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ULTRASOURCE Ultravac 500 Owner's Manual

Vacuum chamber packaging machine
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Vacuum Chamber Packaging Machine
Owner's Manual
Effective Serial 2247+
860052 • Revision U • 06/01/2013
Think
UltraSource
First.

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Summary of Contents for ULTRASOURCE Ultravac 500

  • Page 1 Vacuum Chamber Packaging Machine Owner’s Manual Effective Serial 2247+ 860052 • Revision U • 06/01/2013 Think UltraSource First.

  • Page 3: Table Of Contents

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 TABLE OF CONTENTS General SCHEMATICS Specifications Designation and Function of Controls 5.1 Machine Conformity 230 Volt, Single Phase, Analog Panel 5.2 CE Declaration of Conformity...
  • Page 4 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 ULTRASOURCE LLC Ultravac ® Vacuum Chamber Packaging Machine Owner’s Manual 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.

  • Page 5: General

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 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.

  • Page 6: Specifications

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Specifications 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.)

  • Page 7: Machine Conformity

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Machine Conformity This machine has been manufactured to conform to the following safety standards: UL 73, Motor Operated Appliances, USA The Ultravac 500 is manufactured to conform to the relevant provisions of ANSI/UL-73, Tenth Edition dated 03/2011, Revised 01/2012.
  • Page 8 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 UltraSource LLC 1414 West 29th Street Kansas City, MO 64108-3604 USA T. 816.753.2150 F. 816.753.4976 UltraSource LLC 1414 West 29th Street Kansas City, MO 64108-3604 USA...

  • Page 9: Safety

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 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 Ultravac Services Inc.

  • Page 10: Food Safety

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 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.

  • Page 11: Startup Unpacking

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 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.

  • Page 12: Vacuum Pump

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 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.

  • Page 13: Operation Placement Of Product

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 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.

  • Page 14: Operation With Analog Control Panel

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 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.

  • Page 15: Operation With Digital Control Panel

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Operation with Digital Control Panel The digital control panel is shown below, Figure 3.3. It allows the user more options than the standard control panel. The embedded microprocessor controls each sequence of the packaging operation.

  • Page 16: Operator Menu On Digital Panel

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Operator Menu on Digital Panel NOTE: If the supervisor has set security on, these settings cannot be changed. NOTE: IF THE SUPERVISOR HAS SET SECURITY ON,...

  • Page 17: Selecting A New Program

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Operator Menu on Digital Panel (continued) If the machine is equipped with the gas PROGRAM option, it can be turned ON or OFF by IF YOUR MACHINE IS EQUIPPED WITH THE GAS pressing the UP or DOWN arrow keys.

  • Page 18: Sealing With Air-Assist

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 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...

  • Page 19: Maintenance

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 MAINTENANCE Prior to Cleaning Every environment and application is different; therefore, UltraSource cannot provide cleaning instructions to guarantee microbiological sanitation. UltraSource requests that the...

  • Page 20: Vacuum Pump Maintenance

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 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.

  • Page 21: Reading The Indicators

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Reading the Indicators If your machine is controlled by a digital control module (with touch pad), this design aids in troubleshooting. The digital panel has indicator lights mounted on the front below the ON/ OFF switch.
  • Page 22 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Troubleshooting Problem Indications Remedy Chamber not venting Lid will not open and red Check ventilation valve SOL-1 for (lid will not open) indicator light “VENT” on...

  • Page 23: Supervisor Menu On Digital Panel

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Supervisor Menu on Digital Panel Untrained personnel should not alter any setting in the supervisor menu. This is the Main Menu screen. When...
  • Page 24 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Supervisor Menu on Digital Panel (Continued) COOLDOWN is the time that the machine waits after sealing the bag/pouch before PROGRAM the seal bars retract. This allows time for COOLDOWN: 4.0...
  • Page 25 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Supervisor Menu on Digital Panel (Continued) PULSE VAC allows for a more controlled vacuuming process. Rather than simply PROGRAM opening up the vacuum valve for a...

  • Page 26: Opening Chamber Machine

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Supervisor Menu on Digital Panel (Continued) This is how long the vacuum valve is turned off during the vacuum cycle. PROGRAM The range is from 0 to 3 seconds.

  • Page 27: Changing Vacuum Pump Oil

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Changing Vacuum Pump Oil 1. Open the machine (see page 4.8). 2. Loosen and remove the Oil Filler Cap with a 15/16-in. open end wrench.

  • Page 28: Replacing Power Cord

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Replacing Power Cord 1. Turn the power switch to the “OFF” position and disconnect the power cord from the wall receptacle. DANGER Hazardous voltage.
  • Page 29 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Maintenance Log Date Maintenance Performed Technician Think UltraSource First. • info@UltraSourceUSA.com • UltraSourceUSA.com...
  • Page 30 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Service Log Date Service Provided Technician Think UltraSource First. • info@UltraSourceUSA.com • UltraSourceUSA.com...

  • Page 31: Schematics

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 SCHEMATICS Designation and Function of Controls The following designations are found on the Electrical Diagrams: Manually Activated Switches and Buttons: Solenoid Valves: SW-1...

  • Page 40: Parts

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 PARTS Recommended Spare Parts UltraSource Qty. Description Part No. 1 ea 861032 Seal Bar Assembly 1 ea 860045 Fuse, MDA 10A 6 ft...

  • Page 41: Pump And Chassis

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Pump and Chassis Parts List Item UltraSource Description Part No. 860076 Cabinet Assembly 900052 Vacuum Pump, 230V, 60Hz, Single Phase, 2-hp 900059 Vacuum Pump, 230/380V, 60Hz, 3 Phase, 2-hp...
  • Page 42 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Pump and Chassis Diagram 17 18 Think UltraSource First. • info@UltraSourceUSA.com • UltraSourceUSA.com...

  • Page 43: Seal Bar

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Seal Bar Parts List Item UltraSource Description Part No. 861032 Seal Bar Assembly 860195 Seal Bar End Cap 860986 Seal Bar Spring 861003 Bladder Assembly Complete...
  • Page 44 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Seal Bar Diagram Think UltraSource First. • info@UltraSourceUSA.com • UltraSourceUSA.com...

  • Page 45: Lid And Hinge System

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Lid and Hinge System Parts List Item UltraSource Description Part No. 860094 860220 Lid Gasket 861240 Double-Sided Foam Tape 860025 Channel for Backup Strip...
  • Page 46 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Lid and Hinge System Diagram 23 21 Think UltraSource First. • info@UltraSourceUSA.com • UltraSourceUSA.com...

  • Page 47: Gas Flush Components

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Gas Flush Components Parts List Item UltraSource Description Part No. 860291 Brass Hex Nut, 3/8-24 860109 Fitting, Dual Hose Barb 860110 Hose Clamp for 1/4-in. Reinforced Hose Reinforced Hose, 1/4-in.
  • Page 48 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Gas Flush Components Diagram To Front To Rear Nozzle Nozzle To Other Side Port A To Bladder Port R To Vacuum Think UltraSource...

  • Page 49: Main Control - Front Side

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Main Control - Front Side Parts List Item UltraSource Description Part No. 860044 Sealing Transformer, 750VA [T1] 860311 Control Power Transformer, 50VA [T3] 860041...
  • Page 50 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Main Control - Front Side Diagram Think UltraSource First. • info@UltraSourceUSA.com • UltraSourceUSA.com...

  • Page 51: Analog Control Panel

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Analog Control Panel Parts List Item UltraSource Description Part No. 861056 Complete Front Panel without Gas Flush (Not Shown) 861057 Complete Front Panel with Gas Flush (Not Shown)
  • Page 52 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Analog Control Panel Diagram Think UltraSource First. • info@UltraSourceUSA.com • UltraSourceUSA.com...

  • Page 53: Digital Control Panel

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Digital Control Panel Parts List and Diagram Item UltraSource Description Part No. 860995 Front Panel Assembly 860637 Vacuum sensor 860316 Main Power On/Off Switch [SW-1]...

  • Page 54: Main Control - Back Side

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Main Control - Back Side Parts List and Diagram Item UltraSource Description Part No. 861216 Seal Pilot Valve [SOL-3], 3-way, Normally Closed 835572 Hose Barb, 1/4-in.

  • Page 55: Mebner Valve

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Mebner Valve Parts List and Diagram Item UltraSource Description Part No. 860967 Valve, Mebner Vacuum and Vent 889559 Fitting, 1-¼-in. 90° Elbow, SS 860141 Nipple, Close 1-¼-in.

  • Page 56: Miscellaneous Machine Parts

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 Miscellaneous Machine Parts Parts List and Diagram Item UltraSource Description Part No. 860050 Filler Plate Set 860051 Stainless Steel Product Tray 860124 Magnetic Stop for Product Tray...

  • Page 57: Inline Filter Kit (Optional)

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Inline Filter Kit Parts List and Diagram Item UltraSource Description Part No. 843034 Filter, Vacuum 1-1/2” NPT 860600 Reducer, 1-1/2” to 1-1/4” 860771 Piping, 1-1/4” NPT Male X Female SS...
  • Page 58 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 THIS PAGE LEFT BLANK INTENTIONALLY. Think UltraSource First. • info@UltraSourceUSA.com • UltraSourceUSA.com...

  • Page 59: Reference Manuals R5 Series Vacuum Pumps

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 REFERENCE MANUALS R5 Series Vacuum Pumps Included within this Ultravac 500 owner’s manual is an installation and operating manual ® for the vacuum pump equipped with this vacuum chamber machine.
  • Page 60 INSTALLATION OPERATING MANUAL R5 Series Current Models 0025, 0040, 0063, 0100 and 0250 Single Stage Rotary Vane Vacuum Pumps...

  • Page 61: Table Of Contents

    TABLE OF CONTENTS GENERAL Identification Operating Principles 1.0 INSTALLATION 1.1 Unpacking 1.2 Location 1.3 Power Requirements 1.4 Vacuum Connections 1.5 Oil Filling 2.0 OPERATION 2.1 Start-up 2.2 Gas Ballast 2.3 Stopping Pump 2.4 Water-Cooled Pumps 2.5 Oxygen Service Pumps 3.0 MAINTENANCE 3.1 Pump Oil 3.1.1 Oil Level 3.1.2 Oil Type and Quantity...

  • Page 62: General

    GENERAL All R5 series pumps are designed to handle air. Vapor in the air stream can be tolerated when the Identification pump is operated within certain operating parame- ters as defined by Busch, Inc. Engineering (see For model identification, see the nameplate Section 2.2 Gas Ballast).

  • Page 63: Location

    NOTE: See the motor manufacturer’s manual The inlet port of the pump is covered with a plas- for start-up maintenance of the motor. tic cap prior to shipment to prevent dirt and o t h e r foreign material from entering the pump. Do not remove this cover until the pump is actually ready Correct direction of rotation is marked by an for connection to your system.

  • Page 64: Oil Filling

    If the gas that is pumped contains dust or other Pump Type Oil Capacity (Qt.) foreign solid particles, a suitable (10 micron rating or less) inlet filter should be connected to the inlet 0025/0040 port. Consult the factory for recommendations. 0063/0100 2.5/2.7 0250...

  • Page 65: Gas Ballast

    had sufficient time to return to the oil sump. has a built-in anti-suck-back valve (Ref. 251 thru 255) to prevent the pump from rotating backwards NOTE: The oil separated by the exhaust filter when it is shut off. element forms droplets on the outside of the exhaust Caution: Do not use the anti-suck-back valve filter which collect at a low point in the upper half of as a check or shut-off valve for your vacuum sys-...

  • Page 66: Oxygen Service Pumps

    2.5 Oxygen Service Pumps These Installation and Operating Instructions are valid for the following vacuum pumps: Warning: This pump is filled with a special RA/RC 0025 RA/RC 0100 operating fluid. Do not use any other type of RA/RC 0040 RA/RC 0250 fluid, oil and/or grease.

  • Page 67: Maintenance

    pump should be smoking excessively. It is normal THERMOSTAT VALVE for the oil to be foamy and light in color in an oper- ating pump. However, if the oil is milky colored, it is an indication that water is present in the oil. Normally, by operating the pump for an extended period, with the inlet suction blanked off and the gas ballast (Pos 440) open on RA pumps, the water will...

  • Page 68: Automotive-Type Oil Filter

    and Repair Manual. Auxiliary oil cooling is the WARNING: If the gas entering this pump is most practical approach to a severe heating prob- a health hazard, use rubber gloves and all neces- lem. sary personal protection equipment when per- forming the exhaust filter replacement opera- tion.
  • Page 71 0025 - 0250 "C" & "E" Parts List Description Description Description Screw hex head cap Cylinder Exh. Screen, coarse Socket set screw Exh. Screen, fine Lockwasher Motor adapter flange Rotor Valve assembly, exhaust Bearing sleeve Oil service block Lockwasher Coupling half, pump side Vane Oil service block gasket Endplate, motor side...

  • Page 73: Vacuum Inlet Filter

    requires an immediate change of the exhaust filter. 3.1.3). Inspect inlet filter (see Section 3.4). In order to replace the filter, remove the four Every three (3) or four (4) months, 500 to 750 socket head cap screws (Ref. 155, 146) retaining the hours of operation, or as necessary: See 3.1.3 and exhaust port housing.
  • Page 74 ing temperature is reached (at least 20-30 minutes). 4.1.7 Possible Cause 4.1.2 Possible Cause Oil tubing defect and/or leaking. Oil return line broken on RC model. Vacuum system or vacuum piping not leak-tight. Remedy: Remedy: Replace or retighten the oil fittings or oil tubing. Check hose and pipe connections for possible Replace only with same size tubing.
  • Page 75 Remedy: ing to motor nameplate data; check fuses; and install proper size wire. If ambient temperature is high, use Follow disassembly and assembly steps outlined larger size overloads or adjust setting 5% above in the Maintenance and Repair Manual on resetting nominal motor nameplate value.
  • Page 76 Remedy: Pump smokes at the exhaust side or expels oil droplets from the exhaust. Correct the oil level and quality per Section 1.5 and use recommended motor oil. 4.4.1 Possible Cause 4.3.4 Possible Cause Exhaust filter is not properly seated with O-ring (Ref.
  • Page 77 4.4.5 Possible Cause replace vanes. Oil return line (Ref. 290) on RC Standard pump 4.6 Trouble is clogged or broken. The pump runs very hot. See Technical Data for Remedy: typical oil sump temperature. Free clogged line, replace broken line, but only 4.6.1 Possible Cause with proper size, and check that oil is pumped out of oil sump while vacuum pump is operating.
  • Page 78 Remedy: Remedy: Disassemble and exchange vanes as outlined in Replace automotive-type filter per Section 3.2 the Maintenance and Repair Manual. and exchange oil per Section 1.5. 4.7.2 Possible Cause 4.8.2 Possible Cause Pump was operated for an extended period of Wrong automotive-type filter is used and/or oil time in the wrong rotation.
  • Page 79 5.0 LIMITED STANDARD WARRANTY This Limited Standard Warranty applies only to the above and is for the period set forth. Busch, Busch, Inc. warrants that all products furnished Inc.'s maximum liability shall not, in any case, by it are free from defects in material and work- exceed the contract price for the product, part, or manship at the time of shipment for a period of 18 component claimed to be defective;...
  • Page 80 * Maximum oil temperature with 80°F ambient temperature and no supplemental oil cooling.
  • Page 82 UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 USA • 800.777.5624 • 816.753.2150 THIS PAGE LEFT BLANK INTENTIONALLY. Think UltraSource First. • info@UltraSourceUSA.com • UltraSourceUSA.com...

  • Page 83: Index

    UltraSource LLC • 1414 West 29th Street • Kansas City, MO 64108-3604 • 800.777.5624 • 816.753.2150 Index Lid 4.1, 4.4, 6.6 Safety Guidelines 1.2 Seal Bar 4.1, 4.2, 4.4, 6.4 Air-Assist 2.2, 3.6 Seal Bar Maintenance 4.2 Analog Control Panel 3.2, 4.9, Seal Bladder Valve 4.3...
  • Page 84 800.777.5624 UltraSource LLC 1414 West 29th Street Kansas City, MO 64108 USA Phone 816.753.2150 • Fax 816.753.4976 info@UltraSourceUSA.com • UltraSourceUSA.com Replacement Parts Toll-Free 800.777.5624 Fax 816.561.2854 Ultravac Services Inc. Technical Support Toll-Free 800.777.5624 Fax 816.753.4976 Think UltraSource First.

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