Page 1 Vacuum filler HP25E (from 1640800) HP30E (from 1660917) Operating instructions...
Page 2 We reserve the right to make technical modifications Issue: 09/18 Version: 2.8 EN (Original operating instructions) © 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 HP25E / HP30E 2.2 Brief description 2.2.1 Hopper 2.2.2 Feed screw 2.2.3 Double screws 2.2.4 Filling horn holder 2.2.5 Linking gear (optional)
Page 4 Index HP25E / HP30E 6.5.3 Select mode group, mode and view 6-15 6.5.4 Select start/stop method 6-17 6.5.5 Make settings (language, date/time, password) 6-19 6.5.6 Set up userkey 6-21 6.6. Mode groups, modes, start/stop methods and parameters 6-23 6.6.1 Mode groups, modes and views 6-24 6.6.2 Start/stop methods...
Page 5 6.6.4.47 Belt control (analog output 1) 6-50 6.6.4.48 Belt control (analog output 2) 6-50 Working with the scale 6-51 6.6.4.49 Number of samples (VEMAG Scale 877) 6-51 6.6.4.50 Sample interval (VEMAG Waage 877) 6-51 6.6.4.51 Tendency control (e.g. Process Check) 6-51...
Page 6 8-20 9. Troubleshooting 9.1 General information 9.2 Troubleshooting table 10. Appendix 10-1 10.1 General information 10-1 10.2 Technical data HP25E / HP30E 10-2 10.3 Dimensional drawings HP25E / HP30E 10-3 10.4 Hydraulic plan 10-4 10.5 Lubricants 10-5 10.5.1 Double screw drive 10-5 10.5.2 Feed drive...
Page 7: Declaration Of Conformity
HP25E / HP30E 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 HP25E type 164 HP30E type 166 Machine no.
Page 9 • HP25E / HP30E in the form of a portioning machine • HP25E / HP30E in the form of a portioning and linking machine (optional) Operating and maintenance instructions for any attachments (optional) can be found in the appropriate separate operating instructions.
Page 11: Safety Instructions
• HP25E / HP30E in the form of a portioning machine • HP25E / HP30E in the form of a portioning and linking machine (opti- onal) It can also be fitted with special attachments (optional). 1.2 Use in accordance with purpose...
Page 12: Explanation Of Symbols
1. Safety instructions HP25E / HP30E 1.3 Explanation of symbols The following symbols appear in these operating instructions, indicating residual hazards when operating the machine or referring the reader to other important information. Danger! This warning symbol refers to important instructions which must be follo- wed to prevent faulty operation which could pose a threat to human life or lead to injury.
Page 13: General Safety Instructions
Corrosion at the contacts can lead to switching errors. It is prohibited to remove, switch off or override safety devices. In the • event of damage to safety devices, inform VEMAG Customer Service immediately. • Warning signs on the machine may not be removed or painted over.
Page 14: Special Safety Instructions
Check that the safety devices on the hopper and filling horn holder are • working properly. Section 5 If you notice any damage, inform VEMAG Customer Service immedi- ately. Danger! To prevent injury, switch off the machine before doing any work on the hopper.
Page 15: Brief Description
HP25E / HP30E 2. Description 2. Description 2.1 Overview HP25E / HP30E Hopper Vacuum pot Vacuum display Vacuum control valve Lifting/tipping device (optional) Control panel Adjustable feet Step Knee lever 10 Filling horn 11 Locking nut 12 Hopper release mechanism...
Page 16 2. Description HP25E / HP30E 2.2.2 Feed screw The product is compressed in the hopper by the feed screw (1) and fed to the thread of the double screws with the aid of the vacuum. Spiral stopper (2) improves product feed. The scraper (3) attached to the feed screw completely empties the hopper.
Page 17 HP25E / HP30E 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 HP25E / HP30E 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. 2-6 Controls Behind the cover is main switch (1) which is used to switch the power supply to the machine on and off.
Page 19 HP25E / HP30E 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) • UP key (3) for lifting/tipping device (optional) •...
Page 20 2. Description HP25E / HP30E 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. To move it into its bottom end position, the key must be pressed again and held down until the final position is reached.
Page 21 HP25E / HP30E 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. Section 4.7 2.2.8 Step At the front of the machine is a step which allows the operator to fill the hopper or get at it for cleaning and maintenance purposes.
Page 23: Installation And Commissioning
HP25E / HP30E 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 HP25E / HP30E • 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: Setting Up The Machine
HP25E / HP30E 3. Installation and commissioning 3.2 Setting up the machine The machine must stand firmly on all four feet at all times and be aligned as horizontally as possible in the longitudinal direction (outlet side). There may be a slight inclination (max. 2°) in the direction of the outlet side to encourage water to drain off after cleaning.
Page 26: Electrical Connection
3. Installation and commissioning HP25E / HP30E 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: Checking Direction Of Rotation
HP25E / HP30E 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. This is why it is essential to check whether the individual phases of the alternating current supply have been connected according to specification after the machine has been electrically connected;...
Page 28 3. Installation and commissioning HP25E / HP30E 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 HP25E / HP30E 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 HP25E / HP30E • 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 HP25E / HP30E 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: General Information
HP25E / HP30E 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. Danger! To prevent injury, switch off the machine before setting up. Then switch off the main switch to disconnect the machine from the mains.
Page 34 4. Setting up HP25E / HP30E 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. Centring pin Coupling pins Fig. 4-2 Centring the double screw housing ©...
Page 35 HP25E / HP30E 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. • Bring the slots of coupling claws (2) into the correct position in relation to the coupling pins in the feed cylinder by turning the double screws in opposite directions.
Page 36 4. Setting up HP25E / HP30E 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). Turn locknut (1) clockwise to lock the filling horn holder. The handle •...
Page 37 HP25E / HP30E 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 HP25E / HP30E 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. • Fit lip seal (1) in linking horn (2) so that the lug of the lip seal is poin- ting forwards.
Page 39 HP25E / HP30E 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. Linking horn...
Page 40: Setting The Vacuum
4. Setting up HP25E / HP30E 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 HP25E / HP30E 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. Danger! There is a risk of crushing when fitting and removing the scraper. To prevent injury, proceed extremely carefully when fitting and dismantling the part.
Page 42 4. Setting up HP25E / HP30E 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. • Undo the hexagonal nut (1) using the universal spanner (2).
Page 43: Operation
In each of the cases described, the machine must switch off automati- cally. If the machine does not switch off, work may not continue with the machine. In this case, inform VEMAG Customer Service immediately. Pull on a casing suitable for the product to be filled.
Page 44 5. Operation HP25E / HP30E • Unlock the locking lever (1) with your foot and pull the trolley out of the trolley hoist. Locking lever Fig. 5-1 Trolley © VEMAG 2018...
Page 45 HP25E / HP30E 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 •...
Page 46 5. Operation HP25E / HP30E 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. 50 % of nominal speed.
Page 47 HP25E / HP30E 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? • What functions do the keys have? •...
Page 49: Control Panel
HP25E / HP30E 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 HP25E / HP30E Header Mode group Program Mode View Product name Start/stop method Parameters Parameters Footer © VEMAG 2018...
Page 51: Basic Parameters
HP25E / HP30E 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 • Parameters on the right-hand side of the screen •...
Page 52 6. Graphical control HP25E / HP30E Numerical keypad Key C (Cancel) Padlock key Screen up/down keys Plus/minus keys Cursor keys Enter key © VEMAG 2018...
Page 53: Numerical Keypad
HP25E / HP30E 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: • back to main screen •...
Page 54: Status And Error Messages
6. Graphical control HP25E / HP30E 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: Principles Of Operation
HP25E / HP30E 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 HP25E / HP30E Program number Product name Program list with action buttons 6-10 © VEMAG 2018...
Page 57 HP25E / HP30E 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. Program numbers 0 to 99 are available.
Page 59 HP25E / HP30E 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. • Plug in USB stick. The stick is detected automatically.
Page 61 HP25E / HP30E 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 63 HP25E / HP30E 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 HP25E / HP30E 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. • • Press Enter.
Page 67 HP25E / HP30E 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 HP25E / HP30E 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? • What modes are there? • What start/stop methods are there? •...
Page 70 6. Graphical control HP25E / HP30E 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. The mode and view depend on the selected mode group.
Page 71 HP25E / HP30E 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. Supplementary parameters for various applications (e.g. working with a clipper) are explained in the sections which follow.
Page 72 6. Graphical control HP25E / HP30E 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” and “Portions per minute”) Enter the weight for the first portion.
Page 73 HP25E / HP30E 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) • Enter pause time.
Page 74 6. Graphical control HP25E / HP30E 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. • Press Enter. Maximum feed rate depends among other things on the feed element and on the machine type.
Page 75 HP25E / HP30E 6. Graphical control 6.6.3.7 Individual speed Display: Individual speed Unit: Per cent [%] Resolution: 0,1 % Setting range: 25.0 – 75.0 % Application: Double outlet • Enter speed. • Press Enter. If only one outlet of a double outlet is operated, you can set the speed for this outlet.
Page 76 6. Graphical control HP25E / HP30E 6.6.3.10 Portions per minute Display: Portions per minute Unit: Number Resolution: Setting range: 1.0 – speed limit Application: Cutter / continuous cutter / continuous PPM • Enter the portions per minute. • Press Enter.
Page 77 HP25E / HP30E 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 HP25E / HP30E 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 HP25E / HP30E 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. • Press Enter. 6.6.4.7 Stop counter Display: Stop counter...
Page 80 6. Graphical control HP25E / HP30E 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 – 2,000 g / 10 – 2,000 ms / 10 – 100 %...
Page 81 HP25E / HP30E 6. Graphical control 6.6.4.11 Synchronizing the machine using an external signal Display: Portions per signals Selection: Off / Number Unit: Number Resolution: Setting range: 1 – 999,999 Application: Continuous mode and portioning controlled by machine downstream (optional) •...
Page 82 6. Graphical control HP25E / HP30E Working with sausage lines 6.6.4.13 Product type Display: Product type Selection: Cooked sausage / Fresh sausage Application: LPG 208, LPG 209 • Enter product type • Press Enter. 6.6.4.14 Last portion Display: Last portion...
Page 83 HP25E / HP30E 6. Graphical control 6.6.4.16 Remaining portions Display: Remaining portions Unit: Portion Resolution: Setting range: 0 – 50 / -1 = Off Application: LPG 208, LPG 209, FSL 210, FSL 211 • Enter number of portions still to be produced once casing end detection is triggered.
Page 84 6. Graphical control HP25E / HP30E 6.6.4.18 Calibre and sausage length Display: Calibre / Sausage length Unit: Millimeter [mm] Resolution: 1 mm Setting range: 14 – 40 mm (FSL 210) / 14 – 50 mm (FSL 211) Application: FSL 210 / FSL 211 •...
Page 85 HP25E / HP30E 6. Graphical control 6.6.4.21 Conveyor belt calibre/discharge conveyor calibre Display: Conveyor belt calibre/discharge conveyor calibre Unit: Millimeter [mm] Resolution: 1 mm Setting range: dependent on calibre Application: FSL 210 / FSL 211 (conveyor belt calibre only) •...
Page 86 6. Graphical control HP25E / HP30E Working with the hanging machine 6.6.4.24 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 87 HP25E / HP30E 6. Graphical control 6.6.4.27 Sausages on last hook Display: Sausages on last hook Unit: Number Resolution: Setting range: 1 – 50 Application: AH 204, AH 212 • Enter the number of sausages to hang on the last hook.
Page 88 6. Graphical control HP25E / HP30E 6.6.4.29 Hooks per stick Display: Hooks per stick Unit: Number Resolution: Setting range: 1 - 55 (0 = Off) Application: AH 204, AH 212 • Enter the number of hooks which should be gathered on one smoke stick.
Page 89 HP25E / HP30E 6. Graphical control 6.6.4.32 End of stick Display: End of stick Selection: Stop / filled portions / empty casing Unit: Number / Millimeter [mm] Resolution: 1 / 1 mm Setting range: 0 – 10 (default = 0)
Page 90 6. Graphical control HP25E / HP30E 6.6.4.34 End of portioning (LPV 802 and DHV 841 only) Display: End of portioning Selection: Immediate / Even number Application: AH 204 (LPV 802 and DHV 841 only) • Enter criterion for stopping the machine.
Page 91 HP25E / HP30E 6. Graphical control 6.6.4.37 Last hook later Display: Last hook later Unit: Millisekunden [ms] Resolution: 1 ms Setting range: 0 – 999 ms Application: AH 204, AH 212 • Enter a delay for the last hook of any stick •...
Page 92 6. Graphical control HP25E / HP30E Working with the automatic separation valve 6.6.4.38 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 – 9,999 ms Application: When a “Portion end” signal is given, portion with the auto- matic separation valve.
Page 93 HP25E / HP30E 6. Graphical control 6.6.4.41 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 •...
Page 94 6. Graphical control HP25E / HP30E Working with the minced meat line and forming machine 6.6.4.43 Weight groups Display: Weight groups Unit: Number Resolution: Setting range: 0 (=off) – 99 Application: Forming machine FM 250 (kebab production) • Enter the number of weight groups (e.g. number of kebab sticks) to be produced simultaneously.
Page 95 HP25E / HP30E 6. Graphical control 6.6.4.45 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) • Enter the number of portions (e.g. kebab slices) of identical weight.
Page 96 6. Graphical control HP25E / HP30E 6.6.4.47 Belt control (analog output 1) Display: Analog output 1 (general applications) / upper belt (forming machine 250) / feed belt (minced meat portioner MMP 220) Unit: Per cent [%] / Volts [V] Resolution: 1 % / 0.1 V...
Page 97 HP25E / HP30E 6. Graphical control Working with the scale 6.6.4.49 Number of samples (VEMAG Scale 877) Display: Number of samples Unit: Number Resolution: Setting range: 1 – 99 Application: VEMAG scale 877 • Enter the number of samples to be placed on the scale.
Page 98 6. Graphical control HP25E / HP30E Working with special devices 6.6.4.52 Casing pusher Display: Casing pusher Selection: Off / On Application: Automatic casing pusher (LPG 208, LPG 209) Switch casing pusher on or off. • • Press Enter. If you activate this parameter, the filling machine stops when it reaches the end of the casing.
Page 99 HP25E / HP30E 6. Graphical control 6.6.4.54 Type of special control Display: Special control Selection Off / Fill / Separate / Start instruction / Ready Application: Special controls using remote-P contact • Select special control. • Press Enter. „Off“ = Special control switched off „Fill“...
Page 100 6. Graphical control HP25E / HP30E 6.6.4.56 Knife (cutter) Display: Knife Selection: Portion end closed / Portion end open Application: Servo cutter 808 • Select whether the knife leaves the outlet open or closes it at the end of the portion.
Page 101 HP25E / HP30E 6. Graphical control 6.6.4.58 Maximum temperature (temperature monitoring for the grinding system) Display: Temperature Unit: Degrees [°C] / Kilogram [kg] Resolution: 0.1 °C / 1 kg Setting range: Off / -19.9 °C – +31.0 °C / 1,0 kg - 99 kg...
Page 102 6. Graphical control HP25E / HP30E 6.6.4.60 Hopper vacuum Display: Hopper vacuum Unit: Per cent [%] Resolution: Setting range: 5 – 98 % (control range +/- 1 to 10 %) Application: Vacuum hopper 149 • Enter hopper vacuum. • Press Enter.
Page 103 HP25E / HP30E 6. Graphical control 6.6.4.62 Hopper level (optional) Display: Hopper level Unit: Off / Automatic / Signal+Stop / Signal / Stop / Speed control Application: Monitoring level of hopper (optional) • Enter the mode in which hopper level is to be monitored.
Page 104 6. Graphical control HP25E / HP30E 6.6.4.63 Speed limit Display: Speed limit Unit: Per cent [%] / portions per minute [p/min] Resolution: 0.1 % / 1 % / 1 Setting range:: 0 – 100 % / 1 - 999 Application:...
Page 106 6. Graphical control HP25E / HP30E Operating mode group Operating mode Machine type / Can be combined option with Filling continuous Pressure control Double outlet Twist Twisting horn AH 204 / AH 212 LPV 802 AH 204 / AH 212...
Page 107 HP25E / HP30E 6. Graphical control 6.7 Configurations (operating mode settings) Different configurations can be selected, depending on operating mode group and operating mode. A grinder can be selected in all operating modes except for „Pressure control“. © VEMAG 2018...
Page 109 Make a note of the current version numbers so that you can quote them in the event of a VEMAG Customer Service query. The operating hours which have been clocked up are shown at the bottom of the page.
Page 110: List Of Messages
6. Graphical control HP25E / HP30E 6.9 Messages 6.9.1 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. Number Message Cause Remedy IO modules ready The IO modules are ready.
Page 111 HP25E / HP30E 6. Graphical control Number Message Cause Remedy Check that module A6 is firmly IO module A6 IO module A6 is not present or not functioning properly. seated; replace the module if necessary. Lubrication filling level The lubrication filling level is too Check the lubrication filling level.
Page 112 6. Graphical control HP25E / HP30E Number Message Cause Remedy ********** too light Scale 877 The sample is min. 20 g To have the sample weight accepted, lighter than the set weight. place the sample on the scale again. too heavy ********** Scale 877 The sample is min.
Page 113 Machine parameters are Serious problem when loading Software update or reinstallation. missing machine parameters. Make a note of the error number and inform the VEMAG Customer Service team. Machine parameters set Loaded machine parameter was Check whether the machine is to default outside valid range - set to default.
Page 114 6. Graphical control HP25E / HP30E Number Message Cause Remedy Target position timeout The main drive has reached the Update is needed for the main target position but the „in position“ drive parameter set. Inform VE- signal has not been sent.
Page 115 HP25E / HP30E 6. Graphical control Number Message Cause Remedy Jumper A-G is misplaced The jumper A-G is not permitted in Change the operating mode or in the remote control this operating mode. insert the corresponding remote connector! control cable.
Page 116 6. Graphical control HP25E / HP30E Number Message Cause Remedy Weight/speed limits knife The value range for input depends offset on another parameter and vice versa. input limit reached The value range for input depends on another parameter and vice versa.
Page 117 Make a note of the error messa- celled from the main drive to the machine ges displayed before this error controller. and inform the VEMAG Customer Service team. Main drive inhibit Controller for main drive not Check controller release at FU1, released.
Page 118 Twist drive application Fault in the application module. Note the numbers of all current This fault occurs in combination faults and contact VEMAG Service. with other fault numbers. Main drive manual Main drive operated manually. Release manual drive button S10.
Page 119 The reference movement of the Check the reference sensor and first drive of attachment 2 took too the application module. If there is long. no error, contact VEMAG Custo- mer Service. External drives ready The external drive(s) are ready. External drive 1 not found...
Page 120 6. Graphical control HP25E / HP30E Number Message Cause Remedy 20006 Safety cover open (casing Casing pusher safety cover is pusher) open 20007 Safety cover open Casing magazine safety cover is open 20008 Fallen below voltage of Power supply for casing magazine...
Page 121 HP25E / HP30E 6. Graphical control Number Message Cause Remedy Link point length (filling 20202 pause too short 1st link point length (filling 20203 pause too short) Link point stretch (filling 20204 speed too high) Link point stretch (filling 20205...
Page 122 6. Graphical control HP25E / HP30E Number Message Cause Remedy 20225 Gripper swivel drive refe- Drive could not be referenced in the specified time rencing failed 20226 Casing applier drive refe- Drive could not be referenced in the specified time...
Page 123 HP25E / HP30E 6. Graphical control Number Message Cause Remedy 50203 No hook detected 50204 Additional hooks not pos- Additional hooks > 0, but no full Set additional hooks to 0 or sible — group loading load detected. change loading. Check the sensor position if necessary.
Page 124 The reference movement of the Check the reference sensor and second drive took too long. the application module. If there is no error, contact VEMAG Cus- tomer Service. The PC could not find the fourth 50929 External drive 4 not found...
Page 125: General Information
HP25E / HP30E 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. • Press the OFF key on the machine control panel.
Page 126 7 Cleaning HP25E / HP30E 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. 1 Linking nut...
Page 127 HP25E / HP30E 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 hou- sing, holding the screws steady with the other hand.
Page 128 7 Cleaning HP25E / HP30E • 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 • Push down the catch in the inlet bore (1) and pull the extraction device (2) out of the double screw housing (3).
Page 129 You must check the seals of the double screw drive for traces of oil be- fore cleaning. If traces of oil are present, the double screw drive must be overhauled or replaced. In this case inform VEMAG Customer Service. © VEMAG 2018...
Page 130 7 Cleaning HP25E / HP30E 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. • Unlock the two locking levers (1) on the hopper housing and carefully tip the hopper backwards.
Page 131 HP25E / HP30E 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. 1 Sealing ring 2 Hopper insert 3 Cleaning plug Fig. 7-11 Feed unit seal 7.2.7 Scraper...
Page 132: Vacuum System
7 Cleaning HP25E / HP30E 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 133 HP25E / HP30E 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 134: Cleaning The Machine
7 Cleaning HP25E / HP30E 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. The machine is suitable for clea- ning with low-pressure cleaning equipment (max.
Page 135: Cleaning Schedule
HP25E / HP30E 7 Cleaning 7.4 Cleaning schedule 7.4.1 General recommendations All information relates to single-shift operation. • Use predominantly alkaline foam cleaning agents. • Use acidic foam cleaning agents to remove mineral deposits such as lime scale as required (at least once a week).
Page 136 7 Cleaning HP25E / HP30E 7.4.4 Recommended cleaning agents and disinfectants Germany/Europe Properties Cleaning Disinfec- Foam Manual Spray tion application P3-sterile Quorum Clear V Combined, alkaline cleaning Whisper V agents and disinfectants P3-topactive DES Oxonia Active + Acidic disinfectants/ Liquid K...
Page 137 HP25E / HP30E 7 Cleaning 7.4.5 Foam cleaning Warning! The following information can be regarded as for guidance only. The cleaning process that is implemented in practice must be tailored to the present framework conditions and contamination. Warning! The foam process (COP = Cleaning Open Plant) is recommended for...
Page 138 7 Cleaning HP25E / HP30E Carry out foam cleaning on a daily basis as follows *: Cleaning procedures and cleaning agents Min. * Comment * °C * Remove foodstuffs. Protect sensitive Preparing for cleaning parts of the system. Disassemble machine parts.
Page 139 HP25E / HP30E 7 Cleaning 7.4.6 Special cleaners for the machine interior Check inside the machine regularly for any build-up of micro-organisms and dirt. Clean the inside of the machine if the dirt is excessive. Clean any smeared or dirty areas inside the machine as follows: Spray the cleaning agent onto smeared and dirty parts and wipe off •...
Page 140 7 Cleaning HP25E / HP30E 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. Section 10 Refit the dismantled parts after cleaning and lubrication.
Page 141: Maintenance
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. The information below describes the maintenance work to be perfor- med by the owner of the machine.
Page 142 8. Maintenance HP25E / HP30E • 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. Service hatch, rear • Unlatch toggle (1) and open cover (2) completely.
Page 143 HP25E / HP30E 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. Service hatch, right-hand side •...
Page 144 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 145: Grease Gun
HP25E / HP30E 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 146 8. Maintenance HP25E / HP30E 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. Section 8.4 after 500 operating hours: Change hydraulic oil in the lifting and tipping device (optional).
Page 147: Maintenance Schedule
Vacuum pump 40 m³ Check exhaust air. Operating instructions for vacuum pump six-monthly 1000 Feed unit seals Have seals checked by VEMAG Customer Service. 1000 Hydraulic unit lifting and Check oil level. tipping device (optional) 1000 Vacuum pump 40 m³...
Page 148: Daily Maintenance
8. Maintenance HP25E / HP30E 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. • Carefully press the sealing ring into the appropriate groove in the hop- per flange.
Page 149 HP25E / HP30E 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. • Push the sliding sleeves outwards so that they engage behind the shoulder, holding the feed screw steady with the other hand.
Page 150: Weekly Maintenance
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 2018...
Page 151: Intake (Air Filter)
HP25E / HP30E 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 152 8. Maintenance HP25E / HP30E 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 •...
Page 153: Monthly Maintenance
• 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 40 m³...
Page 154: Six-Monthly Maintenance
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. There is a sight glass for checking oil level on the front of the hydraulic unit.
Page 155: Annual 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 156 8. Maintenance HP25E / HP30E 8.9.3 Vacuum pump 40 m³ 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. The vacuum pump has to be removed to allow these maintenance tasks to be performed.
Page 157 HP25E / HP30E 8. Maintenance Undo the two assembly bolts (1) used to fix the vacuum pump to the • base plate. Assembly bolt Fig. 8-17 Removing the vacuum pump • Lift the vacuum pump forwards out of the machine.
Page 158 • 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. 8-18 © VEMAG 2018...
Page 159: Biennial Maintenance
HP25E / HP30E 8. Maintenance 8.10 Biennial maintenance 8.10.1 Double screw drive • Replace the double screw drive and have this checked by the VEMAG Customer Service. © VEMAG 2018 8-19...
Page 160 8. Maintenance HP25E / HP30E 8.11 Three-yearly maintenance 8.11.1 Feed drive (oil change) Danger! To prevent injury (burns), do not carry out the work listed below when the transmission/motor is still warm from operation. Wait until the transmissi- on/motor has cooled down.
Page 161 HP25E / HP30E 8. Maintenance Fill the transmission housing with oil (filling quantity = 0.8 l) through • the filling opening (1). Filling opening Fig. 8-20 Changing the oil in the feed drive • Close the cover and latch the toggle on the rear of the machine.
Page 163: General Information
HP25E / HP30E 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 purposes. The relevant safety instructions must be followed. Possible faults, causes and the measures you need to take to remedy them are listed below.
Page 164 9. Troubleshooting HP25E / HP30E 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. If the vacuum display is fluctuating, the vacuum pump is taking in air.
Page 165 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 166 10. Appendix HP25E / HP30E 10.2 Technical data HP25E / HP30E HP30E HP25E Filling rate: up to 25.000 kg/h (double screw with 112-mm up to 8.700 kg/h (double screw with 72-mm pitch) pitch) Portion size: 1 - 99,999 g, adjustable in increments of 0.1 g 1 - 99,999 g, adjustable in increments of 0.1 g...
Page 169: Individual Parts
ISO-VG 68 to DIN 51519 Quality: VSL to DIN 51506 Example: VEMAG special oil (order no. 052001029) 10.5.5 Feed unit seals and feed unit drive Type of grease: high-performance grease which is safe for food use and resistant to cleaning agents and...
Page 170 10. Appendix HP25E / HP30E 10.6 Accessories 10.6.1 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 Order no. Application 72-367HZ...
Page 171 HP25E / HP30E 10. Appendix 10.6.2 Filling horn selection The following filling horns are available for straight filling. Horn dia. Filling horns to DIN 9798 Filling horns with crowned outlet 901100080 901100090 901100100 901100120 901500119 901100125 901100140 901500139 901100145 901100160...
Page 172: Miscellaneous Accessories
10. Appendix HP25E / HP30E 10.6.4 Miscellaneous accessories Component Order no. Filling horn holder for 367 mm double screws 936315000 Filling horn holder for 454 mm double screws 936316002 for attaching filling horn Filling horn nut 930100017 Blind plug double screw housing...
Page 173: Proper Disposal
HP25E / HP30E 10. Appendix 10.7 Disposal 10.7.1 General information The machine must be dismantled at the end of its service life and dispo- sed of properly in accordance with the applicable national environmental regulations. Warning! Contact a specialist company for proper disposal.
Page 175: Intended Use
Check the vacuum pump for oil leaks - in case of leaks have The oil and the exhaust filter can be contaminated with process the vacuum pump repaired ( Busch service) residues: wear personal protective equipment as appropriate! KC 0016 VEMAG Seite 1 0870149431 / 130422...
Page 176 0210 105 135 • Pull the exhaust filter out of the oil separator (i) Clamping screw 0416 140 926 • Install the new exhaust filter in reserve order Clamping ring 0432 140 927 KC 0016 VEMAG Seite 2 0870149431 / 130422...
Page 177 Part no. 5 l packaging 0831 131 847 Oil sight glass 0583 000 006 Food applications (NSF H1); Gasket 0480 139 908 Remark VEMAG-part no. 1 l-packaging: 052001029 Stud bolt 0412 000 206 Filling quantity, approx. [l] Hex nut 0420 000 035 Valve insert...
Page 178: Troubleshooting
(Busch service) The radial clearance between the rotor and Readjust the vacuum pump (Busch service) the cylinder is no longer adequate Internal parts are worn or damaged Repair the vacuum pump (Busch service) KC 0016 VEMAG Seite 5 0870149431 / 130422...
Page 179 When the vacuum pump was restarted too much oil was enclosed between the vanes Oil could not be compressed and thus broke a vane KC 0016 VEMAG Seite 6 0870149431 / 130422...
Page 180 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 Oil burnt from overheating Flush the vacuum pump KC 0016 VEMAG Seite 7 0870149431 / 130422...
Page 181 Mixing of incompatible oils Flush the vacuum pump Replace the exhaust filter Fill in new oil page 9: Maintenance) (➔ Make sure the proper oil is used for changing and topping up KC 0016 VEMAG Seite 8 0870149431 / 130422...
Page 182: Ec Declaration Of Conformity
For maintenance of this Declaration of Conformity of vacuum pumps without a drive may only be used a drive with awritten consent of Busch. Busch Produktions GmbH Schauinslandstr. 1 79689 Maulburg Germany Declare that the vacuum pumps KC 0016 VEMAG In accordance with the European Directives: − “Machinery” 2006/42/EC, −...
Page 183 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 184 (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 185 -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 186 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 187 Drain condensate regularly Condensate could not be compressed and thus broke a vane KC 0040 D VEMAG page 5 0870149117 / 100111...
Page 188 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 189 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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