plate

• Is located on the back of the machine

Regularly check whether the pictograms and markings are still clearly recognisable and legible. Replace them if this is not the case.

2.3General Warnings

• All persons responsible for the operation of this machine must at least fully read and understand the chapters Safety and Operation on page 26.

•Failure to follow the safety instructions may result in serious injury.

•Never pack products that can be damaged by vacuum.

•Never vacuum live animals.

•Warranty, liability and/or ETL certification is void if any damage is caused by repairs and/ or modifications that are not authorised by the supplier or any of its distributors.

•In case of malfunction, contact the supplier.

Safety 9

•High pressure cleaning is not allowed. This may cause damage to the electronics and other components.

•Prevent water from entering the ventilation inlet of the chamber or the exhaust of the pump. This causes irreversible damage to the pump.

•The work space around the machine must be safe. The owner of the machine must take the necessary precautions to operate the machine safely.

•It is forbidden to start the machine in an explosive environment.

•The machine has been designed in such a way that production is safe under normal ambient conditions.

•The owner of the machine must ensure that the instructions in this manual are actually complied with.

•The available safety devices may not be removed.

•The correct operation and safety of the system can only be guaranteed if the recommended maintenance is performed on time and properly.

•If work must be carried out on the machine, it must be disconnected and blocked from the power supply and, if applicable, from the air and gas supply.

•Only a technical expert may perform work on the electrical installation.

• Internal procedures and monitoring must be in place to ensure that all relevant power supplies are disconnected.

•The machine may not be used during cleaning, inspection, repair or maintenance and must be disconnected from the power supply by disconnecting the plug and/or using the main switch.

•Never perform welding work on the machine without first disconnecting the cable connection to the electrical components.

•Never use the power supply of the control unit to connect other machines.

•All electrical connections must be connected to the terminal strips according to the wiring diagram.

2.4Warnings During Use

•Before starting the machine, make sure no work is being performed on the installation

and that the machine is ready for use.

•The machine may not be operated by unauthorised persons. This should be monitored by the machine operator(s).

•Immediately contact the service technician of your technical department or dealer if something does not seem right, such as unusual vibrations or unusual noise.

•Components of the sealing system can become very hot. Contact with these components may cause injuries.

•Improper use, such as switching off the machine while it is creating a vacuum, is strongly discouraged. Such actions may cause oil leaking back to the vacuum chamber.

Safety 10

2.5Warnings for Operating Personnel

• Operating personnel must be 18 years or older.

• Only authorised persons are allowed to perform work on or with the machine.

•Personnel may only perform work for which it was trained. This applies to both maintenance and normal use.

•The machine may only be operated by trained personnel.

•Operating personnel must be familiar with all circumstances, so quick and effective action can be taken in case of an emergency.

•If an operator notices errors or risks or disagrees with safety measures, he or she should report this to the owner or manager.

•Safety shoes are mandatory.

•Appropriate work clothing is mandatory.

•All personnel must obey the safety regulations to avoid danger to themselves and others. Always strictly follow the work instructions.

Safety 11

3 Introduction

Henkelman Inc.is a supplier of ultra-modern vacuum packaging machines. Our machines are developed and manufactured to meet the highest standards. They combine a sleekly built and functional design with optimal ease of use and a long service life. After mounting the plug, it is just a matter of "plug & pack". The clever design ensures compliance with the hygiene standards at all times.

The Marlin, Falcon and Polar series are floor models with various options suitable for a variety of applications. These machines have several programmes and options for optimal packaging.

Introduction 12

4 Description of the Machine

This section provides an overview of the main components and functions. If detailed information is available in this manual, you will be referred to the specific sections.

4.1Overview of the Main Components

The figure below shows the main components of the system. The model shown may differ from your machine.

Figure 1: Overview of the Main Components

1.Lid

The lid closes the vacuum chamber during the application of the vacuum. A rubber is mounted in the lid to ensure proper closing. On machines with two vacuum chambers, the lid can be moved from position 1 to position 2 manually. In these machines, the sealing bars and suction inlet for the vacuum are included in the lid.

2.Vacuum chamber

The products to be packaged are placed on the work surface with the openings of the vacuum bags on the sealing position. On machines with two vacuum chambers, the already packaged product can be removed and new products can be placed on the free work surface during the vacuuming and sealing process.

3.Castor with brake

The machines are fitted with four castors with brake. This allows for easy moving of the machine to a different location.

4.Machine housing

The machine housing contains all the components necessary for the functioning of the machine.

Description of the Machine 13

5.Control panel

This serves to operate the available control functions. Depending on your model, your machine will have the 10-programme control system or the Advanced Control System (ACS).

6.Seal system

Depending on the model, one, two or three sealing bars are mounted in the vacuum chamber. These close the vacuum bag.

7.Vacuum pump

The vacuum pump creates the vacuum.

8.Power connection and cable

This serves to connect the machine to the power supply. The machine is supplied without an electrical plug.

9.Seal pressure connector (optional)

Where the standard model makes use of atmospheric pressure to press the seal bar onto the vacuum bag during the sealing process, it is also possible (optional) to connect to an external source in order to obtain a higher sealing pressure.

10.Gas flush system connector (optional)

After applying vacuum, a gas is injected into the packaging to create a modified atmosphere to protect the shape of the product or increase the shelf life of the product.

4.2Description of the Packaging Process/Machine Functions

This section provides an overview of the packaging process and available machine functions.

For the functions Liquid Control (and Liquid Control+), Gas (and Gas+), Seal 1-2 Cut-off and Soft-air, specific components must be installed on your machine before they can be enabled. Contact your supplier for more details.

See Changing the Programme Settings on page 34 for information about setting the parameters to the correct values.

4.2.1Packaging Process/Machine Functions

This section describes the packaging process and the machine functions. See Operation on page 26 for the realization of the specific steps of the procedure.

Step	Process phase	Operation
1.	Preparation	The operator puts the product in a vacuum bag and places it
		on the work surface with the opening on the sealing position.
2.	Applying vacuum	The vacuum process is initiated by closing the lid.

Depending on the options you selected for your machine and the product you are packaging, the following functions are available:

Description of the Machine 14

Step	Process phase	Operation
	Vacuum	During the cycle, the air is removed from the chamber until
		the set time or pressure has been reached, depending on
		the selected model.
		Applying vacuum until a set value is reached is only possible
		if your machine is sensor-controlled (optional for 10-
		programme control system). This value can be set in %.
		The percentage indicates the depth of the vacuum. This is
		in relation to an outside atmosphere of 0%. In case of the
		Advanced Control System (ACS), the value is indicated in
		percentages, mbar or hPa.
	Vacuum+	Vacuum+ is only available if the vacuum percentage is set to
		the maximum.
		The Vacuum+ option continues the vacuum process for an
		additional time to allow any entrapped air to escape from the
		product.
		The Vacuum+ option is only available on sensor-controlled
		machines.
	Gas (optional)	After applying vacuum, a gas is injected into the package
		to create a modified atmosphere to protect the shape of the
		product or to increase the shelf life of the product. The value
		of the gas function can be set in %, mbar or hPa or time,
		depending on the control type of the machine.

Gas+ (optional)	The Gas+ option continues injecting gas during the closing
	of the bars to increase the amount of gas in the package.
	See Gas+ (optional) on page 36.

Liquid Control	Liquid Control is only available if your machine is equipped
(optional)	with the optional Liquid Control sensor.
	With the Liquid Control option, the system is controlled by
	a highly sensitive sensor. The sensor is able to detect the
	moment that liquids from the product or the product itself
	begin to evaporate (boil). At that time the system will proceed
	to the next step in the process. This will prevent the product
	from dehydrating, losing weight and/or the vacuum bag from

Description of the Machine 15

Step	Process phase	Operation
		bursting, thus contaminating the seal, the chamber, and the
		oil in the pump. See Liquid Control (optional) on page 36.
	Liquid Control+	Liquid Control+ is only available if your machine is equipped
	(optional)	with the Liquid Control option.
		The Liquid Control+ function allows you to continue the
		vacuum process for a certain time after the evaporation point
		has been reached.
	Red meat (optional)	This option is especially designed for the packaging of fresh
		meat. It is added to the normal vacuum function to prevent
		degassing of the product during and after the sealing phase.
		This degassing could create air pockets inside the package.
		See Red Meat (optional) on page 37.
	Sequential Vacuum	This function is only available on machines with the
	(optional)	Advanced Control System (ACS).
		With sequential vacuum, you can alternate vacuum and
		pause steps to allow air trapped inside a product to escape
		from the core. A maximum of 5 steps can be programmed.
	Multi-Cycle Vacuum	This function is only available on machines with a 10-
	(optional)	programme control system. See 10-Programme Control
		System on page 34.
		The Multi-Cycle Vacuum option allows you to vacuum and
		insert gas in steps. This provides an additional reduction in
		the oxygen content.
	Marinating (optional)	This function is only available on machines with the
		Advanced Control System (ACS).
		This function is especially designed to accelerate the
		marinating of a product. This programme allows definition of
		up to 5 vacuuming steps with intermediate ventilation steps.
		The vacuuming steps have a fixed vacuum value of 80%,
		except for the last step. The last vacuuming step has an
		adjustable value of up to 99.8%. This also allows setting
		Description of the Machine 16

Step	Process phase	Operation
		Vacuum+. The intermediate ventilation steps have a fixed
		value of 42%. After the last step, sealing takes place.
		Liquid Control: It is also possible to enable Liquid Control.
		This function will then only be active during the last
		vacuuming step. If, for instance, 3 vacuuming steps have
		been defined, Liquid Control will be active during the third
		step. Vacuum+ is also possible here; however, this would be
		a Liquid Control+ setting of 0.1 sec with a maximum of 5.0
		sec.
	Tenderising	This function is only available on machines with the
	(optional)	Advanced Control System (ACS).
		This feature has been designed to keep the chamber at a
		pre-determined vacuum level for a certain time. This is done
		to tenderise or degas the product.
		During the cycle, the air is removed from the chamber until
		the pre-set value has been reached. Once this value has
		been reached, the chamber will remain at this vacuum level
		for the pre-set time.
3.	Sealing	The sealing bars are pressed against the vacuum bag and
		melt the bag closed.
	Seal	During the sealing process, the material of the vacuum bag
		is heated and pressed together to create a hermetic seal.
		The programming of this function takes place in seconds.
		Optionally, a cut-off wire is available. The purpose of the
		cut-off wire is to remove the excess foil. Depending on the
		selected model, the cut-off wire is controlled simultaneously
		with or independent from the sealing wire (Seal 1-2 cut-off).

Soft-Air (optional for the Falcon)

This function allows air from outside to slowly enter the chamber so the vacuum bag will shape itself slowly around the product. This prevents sharp edges of the product from puncturing the foil and causing leaks.

4.	Decompressing	The vacuum is removed from the vacuum chamber by letting
		air into the chamber.
5.	Opening the	The lid opens.
	vacuum chamber

Description of the Machine 17

Step	Process phase	Operation
6.	Removing the	The operator can remove the packaged product from the
	product	work surface.

4.2.2General Functions

Function	Pictogram	Operation
Cleaning of the		The pump cleaning programme ensures that the pump is
oil pump		thoroughly rinsed. During the programme, the pump and
		oil reach the operating temperature, so the oil and moisture
		are separated and any contamination is filtered. The high
		temperature causes any moisture in the pump to evaporate, thus
		minimising the risk of corrosion.
Menu		This menu is available on machines with ACS control. The menu
		is used to change the machine settings, such as language and
		print options.

Printing	This function is available on machines with ACS control.
	This function allows the creation of one or more labels per cycle,
	to be put on the packaging.
	The following information can be printed on the label: name of
	the producer, name of the product, production date, shelf life,
	achieved vacuum, initials of the user, recommended storage
	temperature and an information field (for example to indicate the
	gas used).
External	This function is available as an option, depending on the type of
Vacuum	machine.
	This function allows special food containers to be vacuumed
	outside the machine.
	The options to set the vacuum value are the same as for
	standard vacuuming (see External Vacuum (optional) on page
	39 for 10-programme control system or External Vacuum
	(optional) on page 47 for ACS control).
Sleeper option	The Sleeper option shuts down the machine after a certain time.
	The default setting is 10 minutes. If you wish to change this time,
	please contact your supplier.

Description of the Machine 18

4.3Sealing System

The sealing system closes the opening(s) of the bag to retain the vacuum and/or gas in the bag. The end of the bag can optionally be cut off by the sealing bar.

	Figure 2: Overview of the Sealing	Figure 3: Overview of the Sealing
		System (Including Seal Bag)
	System (Including Sealing Cylinder)

1.Sealing bar

The sealing bar consists of the following components:

•Sealing wires: during the sealing process, the sealing wires are heated for a certain time causing the edges of the vacuum bag to melt together.

•Cut-off wires (optional): A cut-off wire is heated in such a way that the foil of the bag partially melts, allowing the excess foil of the vacuum bag to be removed easily.

•Teflon tape: sealing and cut-off wires are covered with Teflon tape to prevent the bag from sticking to the sealing bar.

Consult Replacing the Sealing Wire on page 57 for more detailed information about maintenance.

2.Silicone holder

Opposite the sealing bar is a silicone holder which provides counter pressure on the cylinders/ seal bag (Replacing the Silicone Rubber of the Silicone Holders on page 59).

3.Sealing mechanism

The sealing bars are pressed onto the vacuum bag by bellows or cylinders.

By connecting the inlet of the bellows or cylinders with the atmospheric pressure outside, they press the sealing bar onto the bag.

Additional sealing pressure (optional) may, depending on the model you have, be used if additional pressure force is needed.

See Technical Data on page 65 and Connecting the Machine on page 23 for more information.

Description of the Machine 19

4.4Vacuum Pump

The vacuum pump creates the vacuum.

Figure 4: Overview of the Pump (75 m3/h / 2780 cf/h)

1.Vacuum pump - Creates the vacuum for the process.

2.Oil exhaust filter - Filters the air by capturing oil vapours.

3.Oil sight glass - Indicates the maximum and minimum oil levels of the vacuum pump.

4.Oil drain plug - Removing the oil drain plug allows the oil to be drained.

5.Oil filler plug - Removing the oil filler plug allows the oil to be refilled.

6.Oil filter - Filters the oil.

4.5Electrical Installation

The electrical installation provides power for the vacuum pump, the seal system and the operation of the machine.

See the electrical diagram for the further structure and operation of the electrical installation. Please contact your supplier for the electrical diagram.

Only a technical expert may perform work on the electrical installation.

Description of the Machine 20

The machine consists of the following electrical components:

Figure 5: Overview of the Electrical Installation

1.Power connection and cable

This serves to connect the machine to the power supply. The machine is supplied without an electrical plug.

2.Main switch

This switch is used to switch the machine ON and OFF.

3.Circuit breaker

Protects against overload or a short circuit. Also see Troubleshooting on page 62

4.Control panel

This serves to operate the control functions. Depending on your model, your machine will have one of the following control options:

•Operating Elements of the 10-Programme Control System on page 26

•Operating Elements of the Advanced Control System (ACS) on page 27

Description of the Machine 21

5.USB connector (only in case of ACS control)

The USB connector is located on the side of the control box, which is located behind the rear wall. Reaching the USB connector requires removing the rear wall.

After opening the cover of the USB connector, the machine is no longer waterproof (IP65).

The USB connector enables the import and export of data.

Description of the Machine 22

5 Installation

Consult Technical Data on page 65 for the specifications of the machine.

Before installing the machine, carefully read the safety instructions in Safety. Failure to follow or disregard of the safety instructions may result in serious injury.

5.1Transportation and Installation

The machine must be moved and transported in an upright position.

The machine may not be transported using a crane. The machine may be transported with a forklift provided it is still on the pallet packaging.

Moving the machine on wheels on uneven surfaces may lead to loss of stability of the machine. Always move the machine slowly and carefully.

1.Place the machine on a flat, level surface. This is essential to ensure a trouble-free operation of the machine.

Do not position machines with plastic covers in the vicinity of a heat source.

Make sure there is sufficient space (at least 19.7 in (50 cm)) around the machine to ensure a proper ventilation.

2.Ensure the brakes of the machine are activated.

3.Verify that the machine housing is present and correctly fitted.

If the machine is provided with the optional automatic lid (Polar 2-85 and 2-95 only):

4.Remove the panel door on the right hand side of the machine and release the cable of the foot switch.

5.2Connecting the Machine

1.Make sure the voltage stated on the machine plate matches the mains voltage.

2.Fit the correct plug on the cable in accordance with local legislation and connection data. See

Technical Data on page 65.

3.Fit the connecting cable to the machine. See Technical Data on page 65.

4.Connect the machine to a grounded wall outlet to avoid fire or electric shock (the earth connection is green/yellow).

The power cable must be free at all times, and nothing may be placed on it.

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Immediately replace the power cable if damaged.

5.Check the correct direction of rotation of the three-phase model pump. See Figure 6: Direction of Rotation of the Vacuum Pump on page 24.

Operating the machine with an incorrect direction of rotation results in damage to the pump, in which case no vacuum can be created. After connecting the machine to a different threephase power supply, the direction of rotation should be checked again. If the direction of rotation is incorrect, two phases in the plug must be interchanged.

Only a technical expert may perform work on the electrical installation.

Figure 6: Direction of Rotation of the Vacuum Pump

6.Optional: Connect the gas supply for the gas flush system.

7.Optional: Connect the air supply for additional sealing pressure.

If the machine is provided with the optional automatic lid (Polar 2-85 and 2-95 only):

8.Connect the hose for compressed air to the hose pillar (8 mm) at the back of the machine.

Pressure	≥ 5 bar - ≤ 10 bar / ≥ 72.5 Psi -
	≤ 145 Psi
Flow	≥ 100 l/min.

Figure 7: Hose connection for compressed air

5.3Prior to the First Use

1.Check the oil sight glass to see if the amount of oil in the pump is sufficient.

2.Optional: If the amount of oil in the pump is insufficient, refill it. See Removing Oil, Replacing Oil Filter, Refilling Oil on page 55.

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