Related Manuals for CombiSteel Giant 52
Summary of Contents for CombiSteel Giant 52
- Page 1 Vacuum Machine 7004.0045 Giant 52 7004.0050 Prime 240 7004.0055 Prime 285 User manual...
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Page 2: Table Of Contents
CONTENT Preamble ................................. 5 Safety ................................5 List of the symbols used in this manual ....................5 Pictograms on the machine ........................5 General warnings ..........................6 Warnings during use ..........................7 Warnings for operating personnel ......................7 Introduction ..............................8 Description of the machine .......................... - Page 3 6.7.2.8 Red Meat (optional) ....................... 31 6.7.2.9 Sequential Vacuum (optional) ....................32 6.7.2.10 Marinating (optional) ......................32 6.7.2.11 Tenderising (optional) ......................33 6.7.2.12 Seal ............................33 6.7.2.13 Soft-air ............................ 33 6.7.2.14 External vacuum (optional) ....................34 6.7.2.15 Sleeper Option ........................34 6.7.2.16 Dealer Information .........................
- Page 4 The machine is not suitable for the packaging of toxic, corrosive, irritant or potentially explosive materials. All persons responsible for the operation of this machine must at least fully read and understand the chapters about the operation and safety provided in these operating instructions.
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Page 5: Preamble
Preamble This is the manual for your Combisteel vacuum packaging machine. This manual is intended for anyone who works with or services the machine. This manual contains information and instructions for installation, operation and maintenance of the machine. We recommend that you carefully read this manual before use and follow the procedures and instructions strictly. -
Page 6: General Warnings
Machine plate • Is located on the back of the machine Regularly check whether the pictograms and markings are still clearly recognizable and legible. Replace them if this is not the case. General warnings • All persons responsible for the operation of this machine must at least fully read and understand the chapters Safety on page 5 and Operation on page 18. -
Page 7: Warnings During Use
Warnings during use • Before starting the machine, make sure no work is being performed on the installation and that the machine is ready for use. • The machine may not be operated by unauthorised persons. This should be monitored by the machine operator(s). -
Page 8: Introduction
Introduction Combisteel BV is a supplier of ultra-modern vacuum packaging machines. Our machines are developed and manufactured to meet the highest standards. They combine a sleekly built and functional design with optimal ease of use and a long service life. After mounting the plug, it is just a matter of "plug & pack". The clever design ensures compliance with the hygiene standards at all times. -
Page 9: Description Of The Machine
Description of the machine This section provides an overview of the main components and functions. If detailed information is available in this manual, you will be referred to the specific sections. Overview of the main components The figure below shows the main components of the system. The model shown may differ from your machine. Figure 1: Overview of the Main Components The lid closes the vacuum chamber during the application of the vacuum. -
Page 10: Description Of The Packaging Process/Machine Functions
Power connection and cable This serves to connect the machine to the power supply. The machine is supplied without an electrical plug. Gas flush system connector (optional) After applying vacuum, a gas is injected into the packaging to create a modified atmosphere to protect the shape of the product or increase the shelf life of the product. - Page 11 Gas (optional) After applying vacuum, a gas is injected into the package to create a modified atmosphere to protect the shape of the product or to increase the shelf life of the product. The value of the gas function can be set in %, mbar or hPa or time, depending on the control type of the machine.
- Page 12 Marinating (optional) This function is only available on machines with the Advanced Control System (ACS). This function is especially designed to accelerate the marinating of a product. This program allows definition of up to 5 vacuuming steps with intermediate ventilation steps. The vacuuming steps have a fixed vacuum value of 80%, except for the last step.
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Page 13: General Functions
4.2.2 General functions Function Pictogram Operation Cleaning of the The pump cleaning program ensures that the pump is thoroughly rinsed. During the program, the pump and oil reach the operating temperature, so oil pump the oil and moisture are separated and any contamination is filtered. The high temperature causes any moisture in the pump to evaporate, thus minimising the risk of corrosion. -
Page 14: Vacuum Pump
1. Sealing bar The sealing bar consists of the following components: Sealing wires: during the sealing process, the sealing wires are heated for a certain time causing the edges of the vacuum bag to melt together. Cut-off wires (optional): A cut-off wire is heated in such a way that the foil of the bag partially melts, allowing the excess foil of the vacuum bag to be removed easily. -
Page 15: Electrical Installation
Electrical installation The electrical installation provides power for the vacuum pump, the seal system and the operation of the machine. See the diagram for the further structure and operation of the electrical installation. Please contact your supplier for the electrical diagram. Only a technical expert may perform work on the electrical installation. -
Page 16: Installation
Installation Consult Technical Data on page 46 for the specifications of the machine. Before installing the machine, carefully read the safety instructions in Safety on page 5. Failure to follow or disregard of the safety instructions may result in serious injury. Transportation and installation The machine must be moved and transported in an upright position. -
Page 17: Prior To The First Use
Figure 6: Direction of Rotation of the Vacuum Pump 6. Optional: Connect the gas supply for the gas flush system. 7. Optional: Connect the air supply for additional sealing pressure. Prior to the first use 1. Check the oil sight glass to see if the amount of oil in the pump is sufficient. 2. -
Page 18: Operation
Operation The machine is equipped with sample programs with pre-set parameters (see Example Programs on page 49). It is possible to optimise a program for your products by modifying the parameters of a program, see Changing the Program Settings on page 24. •... -
Page 19: Operating Elements Of The Advanced Control System (Acs)
Function display The LED light in front of the function lights up if the function is active during the program cycle or if the function is selected in the programming mode. – / STOP button This is used to interrupt the entire cycle during a packaging cycle. All functions are skipped and the cycle is terminated. -
Page 20: Changing The Acs Settings
▲ ▼ , ◄ and ► Cursor keys These are used to navigate through the functions. The ► button stops the active function and proceeds to the next cycle step. See Proceeding to the Next Step in the Cycle on page 24. Enter This activates/confirms the selected value. - Page 21 Figuur 11: Overzicht van de menu’s...
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Page 22: Importing/Exporting Data
6.2.2 Importing/Exporting Data Data such as programs and labels can be imported and exported via the USB connection. 6.2.3 Data log ID The control system is provided with the option to store the production information. The data log is stored in lined entries. -
Page 23: Starting The Machine
Log in using the owner code (1324). You will be granted access to the relevant settings. Within the menu, go to Import/Export and select Export. Insert a USB stick into the USB port. Various options will appear on the screen. Select Export Data log. -
Page 24: Starting The Packaging Cycle
Starting the packaging cycle The machine must be started in accordance with Starting the Machine on page 23 before starting a packaging cycle. Select the desired program. 10-program control system Press the PROG 0 – 9 button. Press the ► button or the button. Put the product/products in place. -
Page 25: Vacuum+ (Optional)
6.7.1.2 Vacuum+ (optional) If air is trapped in the product, it may be desirable to extend the vacuuming time after the maximum vacuum has been reached. This to allow entrapped air to escape from the product. The Vacuum+ time is set in seconds. If a Vacuum+ time has been set, a dot will appear in the bottom right of the parameter display. -
Page 26: Liquid Control (Optional)
6.7.1.5 Liquid control (optional) The Liquid Control option can be enabled or disabled for each program. If the Liquid Control option is enabled, the machine will vacuum until the maximum vacuum is reached (99%). If the product reaches the boiling point before the maximum vacuum is reached, the machine will proceed to the next step of the cycle. -
Page 27: Multi-Cycle Vacuum (Optional)
6.7.1.8 Multi-cycle vacuum (optional) The Multi-Cycle Vacuum option allows you to vacuum and insert gas in up to 5 steps. This provides an additional reduction in the oxygen content. This function is useful only for very specific applications, which set very special demands on the residual oxygen content or the maximum allowed vacuum. -
Page 28: External Vacuum (Optional)
6.7.1.11 External Vacuum (optional) The External Vacuum function allows special food containers to be vacuumed outside the machine. Depending on whether the machine is time or sensor-controlled, the vacuum value is set in seconds or %. External Vacuum is only available on the Giant series. With the External Vacuum program, you can program as with any other program. -
Page 29: Advanced Control System (Acs)
6.7.2 Advanced Control System (ACS) Users can view the machine programs and activate the functions in the navigation mode. This is the mode that appears immediately after start-up. Figure 14: Screenshot of the navigation mode and the operating buttons of the ACS Element Explanation Program number/name... -
Page 30: Vacuum+ (Optional)
6.7.2.3 Vacuum+ (optional) If a lot of air is trapped in the product, it may be desirable to extend the vacuuming time after the maximum vacuum has been reached. This to allow entrapped air to escape from the product. You can only set Vacuum+ if Vacuum has been set to the maximum (99.8%). To set the Vacuum+ option, follow the steps below: 1. -
Page 31: Liquid Control (Optional)
6.7.2.6 Liquid Control (optional) The Liquid Control option can be enabled or disabled for each program. If the product reaches the boiling point before the set vacuum is reached, the machine will proceed to the next step of the cycle. To set the Liquid Control option, follow the steps below: 1. -
Page 32: Sequential Vacuum (Optional)
6.7.2.9 Sequential Vacuum (optional) The Sequential Vacuum option allows you to vacuum in up to 5 steps, alternating vacuuming steps with maintaining periods. Each step increases the vacuum reached in the previous step. To set the Sequential Vacuum option, follow the steps below: Press the cursor keys ◄... -
Page 33: Tenderising (Optional)
6.7.2.11 Tenderising (optional) This feature has been designed to keep the chamber at a pre-determined vacuum level for a certain time. This is done to tenderise or degas the product. To set the Tenderising option, follow the steps below: Press the cursor keys ◄ and ► and select the program Tenderising. Press Enter to open the menu. -
Page 34: External Vacuum (Optional)
6.7.2.14 External vacuum (optional) The External Vacuum function allows special food containers to be vacuumed outside the machine. The packaging is vacuumed until a vacuum of 99.8% is reached. External Vacuum is only available on the Royal series. Check in advance whether the relevant food container can withstand and hold a vacuum. To select the External Vacuum option, follow the steps below. -
Page 35: Guideline For Function Values
Guideline for function values For each function, values can be set if you are authorised as an owner. In order to understand the consequence of the set value, the table below explains the consequences of giving a low or high value for each function. For the values in the table below, the following rule of thumb applies to setting a value in mbar. - Page 36 Marinating 40 – 99,8% Only in case of ACS control. This is the adjustable value of the last step. If it is set to 40%, no more vacuuming will take place Steps: 1 – 5 during this step, but it will immediately proceed to sealing. 1 –...
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Page 37: Printer (Acs Only)
Printer (ACS only) A printer can be connected to the machine to print package labels. From software version 90, the mounted sensor is automatically detected. A message is displayed if you close the lid and no sensor is detected. 6.9.1 Connecting a Printer To connect a printer to the machine, follow the steps below: Connect the printer to the mains supply. -
Page 38: Maintenance
Maintenance When carrying out maintenance work, always observe the following safety rules. Only trained technicians are authorised to perform the described maintenance activities. Always disconnect the power supply by disconnecting the plug. Always disconnect the air supply (if applicable). ... -
Page 39: Cleaning The Machine
Cleaning the machine Never clean the machine using a high pressure cleaner. Do not use any aggressive or toxic cleaning agents. Do not use any cleaning agents containing solvents. Clean the surfaces with a soft, damp cloth. You can also apply a cleaning agent to the machine and wash it with clean water. -
Page 40: Pump 40-300 M
7.5.1 Pump 40-300 m Figure 17: Replacing the Oil Exhaust Filter (pump 40-300 m Follow the steps below to remove the old oil exhaust filter: Remove the filter cover (4) of the vacuum pump (1) and put it aside. Remove the leaf spring (3) and put it aside. Remove the old filter (2). - Page 41 Figure 18: Removing the Sealing Bar (Plastic Lid) Figure 19: Removing the Sealing Bar (Metal Lid) Remove the sealing bar. Plastic lid: Lift the sealing bar from the cylinders. See Figure 18: Removing the Sealing Bar (Plastic Lid) on page 41. Metal lid: See Figure 19: Removing the Sealing Bar (Metal Lid) on page 41.
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Page 42: Replacing The Silicone Rubber Of The Silicone Holders
Replacing the Silicone Rubber of the Silicone Holders To ensure a seal of good quality, the silicone rubber may not be damaged and the surface must be smooth. Mechanical contact or burning by the sealing wire may damage the rubber. Replace the silicone rubber if damaged or as specified in Maintenance Schedule on page 38. -
Page 43: Replacing The Lid Gasket
Replacing the Lid Gasket The lid gasket ensures the vacuum chamber is fully closed during the machine cycle. This is essential to reach the maximum vacuum level. Due to extreme pressure differences, the gasket wears and should therefore be replaced regularly. -
Page 44: Troubleshooting
Troubleshooting The tables below show the possible malfunctions and the corresponding causes as well as the steps to be taken. Malfunction Activity More information Control panel does not illuminate. Electrical Installation on page 15. Connect the machine to the power supply. -
Page 45: Terms Of Warranty
Terms of Warranty The warranty is subject to the following limitations. The warranty period for products supplied by Combisteel BV is 3 years from the date indicated on the purchase document. This warranty is limited to manufacturing and machining defects and therefore does not cover breakdowns involving any part of the product that is exposed to any form of wear and tear. -
Page 46: Appendices
Appendices 11.1 Technical data 11.1.1 Technical data Giant Giant Giant 52 General Ambient temperature during operation 5 tot 30 °C 5 tot 30 °C Sound emission < 70 dB(A) < 70 dB(A) Maximum daily production 8 h/day 8 h/day Dimensions of the machine... -
Page 47: Technical Data Prime
11.1.2 Technical data Prime Prime Prime 240 General Ambient temperature during operation 5 tot 30 °C 5 tot 30 °C 5 tot 30 °C 5 tot 30 °C Sound emission < 70 dB(A) < 70 dB(A) < 70 dB(A) < 70 dB(A) Maximum daily production 8 h/day 8 h/day... - Page 48 Prime 2-50 2-75 Prime 285 2-95 General Ambient temperature during operation 5 tot 30 °C 5 tot 30 °C 5 tot 30 °C 5 tot 30 °C Sound emission < 70 dB(A) < 70 dB(A) < 70 dB(A) < 70 dB(A) Maximum daily production 8 h/day 8 h/day...
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Page 49: Example Programs
11.2 Example Programs Example programs of the 10-program control system Prog Vacuum Vacuum+ Seal Soft-air Type of product 2.2 s Solid products Liquids/liquidcontaining 2.2 s products 2.2 s Fragile/sharp products Product that may contain 2.2 s entrapped air Set as sensor-controlled Prog no. - Page 50 Example programs of the ACS control system Prog Vacuum Vacuum+ Seal Soft-air Type of product 99.8% 2.2 s Solid products Liquids/liquidcontaining 2.2 s products 99.8% 2.2 s Fragile/sharp products Product that may contain 99.8% 2.2 s entrapped air Set as senor-controlled or controlled by Liquid Control sensor Prog no.
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Page 51: Logbook
11.3 Logbook This logbook must include: • Annual maintenance work • Major replacements and emergencies • Modifications • Tests of the emergency stop buttons and safety devices Description: Performed by: Date: (nature of the activities, which (authority, technician) parts have been replaced) -
Page 52: Replacing A Printer Roll
11.4 Replacing a Printer Roll Follow the steps below to place the label roll in the printer. Despite the inner diameter of the label roll being bigger than the holder, the roll can be used without any issues. Figuur 23: Replacing the Printer Roll... -
Page 53: Aligning The Printer
11.5 Aligning the Printer Switch on the printer and make sure the indication light is green. Press the Pause and Cancel button simultaneously for 2 seconds. Figure 24: Aligning the Printer The printer will print several labels and determine the correct position. Press the Feed and Cancel button simultaneously for 2 seconds.
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