Ultrasource Ultravac 500 User Manual

Ultravac® 500

Vacuum Chamber Packaging Machine

EFFECTIVE SERIAL # 2080 +

860052 Revision Q

Date 9/2011

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TABLE OF CONTENTS

General ...............................................III

Specifications ....................................... IV

SAFETY

Personal Safety ....................................1.1

Food Safety ........................................1.2

General Safety Guidelines ....................1.2

STARTUP

Unpacking .......................................... 2.1

Power Requirements .............................2.1

Grounding Instructions .........................2.1

Vacuum Pump .................................... 2.2

Gas Flush Connection ........................ 2.2

Air-Assist Connection .......................... 2.2

Checking Vacuum Pump Rotation ........ 2.2

OPERATION

Placement of Product ...........................3.1

Operation with Analog Control Panel ... 3.2

Operation with Digital Control Panel .... 3.3

Operator Menu on Digital Panel .......... 3.4

Selecting a New Program .................... 3.5

Sealing with Air-Assist ......................... 3.6

Gas Flush Option ............................... 3.6

Double Seam Seal Option .................. 3.6

MAINTENANCE

Prior to Cleaning ................................. 4.1

Cleaning Recommendations .................4.1

Vacuum Pump Maintenance ................ 4.2

Seal Bar Maintenance ......................... 4.2

Reading the Indicators ........................ 4.3

Troubleshooting ................................. 4.3

Supervisor Menu on Digital Panel ........ 4.5

Opening Chamber Machine ................ 4.8

Changing Vacuum Pump Oil ................4.9

Replacing Potentiometer .......................4.9

Replacing Power Cord .......................4.10

Maintenance Log ..............................4.10

Service Log ....................................... 4.10

SCHEM ATICS

Designation and Function of Controls ....5.1

230 Volt, Single Phase, Analog Panel ... 5.2

230 Volt, 3 Phase, Analog Panel .......... 5.3

380 Volt, 50 Hz, 3 Phase, Analog Panel

.. 5.4

230 Volt, Single Phase, Digital Panel .... 5.5

230 Volt, 3 Phase, Digital Panel ........... 5.6

380 Volt, 50 Hz, 3 Phase, Digital Panel

... 5.7

Non-Gas Flush Pneumatic Diagram ..... 5.8

Gas Flush Pneumatic Diagram ............. 5.9

PARTS

Recommended Spare Parts ...................6 .1

Pump and Chassis .............................. 6.2

Seal Bar ............................................ 6.4

Lid and Hinge System ......................... 6.6

Gas Flush Components....................... 6.8

Main Control - Front Side ...................6.10

Analog Control Panel ........................6 .12

Digital Control Panel .........................6.14

Main Control - Back Side ...................6 .15

Mebner Valve .................................... 6.16

Miscellaneous Machine Parts .............. 6 .17

REFERENCE MANUALS

R5 Series Vacuum Pumps .....................7.1

INDEX .............................................. 8.1

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INTRODUCTION •

PAGE I

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Ultravac® 500

Vacuum Chamber Packaging Machine

Congratulations on your Ultravac® 500 vacuum packaging machine purchase. This
machine was designed to provide years of trouble-free operation and to help in the
packaging of your quality food products.

Please read this owner’s manual to gain the maximum benefits of your vacuum packaging
machine and its different components.

A note about cleaning: Given all the various ways equipment is used in different
environments, we recommend the owner consult sanitation experts on how to properly
clean each piece of machinery in their plant and to do bacterial testing to insure that the
equipment is cleaned properly.

For Sales, Call:

Phone [phone] • Fax [phone]

Toll-Free [phone]

For Replacement Parts, Call:

Phone [phone] • Fax [phone]

Toll-Free [phone]

For Technical Support, Call:

Phone [phone] • Fax [phone]

Toll-Free [phone]

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©Copyright 2009 Koch Equipment LLC

INTRODUCTION •

PAGE II

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General

This owner’s manual contains information pertinent to your Ultravac® 500. Basic instructions
and maintenance information is provided. Please read carefully. Failure to do so could result
in bodily injury and/or damage to the equipment.

Receiving Problems: As in all cases, before signing the bill of lading, be sure all items
have been received as listed and there is no damage in shipment. If needed, a claim must
be made immediately to the local truck line office and noted on the bill of lading.

Please fill in the information from the bill of lading and the product identification tag.

Model No.

Serial No.

Ship Date:

Owner:

Location:

Electrical service size for your Ultravac® 500 (check one):

230 Volt, 3 phase, 60 Hz

230 Volt, Single phase, 60 Hz

380 Volt, 3 phase, 50 Hz

Please fill in the serial number from the pump identification tags:

Serial No.

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INTRODUCTION •

P A G E III

Specifications

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Figure 0.1

Length (A): 718mm (28.25-in.)
Width (B): 610mm (24-in.)
Maximum Height (C): 1334mm (52.5-in.)
Working Height (D): 892mm (35.125-in.)
Seal Bar Length: 457mm (18-in.)
Chamber Length (E): 648mm (25.5-in.)
Chamber Width (F): 489mm (19.25-in.)
Chamber Height (G): 229mm (9-in.)
Between Seal Bars (H): 537mm (21.125-in.)
Vacuum Pump: 48m3/h (28cfm) 1.5kW (2-hp)

70m3/h (41cfm) 2.2kW (3-hp)
Net Weight: 160-kg, 353-lbs.
Electrical Connection: See Power Requirements in Section 2
Capacity: 20-30 seconds per cycle

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INTRODUCTION •

PAGE IV

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DANGER

DANGER

WARNING

WARNING

CAUTION

CAUTION

CAUTION

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SAFETY

Personal Safety

The procedures and guidelines herein must be followed precisely to avoid problems that can
result in property damage, personal injury, or death. If you have any questions related to

this information, please contact Koch Equipment Services Inc. at [phone].

Hazardous voltage.
Disconnect and lockout power before servicing machine or cleaning. Do not remove panels
unless power has been disconnected, locked out, and tagged out at risk of electric shock
hazard.

Hazardous voltage.
Improper connection of the equipment-grounding conductor can result in a risk of electric
shock.

Read and understand owner’s manual before using this machine. Failure to follow operating
instructions could result in personal injury or damage to equipment.

Explosion hazard.
Do not use a gas with an oxygen content greater than 22% with gas flush option.

Blade hazard.
Do not remove, install, or replace blades without protective gloves. Perforating knife blade
is sharp. Use care when handling.

Blade hazard.
Do not remove, install, or replace blades without protective gloves. Precut knife blade is
sharp. Use care when handling.

Cleaning agents.
Do not get the cleaning agents in eyes, on skin, or on clothing. Always wear rubber gloves,
goggles, and protective clothing when contact is likely. Consult product manufacturer for
specific details.

Signal words used in classification of potential hazards are defined as follows:

DANGER: Indicates an imminently hazardous situation, which, if not avoided, may result in death or
serious injury.
WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in death or
serious injury.
CAUTION: Indicates a potentially hazardous situation, which, if not avoided, may result in minor or
moderate injury. Caution also indicates actions that may cause property damage.

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SAFETY •

P A G E 1.1

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Food Safety

Food Packaging

While this machine is often used for food packaging and vacuum cooking, there are
inherent risks associated with this packaging technique that could cause serious illness
or death to the consumer of the food product. If you are using this machine for a food
application, you must consult with a reputable food technologist or specialist in vacuum/
modified atmosphere packaging (M.A.P.) to review the safety of your application.

Gas Flush

In order to ensure proper shelf life of the food product packaged in this machine, you
must contact a reputable food technologist or specialist in vacuum/modified atmosphere
packaging (M.A.P.) to review and develop the appropriate gas mixture for your package,
and you must perform quality control and gas analysis on your finished M.A.P. packages.

General Safety Guidelines

Obvious safety guidelines should be observed.

 Be sure to turn off power to your packaging machine before any maintenance work is

performed.

 Follow approved Lockout/Tagout procedures.

 Place machine on a flat, stable surface.

 Do not place tools, parts, or other objects on or inside machine while operating.

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SAFETY •

P A G E 1.2

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STARTUP

Unpacking

1. Carefully remove crate from the skid.

2. Remove machine from skid.

3. Wipe down outside of the machine.

Power Requirements

The machine is available with 2 horsepower, or 3 horsepower vacuum pumps.

The owner must supply the correct 3 phase or single phase power source in accordance
with the National Electric Code.

Grounding Instructions

The Ultravac® 500 must be grounded. In the event of malfunction or breakdown, grounding
provides a path of least resistance for electric current to reduce the risk of electric shock. All
3 phase units are equipped with a equipment-grounding plug and the single phase units
are equipped with an equipment-grounding conductor cord. The plug must be plugged into
an appropriate outlet that is properly installed and grounded in accordance with all local
codes and ordinances.

Hazardous voltage.
Improper connection of the equipment-grounding conductor can result in a risk of electric
shock.

The equipment-grounding conductor outer surface is green with or without yellow
stripes. If repair or replacement of the cord or plug is necessary, do not connect the
equipment-grounding conductor to a live terminal. Check with a qualified electrician or
Koch Equipment Services Inc. technician if the grounding instructions are not completely
understood, or if there is doubt as to whether the unit is properly grounded. Do not modify
the plug provided with the unit – if it will not fit the outlet; have a proper outlet installed by
a qualified electrician.

Customer Voltage Pump Motor Full Load Amps

230, 60 Hz 1 Phase 13
230, 60 Hz 3 Phase 10
380, 50 Hz 3 Phase 6.3

Supply conductor shall have an
ampacity not less than 125% of

the Pump Motor Full Load Amps

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STARTUP •

P A G E 2.1

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Vacuum Pump

It is essential to check the oil level daily and to change the oil after every 500 hours of
operation. Read the oil level with the machine turned off. Oil may be added until the level
reaches the MAX level shown in the sight glass on the pump. Refer to the pump manual
supplied with the machine for details on changing the oil.

NOTE: ALL ULTRAVAC 500 CHAMBER MACHINES ARE SHIPPED WITH OIL IN THE PUMP.
ALTHOUGH THE FACTORY RECOMMENDS CHECKING THE OIL LEVEL PRIOR TO FIRST
USE!

Gas Flush Connection

The owner must supply a suitable regulator with a range of 0 to 60 p.s.i. We recommend

using food-grade flexible hose with a 1/4-in. I.D. and a maximum length of 15-ft. Maximum

regulator pressure is 15 p.s.i.

OXYGEN ENRICHED USE

KOCH TRAY SEALING AND VACUUM CHAMBER MACHINES ARE NOT DESIGNED FOR
USE WITH OXYGEN ENRICHED PROCESS GASES. ANY APPLICATION THAT REQUIRES
A PROCESS GAS CONTAINING 25% OR MORE OXYGEN SHOULD CONTACT KOCH

EQUIPMENT SERVICES AT [phone] AS RETROFIT OPTIONS ARE REQUIRED.

RUNNING THIS MACHINE WITH AN OXYGEN ENRICHED PROCESS GAS, WITHOUT THE
NECESSARY RETROFIT KIT COULD CAUSE SEVERE INJURY, DAMAGE OR DEATH.

KOCH TRAY SEALING AND VACUUM CHAMBER THAT ARE RETROFITTED WITH THE
NECESSARY KIT WILL HAVE A DECAL ABOVE OR BESIDE THE GAS SUPPLY CONNECTION
INDICATING THE MACHINE’S READINESS TO RUN OXYGEN ENRICHED PROCESS GASES.

Checking Vacuum Pump Rotation

Caution: Check oil level of pump before starting pump (please refer to pump manual).
To check the direction of the pump rotation, briefly engage the “POWER ON” switch and
observe the motor fan at the end of the pump. The fan should rotate as indicated by the
arrow on the fan cover. To correct the rotation, switch any two phases in the plug.

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STARTUP •

P A G E 2.2

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OPERATION

Placement of Product

For best sealing results, it is important to:

• Check the pump oil level daily.

• Select a pouch that fits the product.

• Carefully load the product into the pouch.

• Keep the product and the product residue away from the seal area of the pouch.

• Place the product as far into the pouch as possible.

• Maintain an equal amount of the product above and below the seal bar (see figure 3.1,

below on use of filler plates).

• Use Filler Plates for raising the height of the product.

• Lay the pouch flat on the seal area, keeping the pouch free of wrinkles.

• Place the pouch so that the open end is inside the chamber when the lid is closed.

Figure 3 .1

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PRODUCT HALF HEIGHT

EVEN WITH TOP OF

OPERATION •

SEAL BAR

P A G E 3.1

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Operation with Analog Control Panel

The analog control panel is shown below, figure 3.2.

The range for timed vacuum is 0 to 55 seconds and is controlled by the Vacuum
Potentiometer. We suggest an initial setting of “3” on the dial.

Seal impulse is the length of time the seal bar is turned on and can range from 0 to
2 seconds. The impulse time is controlled by the Seal Potentiometer. Koch Equipment
recommends an initial setting of “6” on the potentiometer. This setting will vary according
to the thickness of the pouch. Thinner pouches will require a lower setting while thicker
pouches will require a higher setting.

Experiment with both settings to achieve the best results.

Figure 3.2

POWER SWITC H

VACUUM

POTENTIOMETER

VACUUM LIGHT

(GREEN)

SEAL

POTENTIOMETER

VACUUM

INDICATOR

SEAL LIGHT

(RED)

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OPERATION •

P A G E 3.2

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Operation with Digital Control Panel

The digital control panel allows the user more options than the standard control panel. The
embedded microprocessor controls each sequence of the packaging operation. Settings for
the vacuum, gas, and sealing are entered as parameters through the keypad. This allows
the user to custom program every step of the packaging process. The precise vacuum
and gas pressures are controlled by a pressure based sensor. The vacuum pressure, gas
pressure, and seal time are displayed on a large 16-character LCD backlit readout, which
is easily readable in all lighting conditions. As each sequence is performed, the real-time
pressure level or cycle time is displayed.

The digital front panel can save up to ten pre-programmed routines, which can be retrieved
at any time for specific packaging applications. With the supervisor security feature turned
on, these programs cannot be inadvertently changed.

The Vacplus option allows the operator to run the pump from 0 to 20 seconds after the set
vacuum level is achieved.

The Gas Flush option allows the operator to introduce an inert gas into the chamber after
the vacuum stage. This option can be used as a filler to prevent crushing of the product
after sealing, as a means to prolong shelf life, or as a means to maintain desirable product
appearance.

The digital front panel has an auto stop, which will automatically seal if the preset vacuum is
not reached. This feature decreases the cycle time and optimizes the vacuum level of each
product.

The digital front panel, which includes the keypad, illuminated display, and microprocessor,
use sealed components and is conformal coated in a moisture-proof coating. The digital

front panel meets or exceeds the requirements of NEMA 4. The front of the digital display is

sealed and flush for easy cleaning.

The digital control has both pulsed vacuum and pulsed venting options for fragile product.

The digital control has a maintenance screen for testing valves and a special loop option for
multiple vacuum/gas cycles before sealing.

Figure 3.3

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OPERATION •

P A G E 3.3

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THAT WAS RUN WILL BE THE CURRENT PROGRAM
SHOWN IN THE WINDOW. TO SET THE OPERATING
PARAMETERS FOR THE PROGRAM SHOWN,
PRESS THE MENU KEY.

THIS IS THE MAIN MENU SCREEN. WHEN
THE MACHINE STARTS UP, THE LAST PROGRAM

NOTE: IF THE SUPERVISOR HAS SET SECURITY ON,
THESE SETTINGS CANNOT BE CHANGED

UP AND DOWN ARROW KEYS.

VACUUM IS SET TO % VACUUM USING THE

(FOR THE SPECIFIED NUMBER OF SECONDS) AFTER

THE % VACUUM SET IN THE VACUUM MENU.

THE PRESSURE IN THE CHAMBER HAS REACHED

PUMP TO CONTINUE EVACUATING THE CHAMBER

A SETTING GREATER THAN ZERO ALLOWS THE

VACPLUS MAY BE SET FROM 0 TO 20 SECONDS.

USE THE UP AND DOWN ARROW KEYS TO

THE SEAL SETTING IS IN SECONDS.

CHANGE THE SEAL TIME.

THE RANGE IS 30% TO 99%.

THE RANGE IS 0 TO 2 SECONDS.

THE RANGE IS 0 TO 20 SECONDS.

PRESS THE MENU KEY.

PRESS THE MENU KEY.

PRESS THE MENU KEY.

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Operator Menu on Digital Panel

NOTE: if the supervisor has set security on, these settings cannot be changed.

+

RUNNING PROG: 1

-

+

VACUUM: 98

-

+

VACPLUS: 4.0

-

+

SEAL: 1.2

-

PROGRAM

YES

This is the Main Menu screen. When
the machine starts up, the last program
that was run will be the current program
shown in the window. To set the operating

NO

parameters for the program shown press
the MENU Key.

PROGRAM

YES

VACUUM is set to % vacuum using the UP
and DOWN arrow keys. The range is 30%
to 99%.
Press the MENU Key.

NO

PROGRAM

YES

VACPLUS may be set greater than zero
to allow the pump to continue evacuating
the chamber (for the specified number
of seconds) after the pressure in the

NO

chamber has reached the % vacuum set
in the vacuum menu. The range is 0 to 20
seconds.
Press the MENU Key.

PROGRAM

YES

NO

The SEAL setting is in seconds.
Use the UP and DOWN arrow keys to
change the seal time. The range is 0 to 2
seconds.
Press the MENU Key.

Figure 3.4

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OPERATION •

P A G E 3.4

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ALSO CORRESPONDS TO THE VACUUM

GAS IS SET TO % GAS USING THE UP
AND DOWN ARROW KEYS. THIS VALUE

IF YOUR MACHINE IS EQUIPPED WITH THE GAS

PRESSING THE UP OR DOWN ARROW KEYS.

OPTION, IT CAN BE TURNED ON OR OFF BY

READING INSIDE THE CHAMBER.

WHEN GAS FLUSHING TO A LOW % VACUUM.
THE RANGE IS 98% TO 30%.

IT IS RECOMMENDED TO USE PULSE VENT

PRESS THE MENU KEY.

PRESS THE MENU KEY.

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Operator Menu on Digital Panel (continued)

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+

PROGRAM

YES

If the machine is equipped with the gas
option, it can be turned ON or OFF by

GAS: YES

pressing the UP or DOWN arrow keys.
Press the MENU Key.

-

+

PROGRAM

NO

YES

GAS is set to % gas using the UP and
DOWN arrow keys. This value also
corresponds to the vacuum reading inside

GAS: 75

the chamber. It is recommended to use
Pulse Vent when gas flushing to a low %

-

NO

vacuum. The range is 98% to 30%.
Press the MENU Key.

Figure 3.5

Explosion hazard.
Do not use a gas with an oxygen content greater than 22% with gas flush option.

Selecting a New Program

RUNNING PROG: 1

ENTER PROGAM: 2

Figure 3.6

860052

•Q

+

PROGRAM

YES

From the Main Menu, use the UP and
DOWN arrow keys to select a new program.

-

+

PROGRAM

NO

Press the UP arrow to switch to Program 2
(or any of the 10 programs).

YES

New parameters may be set for Vacuum,
Seal Time, and Gas for Program 2 (following
the procedures described in the previous
example) or simply close the lid on the

-

OPERATION •

NO

machine and run Program 2.

P A G E 3.5

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Sealing with Air-Assist

All machines are equipped with regulators for air-assisted sealing. Set the air pressure

regulator to 20 p.s.i. increasing to a maximum of 40 p.s.i. While a good seal can be

obtained without air-assist, use air-assist when:

• Gas back-flushing above average pressure.

• Using shrink pouches.

• Packaging a product that easily contaminates the seal area of the pouch.

• Trying to overlap pouches.

• Wrinkles cannot be avoided in the seal area.

• Using the Double Seam Seal Option.

Gas Flush Option

Gas flushing is the introduction of an inert gas into the chamber after the vacuum stage
is finished. Gas can be used as a filler to prevent crushing of the product after sealing, as
a means to prolong shelf life, or as a means to maintain desirable product appearance.
Commonly used gasses include nitrogen, carbon dioxide, or a mixture of both. Consult your
local gas supplier to select the proper gas for your product.

Explosion hazard.
Do not use a gas with an oxygen content greater than 22% with gas flush option.

Double Seam Seal Option

All machines are equipped with standard seal bars having a single seal element per seal
bar. The Double Seam seal bars have two seal elements per seal bar. We recommend using
air-assisted sealing with this option to achieve best results.

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OPERATION •

P A G E 3.6

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MAINTENANCE

Prior to Cleaning

Every environment and application is different; therefore, Koch Equipment LLC cannot
provide cleaning instructions to guarantee microbiological sanitation. Koch Equipment
requests that the owner of this machine consult with sanitation experts to review the
unit working in their particular environment to develop a robust cleaning schedule and
methodology, followed by bacterial testing to ensure satisfactory cleaning procedures are
followed.

Cleaning Recommendations

Before cleaning the machine, turn power off; disconnect the main power, and lockout the
connection.

Hazardous voltage.
Disconnect and lockout power before servicing machine or cleaning. Do not remove panels
unless power has been disconnected and locked out at risk of electric shock hazard.

Check with the detergent and sanitizer manufacturers that their products are compatible
with the listed materials.

Cleaning agents.
Do not get the cleaning agents in eyes, on skin, or on clothing. Always wear rubber gloves,
goggles, and protective clothing when contact is likely. Consult product manufacturer for
specific details.

Never hose down the machine. Damage caused by hosing or high pressure washing is not
covered under warranty.

1. Filler Plates: Remove filler plates. The filler plates are made from polyethylene. Clean,
sanitize, and dry. High pressure water spray can be used on the filler plates.

2. Lid and Backup Strip: The lid is constructed of acrylic. Use only nonabrasive soap and
water. Do not use window sprays or kitchen scouring compounds. The Backup Strip is
made of silicone. Clean, sanitize, and dry.

3. Seal Bars: Remove the seal bars by first lifting them up off of the guide rods. Remove
the wire connectors from the adapter clips on the seal bar and remove the seal bar from
the machine. The seal bars are made of aluminum and phenolic. Clean, sanitize, and
dr y.

4. Chamber and Base: The chamber is made of 304 stainless steel and the base is made

from polyurethane. Clean, sanitize, and dry, including under the seal bar bladder (not
removable).

5. Clean under the machine.

6. Reinstall the seal bar.

7. Use bacteriological testing to insure cleaning process.

860052

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MAINTENANCE •

P A G E 4.1

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Vacuum Pump Maintenance

Consult the pump manufacturer’s manual provided with the machine for detailed
information.

Seal Bar Maintenance

The following illustrations show replacement of the seal elements for the seal bars.

Step 1.
Remove the seal bars from the machine. Pull
off the Teflon® tape strip and discard. Clean
off any remaining Teflon® tape adhesive
using acetone or an equivalent solvent.

Step 2.
Using a 2mm Allen wrench, loosen the set
screws for the cut-off wire and the seal
element on both ends of the seal bar and
discard.

Cut-off wire

CUT-OFF
WIRE

Seal element

Teflon® tape

TEFLON

SEAL ELEMENT

TAPE

Set screw

SET SCREW

2mm Allen

2mm ALLEN

wrench

Figure 4 .1

WRENCH

Figure 4.2

Step 3.
If you are replacing the L-shaped spring retainer and the spring at this time, loosen the set
screw and remove the old spring retainer and spring and install the new ones. Adjust the
spring retainer to allow a 1/8-in. gap between the spring retainer and the seal bar. This will
allow the seal element to remain under tension after tightening the seal element.

860052

Figure 4.3

•Q

Tightening

TIGHTENING

TOOL

tool

MAINTENANCE •

Brass contact

BRASS CONTACT

Slotted tip

SLOTTED TIP
SCREWDRIVER

screwdriver

P A G E 4.2

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Reading the Indicators

If your machine is controlled by a digital control module (with touch pad), this design to aids
in troubleshooting. The digital panel has indicator lights mounted on the front below the
ON/OFF switch. The indicator lights correspond to the operating devices and should turn on
and off in the following sequence when the machine lid is closed:

1. Vacuum Pump [C-1]

2. Gas Flush Valve [SOL-3] (Optional)

3. Seal Bladder Valve [SOL-2]
(Stays on until completion of cycle)

4. Seal Impulse Contactor [C-2]

5. Ventilation Valve [SOL-1]

The device should be operating when the light is illuminated. If the lights illuminate in the
proper sequence, but there is still a problem, look for the problem in the operating device
itself. If the lights do not sequence properly, look for a problem in the control module.

Troubleshooting

Problem Indications Remedy

Machine will not start Green power “ON” light not

lit when switch is turned on

Vacuum pump does not run Make sure that the power

No vacuum When lid is closed, indicator

light (VAC) is “OFF” on the
control module

Vacuum not pulling lid down. Check intake screen in vacuum

Longer vacuum cycle times Check intake screen in vacuum

No gas flush (optional) If indicator light (GAS) is lit Check for proper gas pressure

Make sure that the power
requirements match those given
on the nameplate. Also, check
fuse F-2; replace if blown.

requirements match those given
on the nameplate

Check lid switches LS-1 for proper
adjustment.

pump hose barb for blockage,
pieces of bags, labels, bone, etc.

pump hose barb for blockage

going into gas inlet

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If indicator light (GAS) is not
lit

MAINTENANCE •

Check for proper operation of gas
flush valve (SOL-3)

Check gas flush potentiometer on
analog control module or possible
defective digital control panel

P A G E 4.3

E-MAIL: [e-mail]

Troubleshooting

Problem Indications Remedy

MAIN: 816-753-2150

TOLL FREE: 800-777-5624

INTERNET: kochequipment.com

Chamber not venting
(lid will not open)

Lid will not open and red
indicator light “VENT” on
control module is lit

“VENT” indicator light is not
lit

NOTE: Lid can be released by pulling the hose off of
the vacuum gauge to remove product.

Improper or no
sealing

Seal bladder light on control
module is lit but the seal bar
does not go up

The seal bar is not heating
up even though the red
seal light on the front panel
comes on

The red seal light on the
front panel either does not
light for the proper length of
time (½ to 1 second) or does
not light at all

Check ventilation valve SOL-1 for
proper operation

Check cool down potentiometer
on analog control module or
possible defective digital control
panel

Check to make sure that the
regulator knob is turned fully
clockwise, or, if air-assist is used,
set to the recommended pressure

Check seal bladder valve SOL-2
for proper operation

Check seal bar connection points
and clips for corrosion and proper
tension

Check for broken seal element
Check seal bar fuse F-1. Located

on the analog or digital panel.
If the machine is 110VAC, 2 seal
bar, F-1 is located on the chassis.

Make sure the seal impulse
potentiometer is set high enough
or check for possible defective
digital control panel

NOTE: For proper sealing, three things must occur:

1. The seal bar must come down and place adequate pressure between the seal bar and
the backup strip.

2. The seal element must heat up sufficiently to fuse the pouch.

3. The pouch must be allowed to cool for a time to ensure a good “set.”

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•Q

MAINTENANCE •

P A G E 4.4

MAIN: 816-753-2150

TOLL FREE: 800-777-5624

INTERNET: kochequipment.com

E-MAIL: [e-mail]

Supervisor Menu on Digital Panel

Untrained personnel should not alter any setting in the supervisor menu.

+

PROGRAM

YES

RUNNING PROG: 1

-

NO

The following are parameters that can
only be set in the supervisor menu.

+

PROGRAM

YES

PREVAC: 15

-

NO

This is the Main Menu screen. When
the machine starts up, the last program
that was run will be the current program
shown in the window.

Press and hold down both arrow keys for
at least 3 seconds to enter the supervisor
menu.

NOTE: If your machine is not installed
with the precut option, disregard the
PREVAC, CUTTIME, and WAITTIME
parameters.

PREVAC is the % vacuum that you wish to reach
before activating the knife, which makes slits in
the bag for precut. Use the up or down arrow
keys to change the current setting.
The range is from 5% to 20% vacuum.
Press the MENU key.

CUTTIME: 1

WAITTIME: 3

Figure 4.4

+

PROGRAM

YES

CUTTIME is the number of seconds that the
seal valve is activated. This is the time when the
knife actually makes the evacuation slits in the
bag/pouch for precut. The range is from 0 to 3

-

NO

seconds.
Press the MENU key.

+

PROGRAM

YES

WAITTIME is the number of seconds the machine
waits for the knife to retract before resuming the
vacuum cycle. The range is from 0 to 6 seconds.

-

NO

Press the MENU key.

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MAINTENANCE •

P A G E 4.5

Supervisor Menu on Digital Panel

MAIN: 816-753-2150

TOLL FREE: 800-777-5624

INTERNET: kochequipment.com

E-MAIL: [e-mail]

COOLDOWN: 4.0

SECURITY: NO

+

PROGRAM

YES

COOLDOWN is the time that the machine
waits after sealing the bag/pouch before
the seal bars retract. This allows time for
the actual seal to cool down and take a
set.

-

NO

The range is from 1 to 8 seconds.
Press the MENU key.

+

PROGRAM

YES

SECURITY can be turned on by selecting
yes. If security is on, the operator menu
will be read only and the operator will not

-

NO

be able to change any settings.
Press the MENU key.

# PROGRAMS: 10

TEST: YES

Figure 4.5

+

PROGRAM

YES

number of programs that may be saved in
memory. Each program may have its own
set of unique parameters.
This range is from 1 to 10.

This is how you specify the maximum

-

NO

Press the MENU key.

If TEST is set to YES (using the up arrow

+

PROGRAM

YES

key), the vacuum valve and vent valve
may be operated manually. The up arrow
key activates the vacuum valve, the down
arrow key activates the vent valve, and
pressing both at the same time turns them

-

NO

both off. As you activate either valve, the
vacuum pressure is displayed.
Press the MENU key.

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MAINTENANCE •

P A G E 4.6

Supervisor Menu on Digital Panel

MAIN: 816-753-2150

TOLL FREE: 800-777-5624

INTERNET: kochequipment.com

E-MAIL: [e-mail]

PULSE VAC: YES

PULSE TO: 95

+

PROGRAM

YES

PULSE VAC allows for a more controlled
vacuuming process. Rather than simply
opening up the vacuum valve for a
continuous vacuum the vacuum valve is
opened and closed repeatedly until the

-

NO

chamber reaches the set vacuum level.
Press the MENU Key.

+

PROGRAM

YES

This is the % vacuum reached by pulsing
the vacuum valve before the vacuum valve
opens completely to fully evacuate the
chamber. The range is 99% to 20%.

-

NO

Press the MENU Key.

PULSE ON: 1.2

Figure 4.6

+

PROGRAM

YES

This is how long the vacuum valve is
turned on during the vacuum cycle.
The range is from 0 to 3 seconds.
Press the MENU Key.

-

NO

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MAINTENANCE •

P A G E 4.7

Supervisor Menu on Digital Panel

DANGER

MAIN: 816-753-2150

TOLL FREE: 800-777-5624

INTERNET: kochequipment.com

E-MAIL: [e-mail]

PULSE OFF: 1.0

VAC ERROR: ON

Figure 4.7

+

PROGRAM

YES

This is how long the vacuum valve is turned
off during the vacuum cycle.
The range is from 0 to 3 seconds.
Press the MENU key.

-

NO

VAC ERROR is an option that is turned ON

+

PROGRAM

YES

or OFF. If set OFF, default, the machine
will time out if the preset vacuum is not
reached in 30 seconds, and the machine
with complete the cycle. If set ON and the

-

NO

machine does not reach the preset vacuum
in 30 seconds, then the panels will display
VAC ERROR and vent the chamber without
sealing.

Opening Chamber Machine

1. Turn the power switch to the “OFF” position and disconnect the power cord from the wall
receptacle.

Hazardous voltage.
Disconnect and lockout power before servicing machine or cleaning. Do not remove panels
unless power has been disconnected and locked out at risk of electric shock hazard.

2. Remove the screws located on the back of the machine’s stainless steel cabinet. Lift up on

the stainless panel to access inside the machine.

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MAINTENANCE •

P A G E 4.8

MAIN: 816-753-2150

CAUTION

TOLL FREE: 800-777-5624

INTERNET: kochequipment.com

E-MAIL: [e-mail]

Changing Vacuum Pump Oil

1. Open the machine (see above).

2. A trough and hole is located toward the front of the machine, between the pump and

front edge of the chassis. Slide the machine over to the edge of the table with the hole
over the edge of the table. Position an oil collection pan underneath this hole.

Tip Over Hazard.
Only let the front foot of the chassis hang over the edge of the table.

3. Loosen and remove the Oil Filler Cap with a 1¼-in. open end wrench.

4. Loosen the Oil Drain Plug located to the front and lower middle on the pump with a

1¼-in. open end wrench. Remove the plug slowly to control the flow of oil.

5. With the oil drained, replace the Oil Drain Plug and wipe any excess oil out of the trough

in the chassis.

6. Fill the pump with oil until the level is between the minimum and maximum lines on the

Oil Sight Glass. Replace the Oil Filler Cap.

7. Tilt the machine back down onto the chassis. Plug the power cord back into the wall

receptacle.

8. Cycle the machine a couple of times, unplug, and tilt the machine up to check the Oil

Level. Add oil if necessary. Tilt the machine back down and replace the two screws in the
rear of the machine.

Replacing Potentiometer

Refer to Parts, “Analog Control Panel,” for the disassembly of the panel. Remove the
potentiometer by unbending the mounting tabs holding the potentiometer to the circuit
board. Pull the potentiometer out of the circuit board.

MOUNTING TABS

Figure 4.8

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•Q

MAINTENANCE •

P A G E 4.9

MAIN: 816-753-2150

DANGER

TOLL FREE: 800-777-5624

INTERNET: kochequipment.com

E-MAIL: [e-mail]

Replacing Power Cord

1. Turn the power switch to the “OFF” position and disconnect the power cord from the wall

receptacle.

Hazardous voltage.
Disconnect and lockout power before servicing machine or cleaning. Do not remove panels
unless power has been disconnected and locked out at risk of electric shock hazard.

2. Open the machine as described in “Opening Chamber Machine” on page 4.8.

3. Loosen the cord grip nut on the rear of the machine. Remove the cord from the cable

clamps on the bottom of the chamber. Disconnect the cord from the control panel.

4. Route the new power cord through the cord grip on the rear and through the cable

clamps on the bottom of the chamber.

5. Connect the new power cord to the control panel as shown in the table below.

Connect to

Terminal

110 Volt Wire

Color

230 Volt Wire

Color

Terminal 8 Green (Ground) Green/Yellow
Terminal 7 White Brown
Terminal 6 Black Blue

Maintenance Log

A maintenance log is a journal of all maintenance performed. Each entry includes a
date, maintenance performed (details about the type of work done), and technician (who
performed the maintenance). The maintenance log is also a place where a schedule is kept
for further maintenance.

A maintenance log will clearly show oil changes, daily inspections, Teflon® tape

replacement, and so on. A master copy has been provided on page 4.11, please create a

copy and store in the back of this owner’s manual.

Service Log

A service log is a journal of all service work performed. Each entry includes a date, service
provided (details about the type of service), and technician (who performed the service).

A service log will clearly show training provided, frequent wear items, and so on. A master

copy has been provided on page 4.124, please create a copy and store in the back of this

owner’s manual.

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MAINTENANCE •

P A G E 4.10