Page 1 Vacuum filler ROBOT HP7E (from 160.0215) ROBOT HP10E (from 161.0312) ROBOT HP12E (from 165.0234) ROBOT HP15E (from 162.0241) ROBOT HP20E (from 163.0300) Operating instructions...
Page 2 We reserve the right to make technical modifications Issue: 04/10 Version: 3.1 EN (Original operating instructions) Software Version: 00.02.000 © VEMAG Maschinenbau GmbH • Postfach 1620 • D-27266 Verden Phone: +49 42 31 77 70 • Fax: +49 42 31 77 72 41 E-Mail: e-mail@vemag.de http://www.vemag.de...
Page 3 1.2 Use in accordance with purpose 1.3 Explanation of symbols 1.4 General safety instructions 1.5 Special safety instructions 2. Description 2.1 Overview ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 2.2 Brief description 2.2.1 Hopper 2.2.2 Feed screw 2.2.3 Double screws 2.2.4 Filling horn holder...
Page 4 Index ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.3.5 Plus/minus keys 6.3.6 Cursor keys 6.3.7 Enter key 6.4 Status and error messages 6.5 Principles of operation 6.5.1 Select and edit programs 6-11 6.5.2 Importing and exporting programs using a USB stick 6-13 6.5.3 Select mode group, mode and view...
Page 5 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Index 6.6.4.25 Extra hook 6-40 6.6.4.26 Permitted deviation 6-41 Working with the automatic separation valve 6-42 6.6.4.27 Separation valve 6-42 6.6.4.28 Separation interval 6-42 6.6.4.29 Valve offset 6-42 6.6.4.30 Separation valve open 6-43 6.6.4.31 Separation valve closed...
Page 6 9.1 General information 9.2 Troubleshooting table 10. Appendix 10-1 10.1 General information 10-1 10.2 Technical data ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10-2 10.3 Dimensional drawings ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10-3 10.3.1 Hopper 250 l...
Page 7 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Declaration of conformity Declaration of conformity reflecting the intention of EC Machinery Directive 2006/42/EC, Annex IIA VEMAG Maschinenbau GmbH Weserstraße 32 27283 Verden (Aller) hereby declare that the Continuous vacuum filler...
Page 9 These operating instructions cover all the information required to operate the vacuum filler. Two versions of the machine are available: • ROBOT HP7E / HP10E / HP12E / HP15E / HP20E in the form of a portioning machine • ROBOT HP7E / HP10E / HP12E / HP15E / HP20E in the form of a...
Page 11 1.1 Sphere of application Two versions of the continuous vacuum filler are available: • ROBOT HP7E / HP10E / HP12E / HP15E / HP20E in the form of a por- tioning machine • ROBOT HP7E / HP10E / HP12E / HP15E / HP20E in the form of a portioning and linking machine (optional) It can also be fitted with special attachments (optional).
Page 12 1. Safety instructions ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 1.3 Explanation of symbols The following symbols appear in these operating instructions, indicating residual hazards when operating the machine or referring the reader to other important information.
Page 13 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 1. Safety instructions 1.4 General safety instructions • Any person working on or with the machine must have read and un- derstood these operating instructions, in particular the safety instruc- tions.
Page 14 1. Safety instructions ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 1.5 Special safety instructions Danger! To prevent injury, switch off the machine before any work (assembly, dis- mantling, cleaning, maintenance, repair). Then switch off the main switch to disconnect the machine from the mains.
Page 15 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 2. Description 2. Description 2.1 Overview ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Hopper Vacuum pot Vacuum display Vacuum control valve Lifting/tipping device (optional) Control panel Adjustable feet...
Page 16 2. Description ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 2.2.2 Feed screw The product is compressed in the hopper by the feed screw (1) and fed to the thread of the double screws with the aid of the vacuum. Spiral stopper (2) improves product feed.
Page 17 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 2. Description 2.2.4 Filling horn holder The machine is fitted with a filling horn holder (1) at the outlet as standard and this is locked at the outlet by the locking nut (2). The filling horn (3) is attached to the filling horn holder with the aid of the filling horn nut (4).
Page 18 2. Description ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 2.2.6 Controls The controls on the rear of the machine are protected by a cover (1) which is latched with the aid of a toggle (2). Cover Toggle Fig.
Page 19 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 2. Description The following controls are arranged on the control panel on the front of the machine next to the portioning computer: • ON switch (1) • OFF switch (2) •...
Page 20 2. Description ROBOT HP7E / HP10E / HP12E / HP15E / HP20E DOWN key (optional) This key lowers the trolley hoist of the lifting/tipping device (optional). The trolley hoist stops automatically as soon as the trolley is 500 mm abo- ve the ground.
Page 21 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 2. Description 2.2.7 Knee lever The filling process is switched on and off using the knee lever. It can be adjusted to suit the height and location of the operator.
Page 23 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 3. Installation and commissioning 3. Installation and commissioning 3.1 Transporting the machine The machine may only be transported using suitable lifting trucks or fork- lift trucks with a capacity of at least 1,500 kg. If at all possible, move the fork-lift/lifting truck under the machine from the outlet side.
Page 24 3. Installation and commissioning ROBOT HP7E / HP10E / HP12E / HP15E / HP20E • Drive the lifting truck / fork-lift truck in under the machine so that fork (1) is located precisely centrally between the feet. Warning! Place planks (2) between the fork and the machine to prevent the machi- ne slipping during transportation.
Page 25 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 3. Installation and commissioning 3.2 Setting up the machine The machine must stand firmly on all four feet at all times and be as level as possible. There may only be a slight inclination (max. 2°) in the direc- tion of the outlet side to encourage water to drain off after cleaning.
Page 26 3. Installation and commissioning ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 3.3 Electrical connection Danger! To prevent injury (electric shock), the electrical connection may be made only by authorised specialist staff or specialist companies. • Inside the machine housing, connect the machine to the main switch (1) of the machine using four-core cable with 3 x phase and 1 x earth wire.
Page 27 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 3. Installation and commissioning 3.4 Checking direction of rotation Warning! To avoid damage to the machine, the machine may not be operated for more than 10 seconds in the wrong direction of rotation.
Page 28 3. Installation and commissioning ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 3.5 Levelling the lifting/tipping device (optional) The trolley hoist of the lifting/tipping device is set at the factory with the feet of the machine screwed in and on a level floor (outlet height 1,000 mm).
Page 29 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 3. Installation and commissioning • Undo the two top mounting bolts (1) on the back of drive hood (2) and tap the bolts to release the drive hood. Push the hood and its seal in the direction of the operator side until the pins (3) release the guide grooves and lift it off.
Page 30 3. Installation and commissioning ROBOT HP7E / HP10E / HP12E / HP15E / HP20E • Move the arm of the lifting/tipping device into the bottom end position using the DOWN key. Push a trolley into the trolley hoist to check the correct height of the trolley hoist and repeat setting if necessary.
Page 31 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 3. Installation and commissioning • Check that the trolley hoist is level using a spirit level, and push a trolley right into the trolley hoist. Warning! Check whether the locking lever (1) is properly locked and is holding the trolley securely in the trolley hoist.
Page 33 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 4. Setting up 4. Setting up 4.1 General information • To set up the machine, select a double screw housing, the double screws to suit the product to be processed and the required accesso- ries.
Page 34 4. Setting up ROBOT HP7E / HP10E / HP12E / HP15E / HP20E A pin (1) under the coupling pins (2) in the feed cylinder centres the dou- ble screw housing which has the appropriate bore on its end face.
Page 35 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 4. Setting up 4.3 Fitting the double screws • Position the double screws (1) so that the screw marked left (”links”) is on the left-hand side and the front faces are flush.
Page 36 4. Setting up ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 4.4 Fitting the filling horn • Adjust locking nut (1) so that the handle is between the 10 and 11 o’clock position and insert filling horn holder (2).
Page 37 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 4. Setting up 4.5 Locking the linking gear (optional) Danger! There is a risk of crushing when swivelling the linking gear in and out. To prevent injury, proceed extremely carefully when fitting and dismantling the part.
Page 38 4. Setting up ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 4.6 Fitting the linking horn (optional) • Use a linking horn with the largest possible diameter and shortest possible length related to the size of the casing.
Page 39 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 4. Setting up • Insert linking horn (1) into linking head (2) and tighten linking nut (3) using universal spanner (4). Hold the linking head steady with the second universal spanner as you do so.
Page 40 4. Setting up ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 4.7 Setting the vacuum 4.7.1 Filling raw and cooked sausage • Set the maximum vacuum for filling raw and cooked sausage. 4.7.2 Filling liquid product • Put blind plug (1) together with O-ring (2) and retaining ring (3) in the rear opening of double screw housing (4).
Page 41 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 4. Setting up 4.8 Fitting the scraper A scraper can be fitted to the hopper for product which sticks to the wall of the hopper. The scraper must be used when processing raw sausage.
Page 42 4. Setting up ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 4.9 Adjusting the knee lever The knee lever can be adjusted in terms of height (H), angle (W) and projection (A) to suit the height and location of the operator.
Page 43 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 5. Operation 5. Operation 5.1 Working with the machine To start production with the machine, proceed as follows: • Set up the machine for the product to be filled. Section 4 •...
Page 44 5. Operation ROBOT HP7E / HP10E / HP12E / HP15E / HP20E • Unlock the locking lever (1) with your foot and pull the trolley out of the trolley hoist. Locking lever Fig. 5-1 Trolley © VEMAG 2010...
Page 45 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 5. Operation • If you want to use the machine to link, test the relevant linking horn for concentricity with the aid of the respective program. Section 6 • Use the portioning computer to select a filling program and check whether the double screws are correctly selected in the portioning computer.
Page 46 5. Operation ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 5.2 Working with provisional drive Should the portioning computer of the machine fail, it is possible to conti- nue operating the machine using provisional drive. In this mode, you can run the machine hopper empty at approx.
Page 47 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6. Graphical control This section introduces the individual controls of the graphical control system. • How is the control panel arranged? • How is the screen arranged? •...
Page 48 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Function keys Colour screen Keypad © VEMAG 2010...
Page 49 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.1 Control panel The colour screen and the keys are integrated in the green control panel. The screen is divided into various fields. Section 6.2 There are seven function keys to both the left and the right of the screen which you use to activate the associated area of the screen.
Page 50 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Header Mode group Program Mode View Product name Start/stop method Parameters Parameters Footer © VEMAG 2010...
Page 51 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.2 Screen The screen is divided into five different areas: • Header • Program and mode (mode group, mode, view, start/stop method) • Parameters on the left-hand side of the screen •...
Page 52 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Numerical keypad Key C (Cancel) Padlock key Screen up/down keys Plus/minus keys Cursor keys Enter key © VEMAG 2010...
Page 53 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.3 Keypad 6.3.1 Numerical keypad Numerical values are entered using the numerical keypad. Every value entered must be confirmed with Enter. 6.3.2 Key C (Cancel) Key C (Cancel) performs the following functions: •...
Page 54 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.4 Status and error messages The footer displays status and error messages. You can use the arrow keys in the footer to scroll through the last 100 messages. To do this, you need to activate the footer using the cursor keys.
Page 55 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.5 Principles of operation This section covers the principles of operating the portioning computer. • How are programs selected and edited? • How are programs imported and exported with the aid of a USB stick? •...
Page 56 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Program number Product name Program list with action buttons 6-10 © VEMAG 2010...
Page 57 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.5.1 Select and edit programs In the Program field you can select, edit, copy and delete filling programs and also enter product names for the individual programs.
Page 59 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.5.2 Importing and exporting programs using a USB stick You can import and export filling programs using a USB stick. The USB stick is plugged into the rear of the control board.
Page 61 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.5.3 Select mode group, mode and view In the Operating mode field you can select mode group and mode and set the view required for each application. The modes which can be selected are determined by the machine type and the machine configuration.
Page 62 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Start/stop method Attachment / Optional Attachment 6-16 © VEMAG 2010...
Page 63 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.5.4 Select start/stop method In the Start/stop method field you can select the start/stop method and the attachments used. • Press the Start/stop method key. • Select the Start/stop method field using the cursor key.
Page 65 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.5.5 Make settings (language, date/time, password) You can select various settings in the View field. • Press the Operating mode function key. • Select the View field using the bottom cursor key.
Page 67 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.5.6 Set up userkey Access to certain functions can be blocked with the aid of the userkey. The userkey has five different user types: • Program locking (switch programs, enter weight corrections and per- form a linking horn test) •...
Page 69 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6. Mode groups, modes, start/stop methods and parameters This section introduces the various mode groups, modes, start/stop methods and parameters. • What mode groups are there? •...
Page 70 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.6.1 Mode groups, modes and views Use the Operating mode function key to select the mode group, mode and view. You can set the mode groups and modes in the Service area.
Page 71 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.3 Basic parameters The basic parameters are displayed on the left-hand side of the screen. These parameters are required for the majority of applications. The parameters cannot be scrolled.
Page 72 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.6.3.2 First portion Display: First portion Unit: Gramme [g] Resolution: 0.1 g/1 g Setting range: 0 – 999 g Application: Portioning programs (not for weight groups, “Continuous”...
Page 73 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.3.4 Pause Display: Pause Unit: Milliseconds [ms] Resolution: 1 ms Setting range: 0 – 9,999 ms / -1 = single portions Application: Portioning programs (not for “LPG” or “Continuous” modes) •...
Page 74 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.6.3.6 Speed Display: Speed Unit: Per cent [%] Resolution: 0.1 % Setting range: 0 – 100 % Application: All applications (not for pressure control) • Enter speed.
Page 75 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.3.7 Back suction Display: Back suction Selection: On / Off Unit: Gramme [g] Resolution: 0.1 g Setting range: 0 – 200 g (0 - 120 g for DP machines)
Page 76 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.6.3.10 Pressure control Display: Pressure control Unit: Bar [bar] Resolution: 0.1 bar Setting range: 0.1 – 20 bar / per analogue input Application: All applications requiring a constant filling pressure •...
Page 77 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.4 Supplementary parameters The supplementary parameters are displayed on the right-hand side of the screen. These parameters can be summarized in parameter sets for your applications. It is possible to scroll through the parameters.
Page 78 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.6.4.4 Link offset/clip offset/knife offset (minced meat line) Display: Twist delay / Clip offset / Knife offset Unit: Milliseconds [ms] Resolution: 1 ms Setting range: -3,000 – +3,000 ms (default for linking = -25,...
Page 79 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.4.6 Select pumping system Display: Pumping system Selection: Rotary vane pump type (e.g. 10-rotor) Application: Fillers with rotary vane pump • Enter rotary vane pump type. •...
Page 80 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.6.4.9 Metal detection Display: Metal detection Selection: Off / Manual / Reject system Unit: Gramme [g] / Milliseconds [ms] / Speed [%] Resolution: 1 g / 1 ms / 1 % Setting range: 1 –...
Page 81 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.4.11 Synchronizing the machine using an external signal Display: Portions per signals Selection: Off / Number Unit: Number / Milliseconds [ms] / Number Resolution: 1 / 1 ms / 1 Setting range: 1 –...
Page 82 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Working with the length portioning machine 6.6.4.12 Product type Display: Product type Selection: Cooked sausage / Fresh sausage Application: • Enter product type • Press Enter. 6.6.4.13 Last portion...
Page 83 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.4.14 Remaining portions Display: Remaining portions Unit: Portion Resolution: Setting range: 0 – 50 / -1 = Off Application: LPG 208 • Enter number of portions still to be produced once casing end detection is triggered.
Page 84 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Working with the hanging machine 6.6.4.17 Calibre and sausage length Display: Calibre / Sausage length Unit: Millimetre [mm] Resolution: 1 mm Setting range: 8 – 52 mm (depends on mode) / 1 – 32,000 mm...
Page 85 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.4.20 Sausages per hook Display: Sausages per hook Unit: Number Resolution: Setting range: 1 – 99 Application: Hanging • Enter the number of sausages to hang between the hooks.
Page 86 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.6.4.23 End of stick Display: End of stick Selection: Stop / filled portions Unit: Number Resolution: Setting range: 0 – 10 (default = 0) Application: Hanging •...
Page 87 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.4.26 Permitted deviation Display: Permitted deviation Unit: Number Resolution: Setting range: 0 – max. number of sausages per stick Application: Hanging • Enter the number of sausages which may be missing on the smoke stick.
Page 88 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Working with the automatic separation valve 6.6.4.27 Separation valve Display: Separation valve Selection: Off/In portion/Portion end/Line end/Line start/Group end Unit: Milliseconds [ms] Resolution: 1 ms Setting range: 0 –...
Page 89 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.4.30 Separation valve open Display: Separation valve open Unit: Gramme [g] Resolution: Setting range: 0 – 5,000 g Application: “Continuous” mode • Enter the weight of the filling quantity for which the separation valve is to be open during straight filling.
Page 90 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Working with the minced meat line and forming machine 6.6.4.32 Weight groups Display: Weight groups Unit: Number Resolution: Setting range: 0 (=off) – 99 Application: Forming machine FM 250 (kebab production) •...
Page 91 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.4.34 Group portions Display: Group portion Unit: Number of portions/gramme g Resolution: 1/0.1 g Setting range: 0 - 99/0.1 g - 60,000.0 g Application: Forming machine FM 250 (kebab production) •...
Page 92 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.6.4.36 Belt control (analog output 1) Display: Analog output 1 (general applications) / upper belt (forming machine 250) / feed belt (minced meat portioner MMP 220) Unit:...
Page 93 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control Working with the scale 6.6.4.38 Number of samples (VEMAG Scale 877 / Bizerba ST) Display: Number of samples Unit: Number Resolution: Setting range: 1 – 99 Application: Scale 877 / Bizerba ST •...
Page 94 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Working with special devices 6.6.4.41 Type of special control Display: Casing pusher Selection: Off / On Application: Automatic casing pusher on DHV 841/ • Switch casing pusher on or off.
Page 95 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.4.44 Maximum filling pressure (pressure monitoring on grinding system) Display: Max. filling pressure Unit: Bar [bar] Resolution: 0.1 bar Setting range: Off / 10 – 50 bar (depending on the machine)
Page 96 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.6.4.46 Hopper mode Display: Hopper mode Selection: Off / Continuous Functions: Vacuum / filling Application: Vacuum hopper 149 • Select hopper mode. • Press Enter. The switches "Vacuum" and "Fill" switch the control functions for hopper vacuum and level on or off.
Page 97 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.4.48 Hopper level Display: Hopper level Unit: Per cent [%] Resolution: Setting range: 5 – 98 % (control range +/- 3 to 30 %) Application: Vacuum hopper 149 •...
Page 98 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.6.4.49 Hopper level (optional) Display: Hopper level Unit: Off / Automatic / Signal+Stop / Signal / Stop / Speed control Application: Monitoring level of hopper (optional) •...
Page 99 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.6.4.50 Speed limit Display: Speed limit Unit: Per cent [%] / portions per minute [p/min] Resolution: 0.1 % / 1 % / 1 Setting range:: 0 – 100 % / 1 - 999...
Page 101 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.7 Service This section describes the Service page to which there is general access. • What information is displayed? © VEMAG 2010 6-55...
Page 103 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control 6.7.1 Service pages On the Service pages you will find general information about the version of the terminal, the drive controllers and the filler. Make a note of the current version numbers so that you can quote them in the event of a VEMAG Customer Service query.
Page 104 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6.8 Messages 6.8.1 List of messages If a message should appear which is not included in the list below, please note the fault number and contact VEMAG Customer Service.
Page 105 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control Number Message Cause Remedy IO module A6 IO module A6 is not present or not Check that module A6 is firmly functioning properly. seated; replace the module if necessary.
Page 106 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Number Message Cause Remedy Please press the start In order to restart a machine Press the start button. button equipped with an external safety switch after a safety-related inci- dent, approval is required again.
Page 107 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control Number Message Cause Remedy Remote control blocked The casing pusher option is pre- If desired, deactivate the casing by casing pusher venting selection of remote mode. pusher option and switch to RE- MOTE mode.
Page 108 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Number Message Cause Remedy Limit exceeded „Print mark control“ exceeded „Print mark control“ is a complex permissible weight. application that must be checked by an experienced technician. Un- der certain circumstances, you will have to accept heavier weights.
Page 109 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control Number Message Cause Remedy input limit reached The value range for input depends on another parameter and vice versa. Weight/speed limits knife The value range for input depends...
Page 110 6. Graphical control ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Number Message Cause Remedy Communication main drive CAN bus communication with Check that CAN bus line is wired main drive interrupted. correctly. Communication twist drive CAN bus communication with link- Check that CAN bus line is wired ing drive interrupted.
Page 111 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 6. Graphical control Number Message Cause Remedy Communication belt drive CAN bus communication with belt Check that CAN bus line is wired drive interrupted. correctly. Unexpected belt drive Unconfigured belt drive found on Activate the belt drive in the PC CAN bus.
Page 113 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7. Cleaning 7. Cleaning 7.1 General information The machine and any attachments and additional devices (optional) must be cleaned daily. Danger! To prevent injury, take the following measures before cleaning.
Page 114 7. Cleaning ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7.2.2 Linking horn (optional) • Undo linking nut (1) with the universal spanner (2) and remove linking horn (3). Hold the linking head steady with the second universal span- ner as you do so.
Page 115 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7. Cleaning 7.2.4 Double screws • Screw the screw extractor (1) into the threaded bore of the right-hand double screw and pull the double screws out of the double screw housing, holding the screws steady with the other hand.
Page 116 7. Cleaning ROBOT HP7E / HP10E / HP12E / HP15E / HP20E • Twist the spindle in far enough for the extraction device to catch and pull the double screw housing a little way out of the feed cylinder. Fig. 7-6 Extraction device catching •...
Page 117 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7. Cleaning • Pull the double screw housing/relevant part of the housing right out of the feed cylinder by hand, holding the housing steady with the other hand. Fig. 7-8...
Page 118 7. Cleaning ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7.2.6 Hopper Danger! There is a risk of crushing when fitting/removing the feed screw. To pre- vent injury, proceed extremely carefully when fitting and dismantling the part. •...
Page 119 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7. Cleaning • Remove the sealing ring (1) from the hopper insert (2). Use the appro- priate tool at the cleaning plug (3) to do this. Sealing ring Hopper insert Cleaning plug Fig.
Page 120 7. Cleaning ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7.2.8 Vacuum system • Remove the vacuum pot. • Take hold of the float valve on the valve body (1) and pull it off the intake pipe of the vacuum line in a horizontal direction.
Page 121 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7. Cleaning Warning! Before cleaning, you must plug the cleaning plug onto the intake pipe of the vacuum line to protect the vacuum pump. Cleaning plug (1) is located behind the cover on the rear of the machine.
Page 122 7. Cleaning ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7.3 Cleaning the machine Clean the machine housing, the hopper, the feed screw, the linking gear (optional) and all the parts which have been removed thoroughly with hot water and a brush and then dry them.
Page 123 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7. Cleaning 7.4 Cleaning schedule 7.4.1 General recommendations All information relates to single-shift operation. • Predominant use should be made of alkaline foam cleaning agents. • To remove mineral deposits such as limescale, use acid foam cleaning agents as required (usually 1x a week).
Page 124 7. Cleaning ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Recommended cleaning agents: Europe Application Characteristics Clean Disinfect Foam Manual Rinse P3-steril Combined cleaning agent and disinfectant, slightly alkaline P3-topax 19 Quorum Foam cleaning agent, alkaline P3-topactive 200...
Page 125 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7. Cleaning 7.4.3 Chlorine-containing alkaline cleaning agents Perform cleaning as follows: • Initial rinse with water to remove coarse dirt • Application of foam to the surfaces for cleaning using a 2 – 5 % soluti- on of P3-topax 66 (alkaline) or 2 –...
Page 126 7. Cleaning ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7.4.4 Specialist cleaning agent for machine interior Check inside the machine regularly for the build-up of germs and dirt. Clean the inside of the machine if the dirt is excessive.
Page 127 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 7. Cleaning 7.5 Lubrication and assembly • Thoroughly lubricate all dismantled, cleaned and dried parts (apart from vacuum system parts) with a corrosion-inhibiting oil which is safe for food use.
Page 129 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8. Maintenance 8. Maintenance 8.1 General information Apart from daily cleaning, the filler needs very little maintenance. For your peace of mind, we recommend that you take out a service contract whereby VEMAG Customer Service carries out all the maintenance work due.
Page 130 8. Maintenance ROBOT HP7E / HP10E / HP12E / HP15E / HP20E • Undo bottom assembly bolt (1) of the front door using spanner (2). Assembly bolt Spanner Fig. 8-2 Opening the front door • Swing open the front door.
Page 131 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8. Maintenance • Undo the assembly bolts (1) of the service hatch using screwdriver (2) to assist. Assembly bolt Screwdriver Fig. 8-4 Opening the service hatch • Swing open the service hatch.
Page 132 • Swing the front door closed again/refit the appropriate service hatch. Regularly check the hydraulic system of the machine, including all pipe and hose lines, for damage or leaks. Inform VEMAG Customer Service if you find damage or leaks. Warning! DIN 20066 states that the service life of hose lines should not exceed six years.
Page 133 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8. Maintenance 8.2 Grease gun The cartridges for the grease gun supplied are replaced as follows: • Pull piston rod (1) back firmly to the stop. • Unscrew the head of the grease gun (2) and pull out the empty cartridge.
Page 134 8. Maintenance ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8.3 First-time maintenance work Perform the following maintenance work for the first time after the inter- vals given. After that, these measures should be effected in accordance with the maintenance schedule.
Page 135 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8. Maintenance 8.4 Maintenance schedule All information relates to single-shift operation. The portioning compu- ter shows the number of operating hours reached in each case. All the maintenance tasks included under one operating hours heading should be performed.
Page 136 8. Maintenance ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8.5 Daily maintenance 8.5.1 Feed unit seals (lubrication) The feed unit seals must be lubricated daily every time they are cleaned. Use only high-performance grease which is safe for food use.
Page 137 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8. Maintenance • Guide the feed screw (1) into the hopper in such a way that the three sliding sleeves (2) are located behind the shoulder (3) of the hopper flange.
Page 138 Then remove the grease which has escaped. Lubricating nipple Relief bore Fig. 8-9 Lubricating the feed unit drive • If no grease at all escapes at the relief bore, inform VEMAG Customer Service and have the drive/bearing checked. 8-10 © VEMAG 2010...
Page 139 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8. Maintenance 8.6.2 Intake (air filter) There is an air filter in the service hatch on the rear which needs to be cleaned weekly. • Unlatch the toggle on the rear of the machine and open the cover completely.
Page 140 8. Maintenance ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8.6.3 Vacuum pump (air filter) An air filter is located in the intake line to the vacuum pump and this needs to be cleaned weekly. • Open the two locking clips (1) of the air filter and remove the filter cover (2).
Page 141 • Close the service hatch again. Warning! Inform VEMAG Customer Service immediately if there is oil in the relief hose. The seals of the double screw drive must be replaced before pro- duction is resumed. 8.7.2 Vacuum pump 16 m³ and 40 m³ (optional) Operating instructions for vacuum pump ©...
Page 142 8. Maintenance ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8.8 Six-monthly maintenance 8.8.1 Feed unit seals • Have the feed unit seals checked by VEMAG Customer Service. 8.8.2 Hydraulic unit (oil level) The hydraulic unit for the lifting and tipping device (optional) is located behind the service hatch on the rear of the machine.
Page 143 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8. Maintenance 8.9 Annual maintenance 8.9.1 Feed unit drive and feed unit seals • Have the feed unit checked by VEMAG Customer Service and the feed unit seals replaced. 8.9.2 Hydraulic unit (oil change) The oil in the hydraulic unit needs to be changed once a year.
Page 144 8. Maintenance ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8.9.3 Vacuum pump 16 m³ and 40 m³ (optional) Danger! To prevent injury (burns) do not carry out the following work with the pump still warm from operation, but wait until the pump has cooled down.
Page 145 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8. Maintenance • Undo the two assembly bolts (1) used to fix the vacuum pump to the base plate. Assembly bolt Fig. 8-18 Removing the vacuum pump • Lift the vacuum pump forwards out of the machine.
Page 146 8. Maintenance ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Vacuum pump with 40 m (optional) • Unlatch the toggle on the rear of the machine and open the cover completely. • Remove the air filter in the service hatch.
Page 147 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8. Maintenance • Take the appropriate maintenance measures. Operating instructions for vacuum pump • Replace the vacuum pump in the machine and retighten the two as- sembly bolts in the baseplate.
Page 148 • Close the service hatch again. Warning! Inform VEMAG Customer Service immediately if there is oil in the relief hose. The seals of the double screw drive must be replaced before pro- duction is resumed. 8-20 © VEMAG 2010...
Page 149 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 8. Maintenance 8.11 Three-yearly maintenance 8.11.1 Feed drive (oil change) The oil in the transmission of the feed drive needs to be changed every three years. • Unlatch the toggle on the rear of the machine and open the cover completely.
Page 150 8. Maintenance ROBOT HP7E / HP10E / HP12E / HP15E / HP20E The oil must come up to the top check bore in the transmission housing of the transmission. • Remove sealing screw (1) from the top check bore. •...
Page 151 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 9. Troubleshooting 9. Troubleshooting 9.1 General information Any attachments or additional devices (optional) which may be present should be disconnected from the filling machine for troubleshooting pur- poses. The relevant safety instructions must be followed. Possible faults, causes and the measures you need to take to remedy them are listed below.
Page 152 9. Troubleshooting ROBOT HP7E / HP10E / HP12E / HP15E / HP20E Fault Cause Remedy Air trapped in product. Unsuitable or worn double screw. Check double screws. Vacuum display fluctuating or too Check vacuum system for leaks, low. paying special attention to the dou- ble screw drive seal.
Page 153 Please give the machine number in the event of any query to VEMAG Customer Service or its agents. You will find this on the rating plate on the rear of the filler. It is also embossed on the machine frame.
Page 154 10. Appendix ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10.2 Technical data ROBOT HP7E / HP10E / HP12E / HP15E / HP20E ROBOT HP7E ROBOT HP10E ROBOT HP12E ROBOT HP15E ROBOT HP20E Filling rate with double screw...
Page 155 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10. Appendix 10.3 Dimensional drawings ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10.3.1 Hopper 250 l 10.3.2 Hopper 350 l © VEMAG 2010 10-3...
Page 156 10. Appendix ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 25, 26 1, 2 4, 5 5, 6 5, 6 7, 8 14, 15 10-4 © VEMAG 2010...
Page 157 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10. Appendix 10.4 Electrical control panel (service hatch, right-hand side) Main contactor KM2, KM3 Screening unit KM2, KM3 Auxiliary switch Fuse F3, reserve Fuse holder F1-F3 Fuse F1, F2, reserve...
Page 159 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10. Appendix 10.5 Drive controller ROBOT HP7E (front door) Power switch (optional) Distributing bar QM2, QM3 Radio interference suppression filter Power switch Power switch Main contactor Screening unit Frequency converter linking drive, programmed (optional)
Page 161 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10. Appendix 10.6 Drive controller ROBOT HP10E / HP12E (front door) Power switch (optional) Distributing bar QM2, QM3 Radio interference suppression filter Power switch Power switch Main contactor Screening unit...
Page 163 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10. Appendix 10.7 Drive controller ROBOT HP15E / HP20E (front door) Power switch (optional) Distributing bar QM2, QM3 Radio interference suppression filter Power switch Power switch Main contactor Screening unit...
Page 165 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10. Appendix 10.9 Lubricants 10.9.1 Double screw drive Type of oil: transmission oil Oil capacity: approx. 3.0 l Viscosity class: ISO VG 100 to DIN 51519 Quality: C-LP to DIN 51502 Example: Shell Omala oil 100 (order no.
Page 166 10. Appendix ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10.10 Accessories 10.10.1 Double screw selection The following double screws are recommended for setting up the filling machine as a function of the product to be processed. Type of double screw Application Order no.
Page 167 ROBOT HP7E / HP10E / HP12E / HP15E / HP20E 10. Appendix 10.10.3 Linking horns The linking horn should be selected as a function of the casing holding device used. To select a suitable linking horn Casing holding device operating instructions 10.10.4 Miscellaneous accessories...
Page 169 ● Clean the fan cowlings, fan wheels, the ventilation grilles and cool- ● Check the level and the colour of the oil (i) ing fins No low level indication from the level switch (a), ... KC 0016 D VEMAG page 1 0870146800 / 100111...
Page 170 Food applications (NSF H1); Remark VEMAG-part no. 1l-packaging: Nominal suction capacity m³/h 16 / 19 052.001.029 (50Hz/60Hz) Filling quantity, approx. [l] hPa (=mbar) Ultimate pressure abs. Motor nominal rating 0.55 (50Hz/60Hz) KC 0016 D VEMAG page 2 0870146800 / 100111...
Page 171 -mark. Busch Produktions GmbH Schauinslandstr. 1 79689 Maulburg Germany declare that vacuum pumps KC 0016 D VEMAG in accordance with the European Directives: – “Machinery” 2006/42/EC, – “Electrical Equipment Designed for Use within Certain Voltage Limits” (so called “Low Voltage”) 2006/95/EC, –...
Page 172 In order to exclude this possible cause: either temporarily disconnect the oil return line from its connection near the exhaust opening and close it squirt oil through the gas discharge (g) KC 0016 D VEMAG page 4 0870146800 / 100111...
Page 173 Drain condensate regularly Condensate could not be compressed and thus broke a vane KC 0016 D VEMAG page 5 0870146800 / 100111...
Page 174 Temperature of the inlet gas too high Observe the permitted temperatures for the inlet gas The exhaust filter is partially clogged Replace the exhaust filter Not enough oil in the reservoir Top up oil KC 0016 D VEMAG page 6 0870146800 / 100111...
Page 175 The oil foams Mixing of incompatible oils Flush the vacuum pump Replace the exhaust filter Fill in new oil (Ú page 1: Maintenance) Make sure the proper oil is used for topping up KC 0016 D VEMAG page 7 0870146800 / 100111...
Page 176 Oil level underneath MIN-marking (d): top up oil. A high oil consump- ● Change the oil (Ú Oil Change) tion can be an indicator for a defective vacuum pump. In case of indication of an overfilling, ... KC 0040 D VEMAG page 1 0870149117 / 100111...
Page 177 (EN ISO 2151) (50Hz/60Hz) Operating temperature °C 80 / 85 (50Hz/60Hz) Ambient temperature range °C 0 ... 40 Atmospheric Ambient pressure pressure Oil quantity Oil furnished ex-works VSL 068 Weight approx. (50Hz/60Hz) KC 0040 D VEMAG page 2 0870149117 / 100111...
Page 178 -mark. Busch Produktions GmbH Schauinslandstr. 1 79689 Maulburg Germany declare that vacuum pumps KC 0040 D VEMAG in accordance with the European Directives: – “Machinery” 2006/42/EC, – “Electrical Equipment Designed for Use within Certain Voltage Limits” (so called “Low Voltage”) 2006/95/EC, –...
Page 179 In order to exclude this possible cause: either temporarily disconnect the oil return line from its connection near the exhaust opening and close it squirt oil through the gas discharge (g) KC 0040 D VEMAG page 4 0870149117 / 100111...
Page 180 Drain condensate regularly Condensate could not be compressed and thus broke a vane KC 0040 D VEMAG page 5 0870149117 / 100111...
Page 181 Temperature of the inlet gas too high Observe the permitted temperatures for the inlet gas The exhaust filter is partially clogged Replace the exhaust filter Not enough oil in the reservoir Top up oil KC 0040 D VEMAG page 6 0870149117 / 100111...
Page 182 The oil foams Mixing of incompatible oils Flush the vacuum pump Replace the exhaust filter Fill in new oil (Ú page 1: Maintenance) Make sure the proper oil is used for topping up KC 0040 D VEMAG page 7 0870149117 / 100111...

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