Diamond Boxer User Manual
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Diamond Boxer User Manual

Vacuum packaging machine
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11/2017
Mod: TA-90/IVP
Production code: Boxer 42+ACS

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Summary of Contents for Diamond Boxer

  • Page 1 11/2017 Mod: TA-90/IVP Production code: Boxer 42+ACS...
  • Page 2 Vacuum Packaging Machine Boxer, Lynx, Toucan User Manual Art No. 0895001 Original Instructions for Use...
  • Page 3 • 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.

  • Page 4: Table Of Contents

    Contents List of Figures..........................6 1 Preamble............................7 2 Safety.............................8 2.1 List of the Symbols Used in this Manual................8 2.2 Pictograms on the Machine....................8 2.3 General Warnings........................9 2.4 Warnings During Use......................10 2.5 Warnings for Operating Personnel..................10 3 Introduction..........................12 4 Description of the Machine.......................13 4.1 Overview of the Main Components..................13...
  • Page 5 6.7.1.4 Gas+ (optional)..................... 33 6.7.1.5 Liquid Control (optional)..................33 6.7.1.6 Liquid Control+ (optional)..................33 6.7.1.7 Red Meat (optional)....................34 6.7.1.8 Multi-Cycle Vacuum (optional)................34 6.7.1.9 Seal........................34 6.7.1.10 Soft-Air........................ 35 6.7.1.11 External Vacuum (optional)................35 6.7.2 Advanced Control System (ACS)................. 36 6.7.2.1 Programming the ACS Control Using the PC............37 6.7.2.2 Functions......................
  • Page 6 10 Disposal.............................59 11 Appendices..........................60 11.1 Technical Data........................60 11.1.1 Technical Data Boxer....................60 11.1.2 Technical Data Lynx....................62 11.1.3 Technical Data Toucan....................63 11.2 Example Programs......................64 11.3 Logbook..........................66 11.4 EC Declaration of Conformity.................... 68 11.5 Replacing a Printer Roll..................... 69 11.6 Aligning the Printer......................70...

  • Page 7: List Of Figures

    Figure 14: External Vacuum Adapter Set (ACS)................43 Figure 15: Vapour Pressure Curve of Water.................. 46 Figure 16: Mounting Plate Boxer 52....................50 Figure 17: Replacing the Oil Exhaust Filter (Pump 8 m3).............. 51 Figure 18: Replacing the Oil Exhaust Filter (Pump 16/21 m3)............51 Figure 19: Removing the Sealing Bar.....................52...

  • Page 8: Preamble

    Preamble This is the manual for your Henkelman 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 9: Safety

    Safety Your vacuum packaging machine has been carefully designed and expertly built to be operated safely. This is corroborated by the EC Declaration of Conformity. However, there are always dangers and safety risks that cannot be eliminated. These dangers and risks are the result of the use functions of the machine and operation of the machine by the user.

  • Page 10: General Warnings

    Warning sign "Gas Connection" (optional) Forbidden to connect oxygen • Is located on the back of the machine Warning sign "Gas Connection" (optional) Maximum allowed gas pressure of the gas flush system • Is located on the back of the machine Machine plate •...

  • Page 11: Warnings During Use

    • The available safety devices may not be removed. • The correct operation and safety of the system can only be guaranteed if the recommended maintenance is performed on time and properly. • If work must be carried out on the machine, it must be disconnected and blocked from the power supply and, if applicable, from the gas supply.
  • Page 12 • All personnel must obey the safety regulations to avoid danger to themselves and others. Always strictly follow the work instructions. Safety...

  • Page 13: Introduction

    "plug & pack". The clever design ensures compliance with the hygiene standards at all times. The Boxer, Lynx and Toucan series are table top models with various options suitable for a variety of applications. These machines have several programs and options for optimal packaging.

  • Page 14: 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.

  • Page 15: Description Of The Packaging Process/Machine Functions

    Vacuum pump The vacuum pump creates the vacuum. Power connection and cable This serves to connect the machine to the power supply. 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 16 Step Process phase Operation Depending on the options you selected for your machine and the product you are packaging, the following functions are available: Vacuum During the cycle, the air is removed from the chamber until the set time or pressure has been reached, depending on the selected model.
  • Page 17 Step Process phase Operation Liquid Control Liquid Control is only available if your machine is equipped (optional) with the optional Liquid Control sensor. With the Liquid Control option, the system is controlled by a highly sensitive sensor. The sensor is able to detect the moment that liquids from the product or the product itself begin to evaporate (boil).
  • Page 18 Step Process phase Operation 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.

  • Page 19: General Functions

    Step Process phase Operation This function allows air from outside to slowly enter the Soft-Air chamber so the vacuum bag will shape itself slowly around the product. This prevents sharp edges of the product from puncturing the foil and causing leaks. Opening the The lid opens.

  • Page 20: Sealing System

    Function Pictogram Operation 35 for 10-program control system or External Vacuum (optional) on page 43 for ACS control). Sealing System The sealing system closes the opening(s) of the bag to retain the vacuum and/or gas in the bag. The end of the bag can optionally be cut off by the sealing bar. Figure 2: Overview of the Sealing System Sealing bar The sealing bar consists of the following components:...

  • Page 21: Vacuum Pump

    Vacuum Pump The vacuum pump creates the vacuum. Figure 3: Overview of the Pump (Pump 8 m Figure 4: Overview of the Pump (Pump 16 m Vacuum pump - Creates the vacuum for the process. Oil exhaust filter - Filters the air by capturing oil vapours. Oil sight glass - Indicates the maximum and minimum oil levels of the vacuum pump.

  • Page 22: Electrical Installation

    Electrical Installation The electrical installation provides power for the vacuum pump, the seal system and the operation of the machine. See the electrical 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 23: Installation

    Installation Consult Technical Data on page 60 for the specifications of the machine. Before installing the machine, carefully read the safety instructions in Safety on page 8. 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 24: Operation

    Operation The machine is equipped with sample programs with preset parameters (see Example Programs on page 64). It is possible to optimise a program for your products by modifying the parameters of a program, see Changing the Program Settings on page 31. •...

  • Page 25: Operating Elements Of The Advanced Control System (Acs)

    Pump cleaning program button This is used to activate the pump cleaning program. Moisture can be absorbed by the oil when the pump is running only short cycles or when you are packaging moisture-containing products. This program removes moisture from the oil of the vacuum pump. See Running the Pump Cleaning Program on page 49 for instructions.

  • Page 26: Changing The Acs Settings

    On/Off button Serves to turn the control on or off. Display The display has four possible modes: See Figure 8: Possible Display Modes on page 25 and Figure 9: Possible Display Modes on page 25. • Start-up mode: displays the current date and time when starting the machine. It also displays the installed software version.

  • Page 27: Figure 10: Overview Of The Menus

    be opened. When logged in, the function settings can also be changed. To do so, return to the navigation mode by pressing ◄. The machine remembers the last authorisation code used, even when the machine has been turned off. Therefore, it may be necessary to manually change the authorisation setting when you are done.
  • Page 28 Settings 1.3 Date & 1.5 Screen 1.7 Program 1.8 Data log 1.1 Printer 1.2 Units 1.6 Options Time Language saver names Screen Sleeper Pressure Data log ID Printer Date format English Program saver option unit On/Off On/Off On/Off (only on floor Temperature Time format...

  • Page 29: 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. Each entry consists of: •...

  • Page 30: Exporting Data Log

    6.2.3.2 Exporting Data Log The memory can store up to 100 entries. If the memory is full, you will receive a message. The data log will first need to be exported before you can continue your work. You can export the data at any time.

  • Page 31: Starting The Machine

    Label Number The label that was printed for this package. Number of Cycles The number of cycles run from the start time. Starting the Machine Plug in the machine. Press the on/off button on the control panel to enable the operation. In the 10-program control system, 3 dashes may be shown on the display during the first start-up or ventilation.

  • Page 32: Terminating A Program

    Terminating a Program Programs such as the packaging program or the pump cleaning program can be terminated at any time. Terminate the program. 10-program control system Press the – / STOP button. Press the STOP button. The program will be terminated and the vacuum chamber is decompressed. Changing the Program Settings 6.7.1 10-Program Control System...

  • Page 33: 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 34: Gas+ (Optional)

    6.7.1.4 Gas+ (optional) The Gas+ option only applies if the machine is equipped with the gas option. For some products it may be desirable to insert additional gas into the packaging to create a "balloon packaging". This allows for a better protection of a fragile product. The recommended value for Gas+ is 0.7 seconds. If the Gas+ option is enabled, a dot will appear in the bottom right of the program display.

  • Page 35: Red Meat (Optional)

    Press the – / STOP button and the + / VACUUM STOP button to adjust the value of Liquid Control+. When setting a value, a dot will appear in the bottom right of the parameter display. Press the REPROG button to activate the new parameter. The function display will stop flashing.

  • Page 36: Soft-Air

    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 Boxer and Lynx series. With the External Vacuum program, you can program as with any other program. See Changing the Program Settings on page 31.

  • Page 37: Advanced Control System (Acs)

    Program the External Vacuum program according to the steps specified in 10-Program Control System on page 31. Connect the external vacuum hose to the machine by placing the adapter over the suction inlet (1) in the vacuum chamber. Connect the external vacuum hose to the packaging. Connect the adapter (3) of the external vacuum hose to the valve of the packaging.

  • Page 38: Programming The Acs Control Using The Pc

    Element Explanation Functions These functions are active or inactive. If a function is active, it is displayed in a blue shade. If a function is inactive, it is displayed in a grey shade. Function active/inactive The selected function is marked with a green circle. The name and current value of this function will appear on the screen.

  • Page 39: Functions

    To import the programs and labels into the machine, follow the steps below: Insert a USB stick into the USB port of the machine. In the menu, go to Import/Export and import the data. 6.7.2.2 Functions The built-in functions of the machine can be enabled or disabled by the owner under Settings. See Changing the ACS Settings on page 25.

  • Page 40: Gas+ (Optional)

    The insertion of gas lowers the seal pressure. The minimum final pressure (after the insertion of gas) must be 30% (300 mbar) to ensure proper sealing. To set the Gas function, follow the steps below: Press the cursor keys ▲ and ▼ and select the program Gas. Press Enter to open the menu.

  • Page 41: Liquid Control+ (Optional)

    there might be too much residual oxygen content present in the package. If the product/process requires packaging with a low residual oxygen content, despite the high moisture content, there are two options: Lower the product temperature. This allows for a deeper vacuum to be reached before the product reaches the boiling point.

  • Page 42: Marinating (Optional)

    Press the cursor keys ◄ and ► and select the program Sequential Vacuum. Press Enter to open the menu. If Sequential Vacuum is not enabled, enable it. Press Enter and use the cursor keys ▲ and ▼ to turn ON Sequential Vacuum. Press Enter. Use the cursor keys ▲...

  • Page 43: Seal

    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. If Tenderising is not enabled, enable it. Press Enter and use the cursor keys ▲ and ▼ to turn ON Tenderising.

  • Page 44: 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 Boxer and Lynx series. Check in advance whether the relevant food container can withstand and hold a vacuum.
  • Page 45 Function Range Conditions Vacuum 0 – 99% Rule of thumb: the higher the vacuum, the less oxygen (for 10-prog control) remains in the package and the longer the shelf life of 30 – 99.8% the product. There are exceptions to this rule. (for ACS) Vacuum+ 0 –...
  • Page 46 Function Range Conditions Sequential Vacuum 0 – 99% If the value for the Vacuum+ time is insufficiently (ACS)/Multi-Cycle (for 10-prog control) effective for the entrapped air to escape, the Sequential Vacuum (10-prog 30 – 99.8% Vacuum/Multi-Cycle Vacuum Step must be enabled. control) (for ACS) In maximum five steps, vacuuming is alternated with...

  • Page 47: Printer (Acs Only)

    Figure 15: Vapour Pressure Curve of Water 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:...
  • Page 48 Customer name Label number Name Info Use by / Storage life Storage temperature Print customer name Y/N Print info Y/N Print achieved vacuum Y/N 10. Print expiry date Y/N 11. Print user Y/N 12. Print storage temperature Y/N Once the printer is selected and the required information for the label is entered, the printer can be activated on each separate program.

  • Page 49: 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. • Test the machine after carrying out maintenance work or repairs to make sure the machine can be used safely.

  • Page 50: Cleaning The Machine

    Activity * 1-D 1-W 6-M 1-Y 4-Y Replace the plastic lid. * 1-D = Daily, 1-W = Weekly, 6-M = Every 6 months, 1-Y = Annually, 4-Y = Every 4 years Cleaning the Machine Never clean the machine using a high pressure cleaner. Do not use any aggressive or toxic cleaning agents.

  • Page 51: Replacing The Oil Exhaust Filter

    The oil in the vacuum pump may be hot. Avoid contact with hot oil when removing the oil. Follow the steps below to remove the oil from the pump: Only applies to Boxer 52: Remove the vacuum pump from the housing. Unscrew the mounting screws (1) of the rotating mounting plate (3) and place them in a secure location.

  • Page 52: Pump 8 M

    7.5.1 Pump 8 m Figure 17: Replacing the Oil Exhaust Filter (Pump 8 m Follow the steps below to remove the old oil exhaust filter: Remove the filter cover (3) of the vacuum pump (1) and put it aside. Remove the oil exhaust filter (2) from the vacuum pump. Follow the steps below to install a new oil exhaust filter: Turn the new filter into the vacuum pump.

  • Page 53: Replacing The Sealing Wire

    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). Follow the steps below to install a new oil exhaust filter: Insert the new filter into the vacuum pump.

  • Page 54: Replacing The Silicone Rubber Of The Silicone Holders

    Figure 20: Replacing the Sealing Wire Remove the Teflon tape (1) that protects the sealing wire. Remove the screws (2) at the bottom of the sealing bar and remove the sealing wires (3). Replace the Teflon tape on the sealing bar. Pull the Teflon tape from the top of the sealing bar (4).

  • Page 55: Replacing The Lid Gasket

    Figure 21: Replacing the Silicone Rubber of the Silicone Holders Pull the old silicone rubber from the holder, see Figure 21: Replacing the Silicone Rubber of the Silicone Holders on page 54. Cut a new piece of silicone rubber. Make sure it is the same length as the holder. If the rubber is too short or too long, this may cause problems with the seal of the bag.

  • Page 56: Inspecting The Lid Springs

    Figure 22: Replacing the Lid Gasket Pull the old gasket loose to remove it. Cut a new piece of rubber. Preferably cut the new piece of rubber slightly longer than the old piece. The edges must be cut straight. If the lid gasket is too short or too long, this may cause problems when closing the lid or it may cause leakage.

  • Page 57: 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 • Connect the machine to the Electrical Installation on page illuminate. power supply. The control panel is on, but •...
  • Page 58 Malfunction Activity More information The lid does not open • Check the gas spring/ Contact your supplier. automatically. springs of the lid. Error messages for the 10-program control system Malfunction Activity More information F1 in display. • Check or adjust the switch of Contact your supplier.

  • Page 59: Terms Of Warranty

    Terms of Warranty The warranty is subject to the following limitations. The warranty period for products supplied by Henkelman 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 60: Disposal

    Disposal Do not dispose of oil and components as household waste. When replacing oil or components at the end of the service life, ensure that all materials are collected and disposed or reused in a legal and environmentally sound manner. Disposal...

  • Page 61: Appendices

    Appendices 11.1 Technical Data 11.1.1 Technical Data Boxer Boxer 42XL 42XL BA General Ambient temperature 5 to 30°C 5 to 30°C 5 to 30°C 5 to 30°C 5 to 30°C during operation Sound emission < 70 dB(A) < 70 dB(A) <...
  • Page 62 *See machine plate. **For different temperatures, please contact your dealer. Appendices...

  • Page 63: Technical Data Lynx

    11.1.2 Technical Data Lynx Lynx General Ambient temperature during operation 5 to 30°C 5 to 30°C Sound emission < 70 dB(A) < 70 dB(A) Maximum daily production 5 hrs/day 5 hrs/day Dimensions of the machine Width 534 mm 534 mm Length 400 mm 491 mm...

  • Page 64: Technical Data Toucan

    11.1.3 Technical Data Toucan Toucan Regular Square General Ambient temperature during operation 5 to 30°C 5 to 30°C Sound emission < 70 dB(A) < 70 dB(A) Maximum daily production 5 hrs/day 5 hrs/day Dimensions of the machine Width 480 mm 480 mm Length 581 mm...

  • Page 65: 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/liquid- 2.2 s containing products 2.2 s Fragile/sharp products Product that may 2.2 s contain entrapped air Set as sensor-controlled Prog no.
  • Page 66 Set as time-controlled Prog no. Vacuum 25 s 20 s 15 s 10 s 30 s 25 s 20 s 20 s 15 s 30 s 10 s 15 s 15 s Seal 2.2 s 2.2 s 2.2 s 2.2 s 2.5 s 2.5 s 2.5 s...

  • Page 67: 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 Date: Performed by: Description: (authority, technician) (nature of the activities, which parts have been replaced) Appendices...
  • Page 68 Date: Performed by: Description: (authority, technician) (nature of the activities, which parts have been replaced) Appendices...

  • Page 69: Ec Declaration Of Conformity

    Titaniumlaan 10 5221 CK, "s-Hertogenbosch The Netherlands declare under our sole responsibility that the product; • Machine type: Boxer/Lynx/Toucan series complies with all relevant provisions of the Directives; • 2006/42/EC: Machinery Directive • 2014/30/EG: EMC Directive • 2014/35/EC: Low Voltage Directive The undersigned is authorised to compile the technical file.

  • Page 70: Replacing A Printer Roll

    11.5 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. Figure 23: Replacing the Printer Roll Appendices...

  • Page 71: Aligning The Printer

    11.6 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.

This manual is also suitable for:

LynxToucanTa-90/ivpBoxer 42+acs

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