USER MANUAL BOXER SERIES MARLIN SERIES FALCON SERIES POLAR SERIES Versie 06.03 DIG.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL This manual refers to the BOXER, MARLIN, FALCON, and POLAR series. The general instructions apply to the models in this category. Henkelman B.V. cannot be held responsible for any damage caused by deviating machine specifications. This manual has been compiled with the utmost of care. Henkelman B.V. accepts no responsibility for any errors in this manual and/or the results of misinterpretation of this manual. Henkelman B.V.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL CONTENT USER MANUAL INTRODUCTION / LIABILITY / GUARANTEE …….…………………………………………………………….. 2 CONTENTS INSTRUCTION MANUAL ……….………………………………………………………….. 3 MACHINE REGISTRATION ……….………………………………………………………….. 4 IMPORTANT FOR INSTALLATION – READ THIS FIRST!!!! …..…………………………………………….. 5 IMPORTANT FOR USE – READ THIS FIRST!!!! ……………………………………………………… 7 WARNING LABELS ……….………………………………………………………….. 8 IMPORTANT MACHINE PARTS ……….…………………………………………………………..
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL PRIOR TO STARTING TO USE THE MACHINE, MACHINE REGISTRATION TO BE COMPLETED BY THE USER Register the machine using the following data. This information is necessary if the supplier or Henkelman BV is contacted concerning questions or references about the specific machine. DATA ON MACHINE TAG Relevant data for answering questions can be found on the machine tag. The machine tag is located at the rear of the machine. Note down the following data: 1.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL IMPORTANT FOR INSTALLATION!!! READ THIS FIRST!!! GENERAL First read this manual carefully before the machine is put into operation. This manual contains relevant information and instructions for starting up, maintenance and applications. If problems arise with the machine that could have been avoided by referring to this manual then the guarantee expires.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL VACUUM PUMP Check before starting the machine if there is oil in the pump (see page 23). NEVER start the machine without oil in the pump. Use the right type of oil for the pump (see page 24). After moving and/or transporting the machine, always first check the oil level before re-starting operation. When starting the machine for the first time or after a lengthy idle period, first run the conditioning program before operating the machine (see page 22).
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL IMPORTANT FOR OPERATION !!! READ THIS FIRST !!! GENERAL Never pack products that can be damaged during or after vacuum packaging. Live oats may never be vacuumed. Refer to this manual if in doubt as to the operation and/or functioning of the machine. If the manual does not offer a solution consult the supplier or Henkelman BV. The guarantee and/or liability expires if damage is caused by repairs and/or changes made by you.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL VACUUM PUMP Regularly check the level and quality of the oil in the pump. If there is too little oil or the quality of the oil is bad (turbid), replace or top up the oil before operating the machine (see page 23). Let the pump conditioning program run at least one full cycle before replacing the oil (see page 22). Use the right type of oil for the pump when replacing or filling up (see page 24).
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL IMPORTANT MACHINE PARTS BOXER SERIES MARLIN SERIES 2 2 4 4 5 1 5 6 6 1 8 9 7 Vacuum chamber 8 7 3 9 1 Rear view MARLIN machines Side view BOXER machines 17 12 18 10 13 16 11 12 14 Rear view BOXER machines 18 17 14 16 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL FALCON SERIES POLAR SERIES 1 1 4 4 4 5 5 2 3 5 1 22 8 8 7 7 6 8 7 6 Rear view FALCON series and POLAR single chamber models Inside lid POLAR series 18 9 17 15 16 13 14 1 11 12 10 1. Sealing bar(s) in lids mounted by using bolts 2. Silicone holder(s) on holders in vacuum chamber (FALCON) or on work plate (POLAR) 3. Gas flush nozzles mounted on silicone holders (if applicable) 4. Lid rubber in lid for hermetic seal 5.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL STARTING AND OPERATING THE MACHINE ON/OFF SWITCH MASTER SWITCH The ON/OFF switch is used to turn the machine on and off before and after operation. CAUTION – The ON/OFF switch does not completely turn off all power to the machine. With the BOXER series, MARLIN 42, MARLIN 42 XL and other models which run on 1 phase power, it is necessary to unplug the power cable from the wall socket before the machine is completely without power.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL STANDARD OPERATING STEPS FOR THE MACHINE 1. Turn the machine on with the ON/OFF switch. Heat up the pump with the condition program when machine has stood idle for some time (instructions page 22). 2. Fill the vacuum bag with product. Select the correct format bag that easily fits around the product but is not too large for the product. Ensure hygienic conditions during this operation.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL MACHINE CONTROL PANEL CONTROL PANEL VERSIONS General The digital control panels are implemented with 9 pre-select programs that can be individually set with different function values (to be able to pack different products) Program 0 can not be set and is used for servicing and testing. A program cycle is the complete program of set functions that the machine runs through to package a product.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL CONTROL PANEL LAYOUT 1 2 3 5 4 6 7 7 7 7 10 8 9 11 1. Small Display Displays active program in operating and program modes. 2. Large Display Displays the current value of the active function during the program cycle or the set value of the selected function in operation or program mode. 3. PROG 0-9 Keys Selects program number in operation or program mode. 4.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL 8. + / STOP VACUUM Key Function during cycle Function in program mode 9. - / STOP Key Function during cycle Function in program mode Interruption of the active function during the program cycle. The cycle immediately continues with the next function. Raise the value of the selected function within the program selected in the program mode. Terminates the program cycle completely. The cycle immediately switches to the ventilation function.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL 4. Gas flush function (if installed) Once the vacuum function has completed then the gas flush function starts to flush gas into the vacuum chamber. The light in front of [GAS] goes on. Large Display: decrementing time per second starting at the time set (max. 99 sec.). Vacuum meter starts decreasing to the right. 5. Seal function When the vacuum function or gas flush function (if installed) ends, the seal function starts to seal the vacuum bag(s).
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL 6. Seal function When the vacuum function or gas flush function (if installed) ends, the seal function starts to seal the vacuum bag(s). The light in front of [SEAL] goes on. Large Display: decrementing time per second starting at the time set (max. 6.0 sec.). The reading on the vacuum meter stays the same. 7. Soft-air ventilation function After ending the seal function the soft air function starts to slowly ventilate the vacuum chamber.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL PROGRAMMING The function values in a selected program number can be changed using either manual or automatic programming. For units, range and limits of the function values refer to the previous chapter, MACHINE CONTROL PANEL. 10 programs can be selected and set, number 0 to 9. Note: program 0 cannot be programmed. The values in this program are set for service and reference use.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL AUTOMATIC PROGRAMMING Starting situation: machine is in normal operating mode and the lid is open A. Select the correct programme with the PROG 0-9 Key for setting function values. The programme number is displayed on the small display. B. Then press the REPROG key to switch into programme mode. The programme number now starts to blink on the small display. Close the lid. The machine cycle starts automatically. C.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL F. SEAL FUNCTION Can only be programmed manually. For automatic programming, the set time length will be run and the machine cycle will automatically carry on with the next function. G. SOFT AIR FUNCTION / STORE FUNCTION VALUES IN PROGRAM Digital Time and Sensor Control Time is increasing. As soon as the desired setting is reached press the STOP VACUUM Key. After this operation the machine cycle ventilation starts and the lid opens.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL MACHINE MAINTENANCE GENERAL Regular, thorough maintenance is essential for extending the machine's life, for preventing malfunctions and for achieving an optimal packaging result. If the machine is used intensively (more than 4 hours per day) then a professional service is recommended every 6 months. In other cases one complete service per year is sufficient (depending on location, environment, and products).
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL STANDARD MAINTENANCE SCHEDULE FOR THE MACHINE Daily Clean the vacuum chamber, lid, and housing after use with a damp cloth. Make sure that no cleaning agents containing solvents are used. Make sure that no high pressure cleaner is used. Weekly Check the oil level and replace or fill up oil when the oil is turbid or the oil level is too low. For instructions, see page 23. Activate the conditioning program for the pump at least once a week.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL Changing Oil / Filling Up The oil level and oil quality must be checked at least once a week. The oil inspection window serves this purpose. Fill up the oil level if it is too low. Replace the oil if it is turbid. Oil must be replaced at least once every 6 months. BOXER series 3 1 4 1. 2. 3. 4.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL Machine Type Pump Capacity Filling (litres) Ambient Temperature Standard “Cold” “Hot” Oil Type Oil Type Oil Type 10 - 30 oC 5 - 10 oC 30 - 40 oC 0.4 Viscosity VG 32 BOXER 35 016 m3/h BOXER 42 / 42 XL - MARLIN 42 / 42 XL 021 m3/h 0.4 Viscosity VG 32 MARLIN 46 040 m3/h 1.0 Viscosity VG 32 MARLIN 52 / 90 - FALCON 52 / 2-60 – POLAR 52 / 2-40 063 m3/h 1.0 Viscosity VG 100 FALCON 2-60 - POLAR 2-50 100 m3/h 2.0 Viscosity VG 100 POLAR 2-75 160 m3/h 5.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL Change oil exhaust filter(s) Open rear or side of machine for pump Screw the cover(s) from the filter housing) The filter(s) is/are visible behind a tensioner Release the tensioner(s) with a spanner Place and tension the new filter (take care that the gasket is correctly positioned) in the housing Screw the cover back onto the housing Screw the back or side plate on the machine Remove tensioner(s) and filter(s) from the housing Take care that the fil
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL Replace sealing wire and teflon tape Remove teflon tape Unscrew and remove sealing wires Replace the teflon tape 1. Remove the sealing bar(s) from the holders (in the chamber or lid) by releasing the click system or by unscrewing the screws. 2. Remove the teflon tape from the sealing bar. 3. The old sealing wires and cut-off wires (if applicable) can be removed by unscrewing the clamp (see illustration) and pulling the wires from the grooves. 4.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL SILICONE HOLDER AND LID GASKET MAINTENANCE Replace the rubber silicone holder The silicone holder must be inspected weekly for irregularities on the silicone rubber (mainly caused by burning by the sealing wire). If irregularities appear then the silicone rubber must be replaced. Average maintenance cycle for silicone rubber is at least once every 6 months (This indication refers to regular use of the machine with standard products.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL LIST OF SERVICE PARTS VACUUM PUMP PARTS BUSCH VACUUM PUMPS HENKELMAN MODELS 016 m3/h 021 m3/h 040 m3/h 063 m3/h – 50Hz 100 m3/h 160 m3/h 300 m3/h BOXER 35 BOXER 42 / 42 XL / 42 XL BA – MARLIN 42 / 42 XL MARLIN 46 MARLIN 52 / 90 – FALCON 52 / 2-60 – POLAR 52 / 2-40 FALCON 80 / 2-70 – POLAR 80 / 2-50 POLAR 2-75 POLAR 2-85 / 2-95 BUSCH 016 m3/h 021 m3/h 040 m3/h 063 m3/h – 50Hz 063 m3/h – 60Hz 100 m3/h 160 m3/h 300 m3/h STANDARD OIL Henkelman Type Litre
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL LID GASKET MODELS HENKELMAN LENGTHS PER MODEL (in cm) REFERENCE BOXER SERIES MARLIN 42 / 42 XL 0320215 BOXER 35 BOXER 42 / MARLIN 42 BOXER 42 XL / BOXER 42 XL BA / MARLIN 42 XL 175 190 210 MARLIN 46 / 52 / 90 FALCON SERIES POLAR 52 / 80 / 2-40 / 2-50 0320210 MARLIN 46 MARLIN 52 / FALCON 52 / POLAR 52 MARLIN 90 FALCON 80 / POLAR 80 FALCON 2-60 / 2-70 POLAR 2-40 / 2-50 255 250 290 300 260 / 300 280 / 300 POLAR 2-75 / 2-85 / 2-95 0320228 POLAR 2-
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL TECHNICAL SPECIFICATIONS VACUUM CHAMBER WORKING PLATE LID BOXER SERIES 35 42 42 XL 42 XL Bi-active Stainless steel Stainless steel Stainless steel Stainless steel Transparent Transparent Transparent Transparent MARLIN SERIES 42 42 XL 46 52 90 Stainless steel Stainless steel Stainless steel Stainless steel Stainless steel FALCON SERIES 52 80 2-60 2-70 POLAR SERIES 52 80 2-40 2-50 2-75 2-85 2-95 MODEL HOUSING DIMENSIONS PUMP (mm) (m3/h) FINAL V
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL ELECTRICAL DIAGRAMS Control Current Diagram BOXER series / MARLIN 42/42 XL Power Circuit Diagram BOXER series / MARLIN 42/42 XL Diagrams are shown for standard configurations. Version 06.03 DIG.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL Control Current Diagram MARLIN 46/52/90 / FALCON 52/80 / POLAR 52/80 Power Circuit Diagram MARLIN 46/52/90 / FALCON 52/80 / POLAR 52/80 Diagrams are shown for standard configurations. Version 06.03 DIG.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL Control Current Diagram FALCON 2-60/2-70 / POLAR 2-40/2-50/2-75/2-85/2-95 Power Circuit Diagram FALCON 2-60/2-70 / POLAR 2-40/2-50/2-75/2-85/2-95 Diagrams are shown for standard configurations. Version 06.03 DIG.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL List of fuses Fuses are located where the power enters the component board Fuses are been located on transformers (control and seal) Two fuses are placed on the control circuit. Due to different mains voltages and machine models there is a variety of fuse types that can be present in the machine. Refer to the specifications of the relevant component for the correct types and values of fuses for replacement, or contact the supplier or Henkelman BV.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL ERROR CODES The controls are programmed with a number of error codes. These error codes are intended to give the user / dealer a clear indication of what the possible cause might be why starting or packaging is not working as expected. F1: This code indicates that the cycle (cover switch) will be interrupted prematurely.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL PNEUMATIC DIAGRAMS BOXER series / MARLIN series FALCON series / POLAR series Diagrams are shown for standard configurations. Version 06.03 DIG.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL PROBLEM SOLVING CAUSE PROBLEM Machine does not work • • • • • • • • • The control transformer fuse is burnt. • The micro switch which is activated when • the lid is closed needs adjustment or is faulty. • There is an internal malfunction. Transparent lid does not open automatically • The gas spring is faulty Final vacuum is insufficient • • The set vacuum time is too short. • There is too little oil in the vacuum pump.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL The vacuum bag is not properly and/or correctly sealed. SOLUTION CAUSE PROBLEM • The vacuum bag is being placed correctly on the sealing bar. • • The sealing time is too long or too short. The silicone rubber in on the silicone holder is damaged or worn. The teflon tape is damaged. The inside of the vacuum bag opening is contaminated. There is too much gas in the package. • • • The amount of gas in • the vacuum bag is • insufficient (optional).
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL DIGITAL TIME CONTROL FACTORY SETTINGS * ** Program 0** 1 2 3 4 5 6 7 8 9 Vacuum time Gas flush time* Sealing time Soft-air time* 30 OFF 2.5 3 25 OFF 2.5 3 20 OFF 2.5 2 15 OFF 2.5 2 10 OFF 2.5 2 30 5 2.5 OFF 25 5 2.5 OFF 20 10 2.5 2 20 15 2.5 OFF 15 15 2.5 OFF Only applicable if the machine is equipped with the options in question.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL REMARKS ON SPECIAL APPLICATIONS MACHINE WITH GAS FLUSH SYSTEM (if applicable) If the machine is equipped with the gassing system then the following remarks are important : NEVER USE GAS MIXTURES WITH MORE THAN 20% OXYGEN AND OR OTHER EXPLOSIVE GASSES. THIS COULD CAUSE FATAL EXPLOSIONS. NEVER USE SEPARATE GAS BOTTLES WITH A MIXER WHEREBY ONE OF THE BOTTLES IS ONLY FILLED WITH OXYGEN.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL EXTERNAL VACUUMING OF FOOD CONTAINERS (if applicable) The BOXER and MARLIN series can be equipped with an option for externally vacuuming special food containers. This system can vacuum special containers for longer storage life of the (food) products in the dish. The container has a special lid with valve. Contact the supplier or Henkelman BV for more information about the containers. The system for the machine consists of a hose with vacuum applicator.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL MAINTENANCE SCHEDULE / NOTES Date Version 06.03 DIG.
BOXER / MARLIN / FALCON / POLAR SERIES USER MANUAL Removal tools front panel With every machine we ship-out we enclose two special tools to make it possible to remove the front panel. The tools slide in the slots at the bottom side of the front panel. Now lift it a little and pull it towards you. Version 06.03 DIG.