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In general

TABLE OF CONTENTS
1. In general .......................................................................................................................... 8

1.1 Introduction ................................................................................................................. 9

1.2 Copyrights ................................................................................................................ 10
1.3 Symbols - comments ................................................................................................ 11
1.4 Fundamental safety tips ........................................................................................... 12
1.5 Work area and danger zone for the operation personnel ......................................... 18
2. Machine description ........................................................................................................ 19

2.1 Short description for the continuous vacuum filling machine.................................... 19

2.2 Usage ....................................................................................................................... 20
2.3 Proceedure sketch for alternating operations ........................................................... 22
2.4 Photo of the continuous vacuum filling machine ...................................................... 23
2.5 Protective devices and their safety functions ........................................................... 25
2.6 Safety-related user information ................................................................................ 26
3. Transport, set up, installation .......................................................................................... 27

3.1 Transport .................................................................................................................. 27

3.2 Interim storage ......................................................................................................... 27
3.3 Setting up the machine ............................................................................................. 27
3.4 Securing/ fuse protection .......................................................................................... 28
3.5 Machine aligning ...................................................................................................... 28
3.6 Necessary space for operation and upkeep ............................................................. 28
3.7 Size, weight and technical data ................................................................................ 29
3.8 Beginning operation ................................................................................................. 30
3.9 Safety precations ...................................................................................................... 34
4. Operation of the vacuum filling machine ......................................................................... 37

4.1 General safety precautions ...................................................................................... 37

4.2 Control elements/function ......................................................................................... 38
4.3 Description of the touch screen ................................................................................ 42
4.4 Description of the Touch-, CPU- controls ................................................................. 45

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4.5 Keyboard description ................................................................................................ 56

4.6 Installation of the straight filling program .................................................................. 60
4.7 Adjustment of a portioning program ......................................................................... 62
4.8 Adjustment of a twisting off program ........................................................................ 66
4.9 Adjustment of the pressure sensor operation ........................................................... 70
4.10 Adjustment of the second machine controls ............................................................. 71
4.11 Special functions ...................................................................................................... 73
4.12 Special function "tube alignment" ............................................................................. 74
4.13 Tune in setup mask, language selection, time and date .......................................... 75
4.14 Screen adjustments .................................................................................................. 78
4.15 Recipe administration ............................................................................................... 81
4.16 User registration ....................................................................................................... 84
4.17 Info-log ..................................................................................................................... 84
4.18 Service plan .............................................................................................................. 85
4.19 Status report ............................................................................................................. 88
4.20 Metal detector ........................................................................................................... 89
4.21 Weighing system ...................................................................................................... 90
4.22 Alarms, malfunction reports ...................................................................................... 91
4.23 Defect repair ............................................................................................................. 94
4.24 Conveyor housing, sliding drum and pressure plate ................................................ 97
4.25 Inserting conveyor parts ........................................................................................... 98
4.26 Hopper, feeder and stopper ..................................................................................... 99
4.27 Overview of feeding system ................................................................................... 100
4.28 Insertion of feeder, scraper and anti-stopper ......................................................... 101
4.29 Fasten straight filling tube ...................................................................................... 102
4.30 Inserting vacuum glass gauge parts ....................................................................... 103
4.31 Inserting the water drain ......................................................................................... 104
4.32 Attachment of the twisting gear, twist off filling tube and intesine holding
device ............................................................................................................. 105
4.33 Processing suggestions for skins ........................................................................... 111

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4.34 Production .............................................................................................................. 112

4.35 End of production ................................................................................................... 116
5. Maintenance .................................................................................................................. 117

5.1 Cleaning and cleaning plan .................................................................................... 117

5.2 Cleaning the vacuum filling machine ...................................................................... 118
5.3 Maintenance and care ............................................................................................ 126
5.4 Maintenance and upkeep ....................................................................................... 126
5.5 Greasing ................................................................................................................. 128
6. Error search and repair ................................................................................................. 132

6.1 Check list ................................................................................................................ 132

7. Putting out of service ..................................................................................................... 140

7.1 Shutting down the vacuum filling machine ............................................................. 140

8. Explanations .................................................................................................................. 141

8.1 Giving over declaration ........................................................................................... 141

8.2 conformity declaration ............................................................................................ 142
8.3 Notes ...................................................................................................................... 144

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ILLUSTRATION INDEX
Figure 1: danger area RVF 327, 327 S, 330, 330 S ............................................................... 18

Figure 2: photograph .............................................................................................................. 23

Figure 3: function elements and their arrangement on the vacuum filling machine ............... 24

Figure 4: RVF 327, 327 S, 330, 330 S, 100 Liter hopper ....................................................... 29

Figure 5: RVF 327, 327 S, 330, 330 S, 160 Liter hopper ....................................................... 29

Figure 6: hopper ..................................................................................................................... 32

Figure 7: knee lever switch..................................................................................................... 39

Figure 8: clipper outlet ............................................................................................................ 41

Figure 9: main switch ............................................................................................................. 41

Figure 10: touch-screen ......................................................................................................... 42

Figure 11: operation elements................................................................................................ 49

Figure 12: filling program selection ........................................................................................ 51

Figure 13: keyboard program name ....................................................................................... 52

Figure 14: altering setting point with keys "+" and "-" ............................................................. 53

Figure 15: directly changing the setting point ......................................................................... 54

Figure 16: mask filling ............................................................................................................ 60

Figure 17: filling correcting mask........................................................................................... 61

Figure 18: mask portioning ..................................................................................................... 62

Figure 19: mask portioning corrections .................................................................................. 63

Figure 20: mask portioning corrections 2 ............................................................................... 64

Figure 21: mask portioning corrections 3 ............................................................................... 65

Figure 22: mask twisting off.................................................................................................... 66

Figure 23: mask twisting off - correction................................................................................. 67

Figure 24: mask twisting off – correction 2 ............................................................................. 68

Figure 25: mask pressure sensor ........................................................................................... 70

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Figure 26: mask portioning of secondary machine................................................................. 72

Figure 27: information mask ................................................................................................... 73

Figure 28: tube alignment....................................................................................................... 74

Figure 29: setup mask ............................................................................................................ 75

Figure 30: switching languages .............................................................................................. 76

Figure 31: setting the date...................................................................................................... 77

Figure 32: setting the time ...................................................................................................... 77

Figure 33: mask screen adjustments ..................................................................................... 78

Figure 34: mask recipe administration ................................................................................... 81

Figure 35: editing the recipe data ........................................................................................... 82

Figure 36: recipe dates........................................................................................................... 82

Figure 37: mask service information ...................................................................................... 85

Figure 38: mask service information 2 ................................................................................... 86

Figure 39: mask service plan ................................................................................................. 87

Figure 40: status report .......................................................................................................... 88

Figure 41: metal detector ....................................................................................................... 89

Figure 42: weighing system.................................................................................................... 90

Figure 43: alarm mask 1......................................................................................................... 92

Figure 44: alarm mask 2......................................................................................................... 93

Figure 45: alarm mask 3......................................................................................................... 94

Figure 46: alarm mask 4......................................................................................................... 96

Figure 47: installation sequence for delivery system .............................................................. 97

Figure 48: hopper cover with feeder....................................................................................... 99

Figure 49: fastening straight filling tube................................................................................ 102

Figure 50: inserting vacuum glass gauge parts .................................................................... 103

Figure 51: water drain .......................................................................................................... 104

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Figure 52: skin holding device .............................................................................................. 105

Figure 53: operational elements vacuum filling machine ..................................................... 112

Figure 54: cleaning the vacuum filling machine ................................................................... 124

Figure 55: grease points of the vacuum filling machine ....................................................... 129

Figure 56: grease point for skin holding device .................................................................... 129

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© 2014 REX-Technologie GmbH & Co. KG. All copyrights belong to the company REX-
Technologie GmbH & Co. KG.

The information and diagrams described here can neither be duplicated, improperly used nor
passed on to a third party without prior authorization from us. Note: The entire documentation
for the Vacuum filling machine RVF 327, 327 S, 330, 330 S are found in the handbook.

1. Operating instructions incl. Replacement parts documentation and detailed schematic dia-
grams as well as

2. The CE-Conformity explanation and the reverse answer sheet (machine handing over pro-
tocol)

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1. IN GENERAL
MANUFACTURER

REX-Technologie GmbH & Co. KG

Irlachstrasse 31
5303 Thalgau
Austria
www.rex-austria.com

OPERATING COMPANY

Name

Address

Zip code, town

MACHINE DESIGN

Type

Machine number

Construction year

ADMITTANCE PERSONNEL

Name

Name

Name

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1.1 INTRODUCTION

This operational instruction is important information and must be read, under-

stood and every point needs to be noted by the personnel working with the Vacu-
um filling machine RVF 327, 327 S, 330, 330 S, or who carry responsibility for
their operation.

The complete operating instructions always need to be stored in the direct vicinity
of the Vacuum filling machine.

Particularly important details concerning the handling will be pointed out in the
instruction manual.

The knowledge and following of the instruction manual contributes to reaching

the attainable current level of safety and problem-free operation in dealing with
this Vacuum filling machine, according to the current state of the art. It is there-
fore very important that the instruction manual remain readily available to the
responsible personnel, and also be circulated among, and read by all those in-
volved in operating the machine.

Official acceptance risk of the Vacuum filling machines must be charged (bought,
paid for) prior to beginning operation. The customer is responsible for establish-
ment of the availability of a national or regional acceptance risk. Non-compliance
excludes liability claims against the manufacturer.

We recommend this instruction manual be carefully and thoroughly read before

beginning operation of this vacuum filling machine! The manufacturer of this ma-
chine will not be held liable for damage and operational failure resulting from not
observing the operation manual!

In the event that difficulties should nevertheless occur, turn to our customer ser-
vice, or replacement parts departments, or with a representative who would glad-
ly be assistance.

The pictures and sketches shown are only completed as is necessarily required
for their understanding.

The technical data, descriptions and construction information correspond with the
time of printing. Constructional changes since then are possible in the interest of
a continuous further development.

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1.2 COPYRIGHTS

On the usage of documents delivered by us concerning the Vacuum filling machine, such as

Instruction manual

Sketches

Photos

Replacement parts lists

Circuit diagrams

Programs etc.

Are copyrighted exclusively for the company REX-Technologie GmbH & Co.
KG. The customer/operator has only the non-transferable right for usage of
these documents for the purpose of assistance in proper operation or mainte-
nance of the Vacuum filling machine. Any further usage, in particular the pass-
ing on, withdrawal, covering up (transfer), duplication or changes cannot take
place without our written consent.

In the usage of any altered or different switch or control programs, including

possible hard and software used here, as well as with any built in alterations to
the Vacuum filling machine, we refuse any liability for object, cost or personal
damage. At the same time, all warranties of the operator associated with the
machine manufacturer are voided.

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1.3 SYMBOLS - COMMENTS

1. symbol for “dangerous for humans"

2. symbol for “danger for machinery”

3. symbol for “electrical specialist/electrician required"

4. symbol for "mechanical specialist required"

5. symbol for "lubrication"

6. symbol for "special tools required"

7. symbol for “special tip for operating personnel"

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1.4 FUNDAMENTAL SAFETY TIPS

 Warning indications and symbols

In the operating instructions symbols are used for the emphasis on important descriptions.
You are on the preceding sheet in chapter 1.3 Symbols - Comments. These characterized
texts are to ensure safety of the personnel and machinery, and particularly important for
trouble-free functioning of the Vacuum filling machine!

 Fundamentals for usage as directed"

The Vacuum filling machine is according to the built according to the developments of the
technology and the recognized technical safety regulations. Nevertheless, its usage could
lead to the danger of bodily injury to the operator, or to a third party. Also negative effects on
the Vacuum filling machine or to other items of value could arise. Dangers could emerge
from the Vacuum filling machine, if it’s:

- Operated with untrained personnel

- Improperly operated or
- Put to use in ways that were not intended for!

The Vacuum filling machine is only to be used in technically perfect working con-
dition, and as directed, with a priority on safety and the danger potential in ob-
servance of the operation manual Particularly malfunctions, which could interfere
with safety need to be remedied immediately, and reported to the responsible
specialists!

The Vacuum filling machine is intended exclusively for filling, portioning, and twisting of the
filling material, and also in frozen condition, however nothing colder than 4°C. Another one,
or a usage from this point onward, like for example, a filling material colder than 4°C or for
products which contain solid material or extremely tough material, such as bones and ten-
dons are not intended for usage. The manufacturer is not liable for damages resulting from
such usage, and therefore, the user alone bears all responsibility.

 Organizational Measures

The operation manual must constantly remain at hand within the immediate vicinity of the
Vacuum filling machine working area.

As a supplement to the operation manual, the knowledge of general legal, and otherwise
binding rules for accident prevention and environmental protection should be given (e.g. rel-
evant information of the appropriate professional trade association.).

Operational instruction notes should be supplemented in chapter 8.3 Notes, in order to, for
example, to have instructions regarding the organization of operational sequences, employed
personnel and the documentation of maintenance work carried out. Documents of notification
duties concerning the Vacuum filling machines or events are to be included in the instruction
manual.

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Prior to beginning any operating the Vacuum filling machine, the authorized per-
sonnel need to have read the operators manual; particularly chapter 4.1 General
safety precautions. This is particularly important for workers who only occasional-
ly work with the Vacuum filling machine (adaptation, maintenance and repair).

There should be an occasional impromptu inspection, regarding safety and dan-

ger awareness, to check if the work done by the personnel complies with that of
the operating manual!

The operating personnel cannot have open, long hair, loose clothing or jewelry, including
carrying rings. There is the danger of injury through getting hung up, or pulled through the
machine.

The operating personnel have strictly instructions to comply with all the safety and danger
warnings of the Vacuum filling machine.

The safety and danger awareness on the Vacuum filling machine must remain easy to read
condition.

If you notice any changes with the vacuum filling machine or if it’s not functioning properly,
particularly concerning safety, then the machine must be turned off and the malfunction be
reported to the proper personnel.

Without permission from the manufacturer, no changes are allowed to be made

which could to the Vacuum filling machine effect functions and safety, whether
adding on, or build around the Vacuum filling machine.

Replacement parts must correspond with the technical standards set by the manufacturer.
The guarantee always covers the use of original replacement parts

Deadlines must be met for maintenance and inspection that are stipulated or given in the
operation manual. (See chapter 5.4 servicing and maintenance work)

 Personal choice and Qualification

The personnel delegated with activities and operating the Vacuum filling machine need to
have read and understood the operation manual prior to beginning their work

Only those personnel who are clearly mentally and physically fit are allowed to operate the
Vacuum filling machine. It must furthermore be expected that they can reliably fulfill their du-
ties. Be sure to comply with the legally allowed age limit!

Persons whose working capability is limited, for example through alcohol, drugs, medications
etc., may not operate, repair or service or inspect the Vacuum filling machines.

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Only employ trained or clearly instructed personnel. Clearly establish responsibility for the
operation, preparation, maintenance, repairing and adapting!
The person responsible for operating the Vacuum filling machine must be au-
thorized to reject one of third desired safety or adverse function activities of the
machine.

Personnel undergoing schooling, training, introduction or in the course of a general training

are only allowed to act under constant supervision of an experienced person on the Vacuum
filling machine!

Working on electrical equipment of the Vacuum filling machine may only be

carried out performed by an electrician in accordance with the electro-technical
rules.

If a malfunction should occur in the Vacuum filling machine, it is to be immediately shut down
and protected. Allow these breakdowns to be immediately repaired by qualified personnel.

 Operator responsibilities

The personnel must be provided with all necessary protection equipment.

Out of duty and a safety conscious environment, there needs to be regular inspection of the
work done by the operating personnel of the Vacuum filling machine.

All safety and danger warnings on the Vacuum filling machine must be complete and kept in
legible condition.

As a supplement to this operation manual, there must be a generally acknowledged statuto-

ry, legal and otherwise binding regulation for accident prevention and environmental protec-
tion, and be instructed to the personnel

 Operator responsibilities

While working, all legal and basic regulations for work safety and accident must be followed.

Observe all safety and danger warnings on the Vacuum filling machine.

In case of malfunctions with the Vacuum filling machine, immediately shut sown and secure.
Order the breakdown to be repaired immediately.

Observe safety instructions when in contact with oil, fats and other chemical substances
which are meant for the product. Use the required personal safety equipment.

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 Safety precautions for certain operational phases

- Normal operation
Refrain from any questionable safety working method. This applies in particular to processing
goods, which clearly do not conform to proper functions of the Vacuum filling machine.

Before beginning work, it is advisable to be sure the surrounding work area is

free of any kind of obstructions, as well as in the work area itself. Potential haz-
ard! ,

Only operate the Vacuum Filling Machine if all the built in or releasable protective equipment,
emergency shut off switch, exhausts etc are available and installed.

At least once per shift, the Vacuum filling machine should be inspected for visible
or obviously recognizable damage/ defects! Changes that should arise including
operational behavior needs to be reported immediately to the responsible person
/position! In a doubtful situation, shut down immediately and guard against an-
other attempted operation (Most important is to shut down and secure with lock).

Prior to turning on the Vacuum filling machine make certain that no person can
be endangered through the operation of the machine!

- Special work and –operation with maintenance, repair taking care of mal-
functions etc.

Stick with the operation manual’s prescribed instructions in adjustment, mainte-

nance and inspection activities and inspection dates including information for
exchanging parts/equipment! These activities may only be performed by profes-
sionals.

Inform the operational personnel prior to special jobs about planned course of
action. Delegate a leading supervisor!

Prior to carrying out special orders, shut down the vacuum filling machine and
safeguard against unsupervised turning on. This can take place by turning off the
main switch and close this off with a lock. At the main switch an additionally a
warning sign must be placed. The key should be safeguarded by the responsible
supervisor.

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The ending the special order must be reported to the responsible supervisor. The
person responsible must convince the properly carried out assignment presents
no danger to a further operation of the Vacuum filling machine. Only then is the
person allowed to remove the lock on the main switch and authorize the machine
to be turned on again.

When cleaning the Vacuum filling machine, no water or steam jet may be used to
handle electronic devices, electro motors, switch cabinets, service console, direc-
tions and indicators, etc. Seeping water or the temperature of the steam damag-
es these parts. They are therefore separate and to be cleansed by hand with a
mild cleaning agent.

If carrying out the special order required the complete, or partial dismantling if the
safety features, then right after the job is finished, the reassembly and functions
inspection of the safety features needs to be carried out! The person responsible
must see that this is performed. .

For safer and environmental consideration, take care with disposal of operation
and consumables, as well as changed parts!

 Precautions over particular types of danger

- Electrical energy

Only use original fuses with indicated voltage and the right melting behavior! Shut
down the vacuum filling machine immediately in case of an electrical malfunction
of the electric energy source!

Electrical power must be shut off to machine and system parts, at which inspec-
tions-, maintenance- and repair work is carried out, and remain power free until it
has been determined that the work has been completed! All the individual switch
parts must be determined as power free prior to beginning the repair work.

The electrical equipment of a Vacuum filling machine must be regularly inspected

Established defects need to be immediately remedied, for example, loose con-
nections, brazed wire, functions unsafe switch and control contactor, relays etc.

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- Structural changes

Alterations or rebuilding of the Vacuum filling machine and attachments to the machine are
forbidden without written consent of the company REX-Technologie GmbH & Co. KG!

Only original-replacement and accessory parts from the Firm REX-Technologie GmbH & Co.
KG are allowed to be used. Otherwise the Firm REX-Technologie GmbH & Co. KG reserves
the right of any warranty or guarantee claims.

- Pneumatic (only with accessory devices)

Only qualified personnel with special knowledge and experience in pneumatics

are allowed to work on the pneumatic equipment!

All pipes, tubes and tube fittings must be inspected regularly for leakage and rec-
ognizable external damage. Any damage noticed is to be immediately remedied.

- Oil, fat and other chemical substances

Follow all product specific safety regulations regarding contact with oils, fats and
other chemical substances (cleaning agents)!

Be careful when in contact with hot service fluids or auxiliary material. Potential
burn hazard!

Conduct disposal of used oils, fats and other chemical substances in accordance
with the local /regional regulations! Under no circumstances are waste products
of this sort to be added to the normal household or company rubbish!

Attention: do not dump used oils in the canal system!

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1.5 WORK AREA AND DANGER ZONE FOR THE OPERATION

PERSONNEL

Following danger zones apply for the RVF 327, 327 S, 330, 330 S (see Figure 1)

Work area

Danger zone

Figure 1: danger area RVF 327, 327 S, 330, 330 S

Type Hopper contents A B C D

RVF 327, 100 Liter 1775 1461 963 844
327 S, 330,
330 S 160 Liter 1858 1461 1042 887

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Machine description

2. MACHINE DESCRIPTION

2.1 SHORT DESCRIPTION FOR THE CONTINUOUS VACUUM

FILLING MACHINE

With this Vacuum filling machine may only be filled with

- flexibly workable
- compressible
- non burnable
- non explosive

filling material, portioned and twisted off; even in a frozen condition no lower than -4°C.

The filling material must also have a somewhat lubricating effect.

The construction method of the Vacuum filling machine corresponds with the newest regula-
tions of the EU guidelines. The same applies for the EU-guidelines concerning the handling
of meats and meat products.

The compact machine housing is smooth and flat surfaced, made completely of non-rusting
steel. It stands on vertically adjustable plastic feet and in this way works with relatively little
noise and vibration. The vertically adjustable feet allow for adaptation to an uneven floor and
comfortable cleaning area of the machine through the ground clearance. The completely
even stainless steel surface makes it easier for both cleaning and also preserving the optical-
ly attractive and hygienically flawless condition of the Vacuum filling machine.

The filling hopper, work level, operating switches and lever for the portioning are ergonomic
arranged and guarantee a practically tireless working performance.

The Vacuum filling machine motor is infinitely variable in its RPM speed. The Vacuum filling
machine is operated, controlled, checked and programmed through a clearly arranged, water
tight display. The machine contains, depending upon the equipment, one or more driving
units, which are observed and regulated through a servo technique.

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Machine description

2.2 USAGE

2.2.1 Operational area and a directed usage

1. This Vacuum filling machine is intended for the filling, portioning and twisting off of organic
food of the following types and quality:

- Meat and meat products up to 55 mm in diameter

- Frozen meat and meat products with a maximum diameter of 55 mm, with a maxi-
mum temperature of 40°C, and minimum temperature of -4° C (attention!: with a long-
er operating time after cutting the temperature of the filling material can further drop.)
- Fish
- Cheese
- Soup granules etc.

Products supplied for human consumption must correspond with the local hy-
giene regulations.

2. The Vacuum filling machine can also be filled with products not meant for hu-
man consumption. The machine is nevertheless not equipped with compo-
nents for preventing the danger of infection, which might emerge from the pro-
cessed material. The subsequent usage of the Vacuum filling machine, ac-
cording to figure 1, is strictly forbidden without the previous cleaning and disin-
fection measures!

3. With alternative usage of the Vacuum filling machine, according to figure 1and
figure 2, cleaning and disinfection measures must be carried out prior to every
order, acc. To fig. 1. These must be carried out according to the cleaning plan
in chapter 5. The following rinsing with warm and cold water of drinking water
quality needs to be so intensely performed that all traces of cleaning agents
are responsibly removed. The directions within the supplier of cleansing and
disinfection agents need to be thoroughly followed!

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Machine description

2.2.2 Non-permitted usage

Using this Vacuum filling machine for the following purposes is not permitted:

- Using meat and meat products in cubes with a greater diameter than 55mm
- Using frozen meats, meat products and other frozen foods with a tem-
perature lower than -4° C

- Usage of cooked meat and warm meat products, roasted meat or other foods
which are warmer than 40°C.
Prior to using materials warmer than 40°C, a consultation with the manufacturer is
necessary.

- Usage of explosive media

Disregard of the warning “Non-permitted usages” could provoke the following
damage and dangers:

- Overloading the drive elements with Motor- or mechanical defects in

the motor area
- Premature wearing down of the conveyor system
- Break in the conveyor system
- Defect in the vacuum equipment
- Excessive warming of the conveyor products and the Vacuum filling
machine
- Accident potential through unusual machine functioning and thereby an
increased hazard potential

Using this Vacuum filling machine for the following purposes is not permitted without
a prior cleansing and disinfection:

- Use for products which are intended for human consumption and cor-
respond with the local hygiene standards, if there were previous products
processed which were not meant for human consumption, or do not com-
ply with local standards.
By alternating operations of the Vacuum filling machine with products for
human consumption which do not correspond with the local Hygiene regu-
lations, or those which are not intended for human consumption, must un-
dergo a basic cleaning and disinfection procedure as directed by the
cleaning plan in chapter 5 prior to processing products for human con-
sumption. For this reason, the directions provided by the suppliers for the
disinfection agent need to be followed precisely!
- Using the Vacuum filling machine with products meant for human consumption af-
ter a work stoppage of more than 1-1 ½ hours:
Concerning this, see the following procedure schematic

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Machine description

2.3 PROCEEDURE SKETCH FOR ALTERNATING OPERATIONS

No disinfection nec-
Operating the Vacu- Operating the Vacu-
essary
um filling machine um filling machine
for human consump- for non-human con-
――――――――――――――
tion sumption
→

Cleaning and disin-

Use of the Vacuum fection
→ → Using the Vacuum
filling machine for Exactly follow the filling machine for
non-human con- instructions of the human consumption.
sumption supplier in doing
this!

Cleaning and disin-

fection Using the Vacuum
Using the Vacuum → → filling machine for
filling machine for Exactly follow the human consumption
human consumption directions of the after a 1-2 work
suppliers in doing stoppage
this!

The cleaning and disinfection must be carried out as shown in the cleaning plan
in chapter 5 maintenance. Particularly important is the following rinsing of all
handled areas with fresh water (of drinking quality) in order to reliably eliminate
all the remains from the cleaning and disinfectant agents!

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Machine description

2.4 PHOTO OF THE CONTINUOUS VACUUM FILLING MACHINE

Figure 2: photograph

The Vacuum filling machine meets the standards of the EU-Machine guidelines and the EU-
guidelines for processing meat and meat products.

The Vacuum filling machine RVF 327, 327 S, 330, 330 S is essentially built of a self support-
ing stainless steel sheet metal construction. It will live up to all operational, structural and
dynamic claims. All requirements in environmental protection are also observed in a special
degree in the manufacturing. The Vacuum filling machine distinguishes itself through the
limited noise and vibration while being operated. The external machine parts are made of
stainless steel and corrosive resistant material. The entire machine surface is specially treat-
ed for easier care and cleaning. Large doors and the sheet metal covering enable easier
access for cleaning and maintenance.
The heart of the Vacuum filling machine, the sliding drum with the sliding valve, is driven
through an electro-servo motor with gear transmission.

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 Machine presentation

1
10
2

12

11

4
9
5

Figure 3: function elements and their arrangement on the vacuum filling machine

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 Explanations to the preceding machine presentation

Pos. name explanation

1 hopper Stainless steel

2 Top plate Stainless steel
3 Inspection glass for water separator Plexiglas
4 Lock handle Stainless steel
5 Machine housing Stainless steel
6 Foot switch Plastic
7 Plastic leveling feet Adjustable
8 Machine cover removable Stainless steel
9 Touch-controls Glass
10 Locking device Stainless steel
11 Twisting gear Stainless steel/plastic
12 Skin holding device Stainless steel/plastic

2.5 PROTECTIVE DEVICES AND THEIR SAFETY FUNCTIONS

All protective devices must be inspected prior to beginning work.

The respective accident prevention regulations In the land of operation must be

upheld.

 Main switch (Figure 9 page 41)

Main switch in position "0" completely separated the Vacuum filling machine from
the net.
Prior to carrying out the following tasks, the "0" position must be switched and
secured with a lock:

- Vacuum filling machine maintenance, repairs, inspections

- Removal of the metal covering
- Opening the switch cabinet
- electric or electronic related operations in hard- or software side

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2.6 SAFETY-RELATED USER INFORMATION

According to 6.3 of the EN ISO 13849-1:2008, based on the risk assessment, safety-related
functions are classified in protection level PL c. Two timing chains which are independent of
each other are safety relevant.

Timing chains of the respective switch (magnet switch, funnel, hopper flap) at the same time
effective on the main drive contactor and grinder drive via the control unit at the same time.

According to Point 11 of the EN ISO 13849-1:2008, user information is provided as follows:

Elements included in the safety-related control loop are in keeping with the following
requirements. Only original components may be used for replacement of the safety
components listed. At a minimum, they must meet the conditions specified.

For all safety relevant switches (magnet switch, funnel, hopper flap), a safety evalua-
tion unit of SIL category 3 (PL e) is built in. This has direct effect on the excitation
winding on the clough of the main drive.

Main drive

1. Magnet switch funnel as turnkey, hopper flap as turnkey

PFH at least 3 x 10-7 to 10-6 cycles per hour
Switch connected as opener
Protection level PL d

2. Analysis unit
PFH at least 10-7cycles per hour
Exit connected as opener
Protection level PL e
Likelihood of breakdown ≥ 10-8 bis < 10-7

3. Electric contactor main drive

PFH at least 10-6 switching cycles per hour
Wiring outlet as an N/C contact
Protection level PL c

If one of the elements fails, the entire chain will go into safe mode.

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3. TRANSPORT, SET UP, INSTALLATION

3.1 TRANSPORT

The Vacuum filling machine is delivered on a pallet all assembled, including built in feeding
system. After unloading, the next step is the further transport by means of a hand fork lift.

Attention: the Vacuum filling machine must be lifted with the hand fork lift
in such a way, as to prevent tipping over during transport.

Set up adjust the Vacuum filling machine at the work area. The machine leveling feet are
adjusted by screwing the feet in or out.

Attention: Vacuum filling machine may not be transported in a slanted or

lying position. (damage to the vacuum pump)

3.2 INTERIM STORAGE

In case an interim storage is necessary, this must be stored in a dry, ventilated and dust free
room. Aggressive chemicals cannot be stored near the Vacuum filling machine, in order to
avoid corrosion to the stainless steel and other built in, or on parts. All machine parts need to
be thoroughly cleaned and disinfected prior to a temporary interim storage and dry lubricat-
ed. The conveyor system parts must be separately stored outside the Vacuum filling machine
in a thoroughly oiled condition.

3.3 SETTING UP THE MACHINE

The setting up, an instruction about the most important functions and the first
start up of the machine should be conducted by one of our customer service rep-
resentatives or through personnel who were authorized exclusively by the manu-
facturer to do so.
The Vacuum filling machine should be placed on a solid, level, and easily
cleaned floor. The grade of the floor cannot exceed 3% and the allowed floor
stress must equal at least 12 kN/m²

The set up location must correspond with the local hygiene- and workplace regu-
lations. The lighting intensity must amount to at least 300 LUX.
The Vacuum filling machine is delivered completely assembled and ready for
operation. In setting up the machine, set a level on the machine housing. The
Vacuum filling machine should be installed by means of the height adjustable feet
in such a way that it tends to lean slightly forward just enough so that the water
runs out during the cleaning phase.

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The Vacuum filling machine comes with an approximate 6,0 meter long electrical
cord. A licensed electrician must take care of assembling the connection to the
Vacuum filling machine. Circuit diagrams and other electrical documents are lo-
cated in the machine switch box and in the with the machine delivered map.
Zeroing, grounding, and FI-protective switching needs to be carried out in ac-
cordance with local regulations.

3.4 SECURING/ FUSE PROTECTION

The securing the electrical unit is not part of delivery specification/ scope of supply. It must
be built in and operationally installed near the Vacuum filling machine.

3.5 MACHINE ALIGNING

The Vacuum filling machine must be horizontally aligned at the determined location. This is
made possible simply by screwing out the plastic leveling feet. The machine leveling feet
may only be screwed out at a maximal 40 mm from their threaded sockets. After alignment,
all four plastic leveling feet must be in contact with the floor.

3.6 NECESSARY SPACE FOR OPERATION AND UPKEEP

The Vacuum filling machine must be easily accessible on all sides for cleaning and
upkeep. For this, an area of at least ½ meter distance on all sides of the Vacuum
filling machine. Secondly, the adequate free movement clearance is required so
that the necessary activities are not restricted for operation, cleaning, service and
repairs, as well as exchanging of machine parts etc. In addition, the work area
must be free to maintain the possibility of uninterrupted fulfillment of all the activi-
ties shown above.

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3.7 SIZE, WEIGHT AND TECHNICAL DATA

Figure 4: RVF 327, 327 S, 330, 330 S, 100 Liter hopper

Figure 5: RVF 327, 327 S, 330, 330 S, 160 Liter hopper

Type RVF 327 RVF 327 S RVF 330 RVF 330 S

Filling capacity 2.700 kg/h 2.700 kg/h 3.000 kg/h 3.000 kg/h
Max. filling pressure 40 bar 40 bar 40 bar 40 bar
Hopper variations 100, 160 litre 100, 160 litre 100, 160 litre 100, 160 litre
Weight 450 kg 450 kg 450 kg 450 kg
Connected power 5 KW 5 KW 5 KW 5 KW
Clipper connection as standard as standard as standard as standard
Servo motor no yes no yes
Noise level of Sound power level Lw(A) = 57.9
Type RKF 327_330 At a distance of 1m Lp(A) = 61.1 dB(A)
in neutral position
At a distance of 1m Lp(C) = 58.2 dB(C)

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3.8 BEGINNING OPERATION

 Electrical connection

Indication sign on the power supply cable must unquestionably be followed!

Indications for the installation and commissioning:

Installations- and commissioning tasks may only be carried out by electrical

specialist personnel or from trusted specialists initiated for this operation,
under observance of the legal and national regulations, i.e. EN 60204.

Protective measures and equipment must correspond with the legal national
standards and norms i.e. EN 50178 and EN 60204

The discharge current can be higher than 3,5 mA AC and higher than 10 mA
DC!

Nominal voltage of the Vacuum filling machine: _____ V

Pre-fusing __________________ A

 FI-protective switch

There can be in principle, dependent upon circumstances, the possibility of a problem arising
in connecting the FL protective switch to our Vacuum filling machine. If no avoidance of the
FI-protective switch is possible, then the problem with the on and off switching be deactivat-
ed through the employment of selective FI-protective switches (cut off delay) or FI-protective
switch with increasing release of electricity (z. B. 100 or 300 mA). This can only be put to use
exclusively with all-electric sensitive FI-protective switch. Es is not recommended to have
several machines to operate off of one FI-protective switch.

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 Prepared activities

Prior to the first start, the following tasks and inspections necessary:

- comparison of line voltage and frequency

The information on the machine sign and the meter des power station must cor-
respond. Voltage fluctuation cannot exceed +/- 10 %. Greater deviations cause
malfunctions and premature deterioration. Non-adherence to these regulations
will nullify all warranties through the manufacturer.

- inspecting rotation direction of the Vacuum pump

(Rotation direction of the main drive is given)
Open vacuum inspection glass and raise the ball at the safety ventilator. If the ball is sucked
in, then the rotation direction of the vacuum pump is correct. If the ball is not immediately
sucked in, then the rotation direction is in the false direction. In this case, the vacuum pump
must be immediately shut down and then reverse the connection wire.

Attention: In order not to damage the vacuum pump, this can only run very
briefly in the wrong direction, and only be operated briefly
against atmospheric pressure.
All electrical related work can only be carried out by electricians.
There is a danger of electrical shock! Extremely dangerous!!

- foot switch positioning

Heights and distance adjustments are made by loosening the hexagonal screw.
Adjust the adequate position and clip on with the hexagonal screw.

Knee switch plate can be turned.

- focus the desired language

- set the local time
- inspect all work programs
- inspect the Functionality of the Vacuum filling machine
(see chapter 4 operating the Vacuum filling machine)

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- Oil level in the stand in the vacuum pump

The oil level in the vacuum pump must be checked (see chapter 4 Operating the
Vacuum Filling Machine). If the oil level is too low, then it must be replenished
(see chapter 5 Maintenance).

- Cleaning
Dismantle conveyor parts and feeder. (see chapter 5 Maintenance) Machine
parts with contact to products are to be cleaned with hot water and also a com-
mercial cleansing agent with preserving agents

Dry the conveyor and conveyor parts after cleaning.

- Operating conveyor parts

Spray and rub into the conveyor system food compatible, edible fat or oil.
Put in sliding drum set in with a leverage tool with sliding drum with. (Sliding drum
must never be installed in a warm condition) Turn on valve. Follow the right in-
stallation; otherwise the conveyor will be damaged.

- Attach scraper

- Set up stopper
In processing hard filling material (grainy, solid or compact) i.e. raw sausage type
filling. Put in the stopper in the filling hopper with the Vacuum filling machine shut
off and with tighten with a screw.

Figure 6: hopper

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- Inspect switch
The position of the top plate and the hopper flap will be checked through the
safety switch. Starting the conveyor system is only possible when the top plate is
bolted in and with the hopper being closed. (see chapter 4 Operation of the vacu-
um filling machine)

- Attach twisting mechanism

If the Vacuum filling machine is fitted with a twisting device, then it must be
cleaned in advance, und then mounted on the machine.

- Attach skin holding device

If the Vacuum filling machine is equipped with a skin holding device, then this
needs to be cleaned in advance, and afterwards attached to the twisting off de-
vice.

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3.9 SAFETY PRECATIONS

3.9.1 Ever present safety risks

(dangers, which are not entirely avoidable, despite built in safety features)

With an excessive amount of effort, one can reach inside the hopper. Do not,
under any circumstances, try to reach inside the hopper when the machine is
operating!

Injuries including the danger of losing fingers and limbs!

Dangers resulting from filling material can affect:

- The operator/user
- The surrounding area around the position of the Vacuum filling ma-
chine
- The vacuum filling machine itself

Therefore one must keep the following away from the Vacuum filling machine:

- Children or trainees without supervision

- All those not instructed in operation of the machine
- All persons not trusted with the operation manual and safety regula-
tions
- Persons who pose a possible interference of responsible handling of
the machine through recognizable physical or mental disabilities.

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3.9.2 ”Check“ machine condition prior to activation

Before turning on the Vacuum filling machine it must be established that:

- Sliding drum, valve and sliding plate are readily available and properly
arranged.
- All parts, particularly the feeder and stopper must be properly mounted
and the top plate is closed.
- Movable parts are not damaged or jammed up.
- Electric components such as switches, cords, plugs push buttons etc
are intact and functional.
- The product to be processed corresponds with the agreed upon usage
(see chapter 2.2.1 Operation area and agreed upon usage)

Defects or worn parts interfere with safety and must be replaced immedi-
ately!

According to UVV meat cutting machines (VBG 19) policy holders

must inspect the functioning ability of protective equipment on every
work day before the "start up" of meat grinding machines. All estab-
lished faultiness must immediately be reported by the responsible
personnel. In the case of a defect which could jeopardize the work
safety, then the Vacuum filling machine cannot be put into operation.
The supervising person must immediately replace or repair defective
protective equipment.

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3.9.3 Initial Customer Instructions

- Explaining the basic functioning of the Vacuum filling machine and dates on the
basis of Chapter 2 Machine description
- Explaining general safety precautions available in chapter 1.4 Fundamental Safety
Precautions
- Explaining Protective equipment inspection and every working step according to
chapter 2.5
- Customize client specific working programs. Explain programming on the basis of
chapter 4.4 Description of the Touch – CPU-control. Save customized electronic pro-
grams.
- Explaining accessories usage
- Explaining every step from chapter 5.1 and 5.2 about cleaning the Vacuum filling
machine
- Explaining maintenance work based on chapters 5.3 und 5.4.
- Explaining every step in production starting (4.34 Production) and supervision.
- Provide record of delivery
- Put the names of all initially instructed staff in the corresponding fields, as shown in
chapter 1 In General. A signature is needed for all staff who received initial instruc-
tions.

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4. OPERATION OF THE VACUUM FILLING MACHINE

4.1 GENERAL SAFETY PRECAUTIONS

Never turn on Vacuum filling machine without all potential personal dan-
gers being previously ruled out!

Dangers can never be completely ruled out, but can be reduced through
observance of important safety regulations. Therefore, every work day
before beginning production, an inspection must be carried out to verify
that:

 The products intended for processing correspond with agreed upon usage
(see chapter 2.2.1 Operation Area and Agreed Upon Usage

 That no person id found in the area of moving machine parts.

 That no foreign objects (wood, rags, tools etc) find themselves in the filling
hopper or the conveyor housing of the Vacuum filling machine.

 Operation personnel is fit and informed about contact with the Vacuum
Filling Machine.

 Safety regulations must be taught to operation personnel

 Ensure the proper machine condition, such as:

- Protective equipment of the Vacuum filling machine are complete

and intact.
- Safety, inspection and steering equipment are in a flawless, opera-
tionally safe condition
- All covers and lids are closed
- Conveyor housing is properly put together.

Carrying out of safety inspections on every work day:

When turning on the Vacuum filling machine, fold back the upper part.
The machine must be turned off at once. This test has to take place un-
der observance of all existing safety measures. If the Vacuum filling ma-
chine doesn’t shut down immediately, then it cannot be put back into
operation! Call the electricians to eliminate the malfunction!

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4.2 CONTROL ELEMENTS/FUNCTION

Note: The touch-screen may only be pressed with the fingers (with, or without gloves).
The touch-screen cannot be activated with pointed, sharp, metal objects or with
a pencil.

 On key "I"

By pressing the key "I" the Vacuum filling machine is started.

 Off-key "0"

After pressing the off key, a dialog field opens up, in which the shutting down process must
be once again confirmed.

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 Explaining the function of the knee lever switch

It must be stated in advance, that the features now explained not only apply for the knee lev-
er switch, but that a switch, which is connected to sockets (C) and (D) of the clip machine
socket (i.e. a clip machine with starting switch) provokes the same reaction.

Knee lever switch

Figure 7: knee lever switch

Depending upon the pre-selection of the controls, the knee lever switch has the following
functions:

- when the knee lever switch is closed, then the Vacuum system is ventilated

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- Manual operation (single portion):

The Vacuum filling machine produces as long as the knee lever switch is suppressed. When
the knee lever switch is released, the straight filling of the Vacuum filling machine stops im-
mediately. When portioning, the Vacuum filling machine stops after the end of the straight
filled product, except when the portion interruption is activated.

- Automatic operation (constant portioning):

The Vacuum filling machine begins filling with the first depression of the knee lever switch. In
order to end the straight filling, portioning and the pressure sensor operation, the knee lever
switch must be once again depressed. In order to start again, an additional lever depression
is required. The advantage of this knee lever function is shown, that with larger straight filling
amounts and greater number of portioned pieces, the knee lever switch doesn’t need to re-
main constantly depressed. In the pressure sensor operation a one time depression of the
knee lever switch is sufficient, in order to begin the function.

- Piece guidelines:
In portioning and the twist off mode it’s also possible to put in a piece number instruction. It
only requires a slight pressure on then knee lever switch to start the Vacuum filling machine.
The machine stops after reaching the selected number of pieces.

- Activating a second entrance for the operation of a double outlet:

With straight filling it’s possible to double the speed, through activating an entrance to the
clipper outlet (the limit is at 100%, so if 60% is doubled, then only 100% comes out as a final
speed!) This function is only possible with the single portion modus

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 Clipper outlet

The outlet is to use for the connection

of different clip machines and REX-
attachments.

Figure 8: clipper outlet

 main switch

The main switch opens and

closes the electrical provision of
the Vacuum filling machine to
the power supply.

Figure 9: main switch

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4.3 DESCRIPTION OF THE TOUCH SCREEN

1 2 3 4 5 6 7 8 9

32

31

30
10

11
29
12
28
13
14
15
27
16

26 25 24 23 22 21 20 19 18 17

Figure 10: touch-screen

On pages 42-91 the numbers are indicated on the Figure 10 touch-screen.

1 In this field the respective operation type symbol is shown.

2 Indications of the respectively chosen type of operation and information mask.

3 Display of the theoretical filling capacity in kilograms per hour (kg/hr)

4 Time display

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5 Date display

6 Vacuum indicator, which shows the nominal height of the vacuum.

7 Vacuum indicator which shows the actual height of the vacuum.

8 Service interval information - quick access to the service information

9 Individually put on customer and dealer logo

10 Lifting device up

11 Lifting device stop

12 Lifting device down

13 Vacuum elevating key "+" (if the key is pressed over a longer period, the
amount/importance will be naturally increased.)

14 Vacuum reduction key "-" (If the key is pressed for a longer time period, then the
amount will naturally be reduced.)

15 Changing key Vacuum pump "I" (on) "0" (off):

The vacuum pump can be separately shut on and off here. By shutting off the vacu-
um pump, which is absolutely necessary for cleaning the Vacuum filling machine, so
that no water can seep into the vacuum system, the vacuum system is automatically
ventilated.

16 Selection key for the alarm mask:

If at least one un-received unconfirmed alarm is available in the Vacuum filling ma-
chine, then key blinks.

17 Backwards key for going back to the respective background page

18 Selection key for assistance texts

19 Selection key for opening the information page

20 Key for saving the respective set program in the central memory.
By pressing this key, a dialog field opens up, in which the saving of the respective
program once more must be confirmed.

21 Selection key for the type of operation "second machine control"

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22 Key for operation mode "pressure sensor operation"

23 Key for operation mode "twisting (off)"

24 Key for the operation mode "portioning"

25 Key for the operation mode "filling"

26 Alternate key machine "I" (on) "0" (off):

When turning off the Vacuum filling machine, a dialog field opens up asking for con-
firmation for the machine to be shut down. The Vacuum filling machine passes on to
the standby-modus.

27 Key for the number of filled portions in the Modus individual/continuous and setting
field for the piece ordering modus for portions to be filled

28 Key for reduction of the respectively chosen amount.

29 Key for the increase of the respectively chosen amount.

30 Key for the desired speed

31 Display of the current program number:

If you press the display field, a numbered dialog opens, in which the program can be
directly chosen.

32 Display of the current sausage name:

If you press the display field, a selection window opens up, in which the desired pro-
gram can be directly chosen.

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4.4 DESCRIPTION OF THE TOUCH-, CPU- CONTROLS

4.4.1 In general

 Individual suggestions for handling the touch-screen

This electronic control consists of a PC based CPU-building group with touch-screen. Es

should therefore be noted that no over voltage (even static) comes inside the device. In turn-
ing on the current supply, refrain from the in and out plugging of the plug cord.

Any seeping of water, other liquids and solid pieces, such as metal chips must be avoided,
because this foreign matter inevitably leads to serious damage. .

The touch-screen (display) consists completely of glass. This means that me-
chanical stress, particularly falling metal pieces (tool accessories) for the use of
this screen lead to expensive repairs being made necessary, which are not cov-
ered by the warranty (see chapter 1.4 and 4.1)

Attention: Please allow at least one minute to pass between shutting off and turning
back on the Vacuum filling machine. Non-compliance could lead to damage
to the electrical parts of the servo-drive, or cause other malfunctions to sur-
face.

 General properties

This new Vacuum filling machine control generation distinguishes itself for the server through
clearly arranged key functions on the touch-screen. It is designed so that it helps bring about
an extremely precise course of movement from a Servo-amplified electronic controlled three
phase current servo-motor.

Languages in the controls are in DE, EN, FR, CS, DA, EL, ES, FI, HR, HU, JA, KO, NL, NL-
BE, NO, PL, RO, RU, TH, TR, ZH. They report operational conditions, malfunctions and
server menus in the language which the operators can easily set themselves.

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The controls support the following operating modes:

Straight filling The Vacuum filling machine produces sausage meat un-
interrupted, as long as the knee lever switch is depressed
(pay attention to individual-continuous portioning switch
over!).

Portioning The Vacuum filling machine produces, depending upon pro-

gram data, a certain portion of sausage meat and then gives
the possible attached twisting- and clip machine the order to
close the sausage. As long as the knee lever is depressed,
this process will be repeated (pay attention to single and con-
tinued portioning!).

Twisting (off) The Vacuum filling machine produces, depending upon pro-
gram data, a certain portion of sausage meat and then gives
the possible attached twisting- and clip machine the order to
close the sausage. (Twisting off). As long as the knee lever is
depressed, this process will be repeated (pay attention to
single and continued portioning!) If a certain amount of pieces
has been selected, the machine fills the selected amount of
sausages and then stops automatically (Interruption of the
filling process is possible by operating the knee lever)

Constant pressure opera- Using a pressure sensor, which will be inserted into the dis-
tion charge pipe of the vacuum filling machine, the control device
regulates the pressure of the sausage meat at the discharge
end according to selected pressure value of the knee lever.
(for adaptive devices)

Secondary machine con- A second vacuum filling machine or a valve can be controlled
trolling when filling, portioning and twisting, so that during filling an
additional function can be controlled. The discharge of the
second filling machine can be activated with a delay at the
beginning of the filling as well as at the end of the portioning it
can be deactivated earlier. Furthermore, one can choose if
this activity should occur during the first portion or after the
second sausage meat.

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4.4.2 Turning on the Vacuum filling machine

After the Vacuum filling machine is connected to the power supply through the main switch, it
requires usually a minute in order to start up the controls. During the first 30 seconds, the
screen is mostly black and after 30 seconds or so, the following start up mask appears,
which moves on to “ready for operation” after starting up the controls are completed.
Start up mask

Ready for operation

Attention:
The Vacuum filling machine will not turn on if the upper section is open. If the Vacuum
filling machine is turned on, and the upper section is opened, then the controls auto-
matically shuts down the Vacuum filling machine and goes over to the operational
readiness. The machine key "I" will then be grey.

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4.4.3 Operating elements

 Machine control key functions (when the Vacuum filling machine is turned on)

After pressing the ON key (26) the operations and additional devices in the Vacuum filling
machine are activated. Now it’s possible with the following keys to reach the following de-
scribed reactions (even if this is not mentioned extra in the following operational mode de-
scriptions in the key function explanations!):

Lifting device up (10) Raising lifting device (drives further automati-

cally if a lifting device already exists on the
Vacuum filling machine)

Lifting device off (11) Stop lifting device (if a lifting device exists on
the Vacuum filling machine)

Lifting device down Lifting device automatically moves down about

(12) 0,5 meter above the floor (in the lower area,
the key must remained pressed!).

Vacuum off (15) Vacuum pump will be shut down and remain in
standstill until key 15 is pressed again.

Vacuum on (15) Through pressing key 15, the Vacuum pump

will automatically turn on. .

Vacuum plus (13) The Vacuum rules put in a high vacuum: Bar
chart (6, 7) shows the set l- and actual -
amount. Attention: the actual-indicator is an
absolute amount and is therefore is dependent
upon the air pressure (sea-level) of the sur-
rounding area in which the Vacuum filling ma-
chine is operated.

Vacuum minus (14) The Vacuum regulations put in a low vacuum.

Bar chart (6, 7) shows the set-and actual-
amount.

Saving Key (20) Through pressing the saving key, the set
amount on the respective adjusted program
area will be saved.

Info Key (19) Under the info mask, there are diverse callable
settings, such as screen set up, recipe admin-
istration, etc.

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Help key (18) In the help mask all necessary help and infor-
mational texts of the respective machine func-
tions accessible.

Alarm key (16) Pending machine alarms can be read and con-
firmed there. .

Off-key (26) Through pressing the off key, a dialog field

open up, in which the shutting down of the Vac-
uum filling machine once again needs to be
confirmed. The machine goes over into the so
called standby mode.

Reverse key (17) Through pressing the reverse key, you return to
the previous screen in the main mask.

10

11

14

13

12

15

16

26 20 19 18 17
Figure 11: operation elements

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 Operational elements of the keyboard- (see Figure 13, page 52) and number fields
(Figure 15, page 54)

Confirmation key With the confirmation key, the correspond-

ing amount or name taken over and pro-
cess confirmed.

Help key Through pressing the help key, the use of

a dialog field will open up, where it con-
tains information for the respectively cho-
sen process.

Discontinue key Through pressing the discontinue key, the

respective process will be deleted and not
taken over.

Erase key With the eraser key, the respective

amount can be removed in the individual
steps.

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4.4.4 Selecting filling and free area programs

1. By pressing the keys 28 "-" and 29 "+" the program numbers from 1-200 can be changed
into individual steps.

2. By pressing field 31, a selection window opens up. The desired program and free pro-
gram area can be directly chosen here.

31

Figure 12: filling program selection

With the scroll bar (right) the selection window can be raised upwards.

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3. Entering the program name:

Through pressing the field 32, a keyboard opens up, in which the desired program name
can be entered.

Figure 13: keyboard program name

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4.4.5 Altering the setting point

1. Changing the setting point into individual steps can be accomplished through pressing
the respective keys "+" (28) and "-" (29).

30

28

29

Figure 14: altering setting point with keys "+" and "-"

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2. Through directly pressing of the setting point, (30) a number field opens up which can
change the point directly.

Figure 15: directly changing the setting point

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Keyboard input field

3. The specific input area will always be shown above with the selected value in the chosen
number field.

Set value

Minimal Maximal
setting setting point
point

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4.5 KEYBOARD DESCRIPTION

4.5.1 Rate (speed)

This value is in % or in pieces per minute (depending on the selection in
the portioning correction mask) and it determines the speed during a cer-
tain portion run..

4.5.2 Weight (volume)

The maximal 6-figure number (adjustment range of 5 to 99999, 9 cm³)
determines the volume and with it the portion weight. Be certain that the
first portion, after a filling pause is added to the first amount, and an even-
tually carried out withdrawal is also added to the first portion. Additionally,
the weight correction value is to be considered in the respective correc-
tion mask.

4.5.3 Filling pause

The time lapse that should occur between the filled portions (adjustment
range of 0-3000 ms), if the portion continuation is not interrupted by de-
pressing the knee lever (note knee lever positions 1-2-3). If every portion
is initiated through pressing the knee lever, then this value is meaning-
less.

4.5.4 Clip impulse

This value (adjustment range of 50-3000 ms) determines the time of the
Clip signal.

4.5.5 Extra volume 1. Portion

This value to the volume is always then to be deducted and added with
the unit of cm³, if the portioning/ twisting are interrupted for duration of ca.
10 seconds. (Adjustment range of –100 cm³ to 100 cm³).

4.5.6 Withdrawal
It is turned off if the setting point is 0. If the withdrawal is greater than 0,
(adjustment range of 0-100 cm³) then it will always withdraw after inter-
ruption of the meat filling process around the set value. No withdrawal
takes place if the filling process is stopped by activating an interruption of
the portion. Attention: By too high of a withdrawal setting and by using an
air recycler, this can lead to air inclusions at the sausage skin ends and
in-between the portions.

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4.5.7 Ramp filling meat pump

Here you can adjust the filling output to either harder or softer, (adjust-
ment range of 10-150 %). Too hard of a filling output can lead to burst-
ing of the skins, or to pear shaped sausages, and too soft of a filling
output can result in too small of a portion output.

4.5.8 Weight correction

Here you can adjust the turned out volume to match the actual volume
(adjustment range of –200 to 200 cm³).
i.e. The adjusted amount in the input field has a weight of 100 cm³, the
filled weight equals 93 g (= 100 cm³) You can resolve to change more
than
+7 cm³ in order to reach the desired 100 g.

4.5.9 Advancing/lagging Clip impulse

This amount (adjustment range of –200 to 200 ms) determines the ext
time as to how long before and after the filling of a portion den the Clip
machine has been started. The installation of both the before and after
curing (advance and lagging) influences the stroke rate of the Clip ma-
chine, and in this way, also the number of portions.

4.5.10 Portion interruption off/on

Portion interruption – deactivated.
If the knee lever is released during the filling of a portion (with single
portioning) and contacted a second time (with continual portioning, ,
piece orders) the conveyor usually doesn’t stops immediately, but rather
completes the already begun Portion until the end of.
Portion interruption – active.
If the portion interruption is nevertheless activated for the respective
program and the operator presses the knee lever during the filling pro-
cedure, and with the clip machine the “emergency shut-off switch, then
the conveyor stops immediately. The started portioning will not be filled
completely.

4.5.11 Twisting off

The adjusted amount (adjustment range of 1to 15 twisting s) determines
the number of twisted off pieces after the end of the portioning.

4.5.12 Twist-off position

Pause between end of filling portion and start of twisting off in ms
Can also be negative, i.e. filling and twisting overlap.

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4.5.13 Filling position

Pause between end of twisting and start of filling portion in ms
Can also be negative, i.e. filling and twisting overlap.

4.5.14 Extra twist off 1. Portion

The adjusted amount (adjustment range 0-10 twists rotations) is with
the
1. Portion for the extension of the adjusted twist offs. This inhibits a
twisting off of at the first twist position in a string of sausages.

4.5.15 Ramp twist off motor

The adjusted amount (adjustment range of 20-150 %) changes the
ramp of the twisting off motor, and this way, the twisting conduct. Too
hard of a twisting conduct leads to splitting of natural lining (the lining
twists itself on the filling tube and becomes hard). Too light of a twisting
conduct leads to reduced twisted off production.

4.5.16 Rate of 1st portion

This allows the machine operator to adjust the speed of the first portion
as a percentage in relation to the following portions.

4.5.17 Preset weight

This is for setting the amount of weight to be produced. Once the de-
sired quantity has been reached, production is stopped and a dialog
opens.
If the quantity is changed during production (or during a production
pause), counting starts over again.
The preset weight is counted only if the preset weight function is
switched on.

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4.5.18 Delay for 2nd clipper pulse

This is for setting the time delay after the end of the 1st clip-
per pulse for the start of the 2nd clipper pulse. The 2nd clip-
per pulse is set only if the 2nd clipper pulse function is acti-
vated. The duration of the 2nd clipper pulse is equal to the
duration of the 1st clipper pulse.

4.5.19 Start before/after beginning filling

It’s possible to determine here when the second machine
should be started after beginning the filling (adjustment range
of –9999, 9 to 9999, 9 cm³)
i.e. adjustment: > 5 cm³, now the second machine would start
5 cm³ after starting to begin filling.

4.5.20 Stop before/after end of filling

It’s possible to determine here when the second machine
before should be stopped before the end of the filling (ad-
justment range of –9999, 9 to 9999, 9 cm³)
i.e. adjustment of 5 cm³ > the second machine would now
stop 5 cm³ before the end of filling.

4.5.21 Beginning the second portion

It’s possible to determine here whether the start of the second
machine is active already before the first portion or if the sec-
ond machine should be started only after the second portion
(adjustment range on/off.).

4.5.22 Weighing system

Open the settings input mask here, if the REX filling machine
is connected to an external weighing terminal - see 4.21
Weighing system

4.5.23 Moving at a certain speed

Here you may select whether the speed on the main input
mask screen is displayed in pieces per minute or in %.

4.5.24 Metal detector

A window for the settings parameters will open when activat-
ed - see 4.20 Metal detector

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4.6 INSTALLATION OF THE STRAIGHT FILLING PROGRAM

1. Press the filling key (25) in the operational performance type.

2. select program area (31)

3. type in the sausage name (32)

4. adjust the desired vacuum pressure (13, 14)

5. The following amounts are available with the help of the respective key:

- speed (30)
- withdrawal (33)
- Knee lever position: single (34) or continual portioning (35)

31

32

30

33

34

35

25

Figure 16: mask filling

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6. Through another pressing of the filling key, (25) a filling correction mask opens up. The
standard amount of the parameter there can be altered for optimizing.
7. The following amount is selectable with the help of the respective key:
- Acceleration ramp of the filling meat pump (36)
- Metal detector
8. Through a repeated pressing of the filling key (25) or the back button (17) the main mask
returns to the screen.

36

Figure 17: filling correcting mask

9. Through pressing the saving key (20) a dialog field opens. The saving process must be
confirmed once more.

(20)

Dialog field

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4.7 ADJUSTMENT OF A PORTIONING PROGRAM

1. Press key (24) in the operational performance type

2. select program area (31)
3. type in sausage name (32)
4. adjust the desired vacuum pressure (13, 14)
5. The following amounts can be selected with help of the respective key:
- speed
- filling weight
- filling pause
- Clip impulse
- 1. additional portioning
- withdrawal
- Knee lever position single portion (34), continual portioning (35) or piece ordering

31

32

14

13

24

Figure 18: mask portioning

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6. Through repeated pressing of the portioning key (24) a portioning correction mask
opens.

The standard amount of the parameter can be altered there for optimizing.

7. The following values can be selected with the help of the respective key.

- Acceleration of the filling meat pump

- Weight correction
- Advance and lagging of the Clip signal
- Last clip impulse
- Portioning interruption

8. Press the portioning button (24) again to open an additional correction mask. Press the
back button (17) to return to the main mask.

24 17
Figure 19: mask portioning corrections

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9. The following values can be selected with the corresponding buttons:

- Rate of 1st portion
- Correction to last portion
- Preset weight
- Delay for 2nd clipper pulse
- Variable weights
- Moving at a certain speed
- Weighing system
10. Repeated touching of the portioning button (24) will take you to another correction input
mask. The Back button (17) will take you back to the main screen.

24 17
Figure 20: mask portioning corrections 2

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11. The following values may be selected via their respective buttons:
- Metal detector
12. Repeatedly touching the portioning button (24) or the Back button (17) will take you back
to the main screen.

24 17
Figure 21: mask portioning corrections 3

11. through pressing the save key (20) a dialog field opens. The saving process must be
once again confirmed.

(20)

Dialog field

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4.8 ADJUSTMENT OF A TWISTING OFF PROGRAM

1. Press key (23) in the operational performance type

2. Select program area (31)
3. type in name of sausage (32)
4. adjust desired vacuum pressure (13, 14)
5. The following amounts can be selected with the help of the respective key:
- speed
- filling weight
- twisting off number
- 1. additional portions
- withdrawal
- Knee lever positioning for single portions (34), continuous portioning (35) or piece
ordering

31

32

14

13

23

Figure 22: mask twisting off

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6. Through an additional pressing of the twisting key, (23) the twisting off correction mask
opens up.
The standard amount of the parameter can be changed there for optimizing.
7. The following amounts can be selected with the help of the respective key:

- Acceleration of the filling meat pump

- Weight corrections
- Twist position
- Filling position
- Additional turn 1. Portion
- Portion interruption

8. Press the twist-off button (23) again to open an additional correction mask. Press the
back button (17) to return to the main mask.

23 17
Figure 23: mask twisting off - correction

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9. The following values can be selected with the corresponding buttons:

- Rate of 1st portion

- Correction last portion
- Preset weight
- Metal detector
- Weighing system
10. Press the twist-off button (24) or the back button (17) again to return to the main mask.

23 17
Figure 24: mask twisting off – correction 2

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11. Through pressing the saver key (20) a dialog field opens up. The saving process must be
repeated once again.

(20)

Dialog field

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4.9 ADJUSTMENT OF THE PRESSURE SENSOR OPERATION

1. Press key (22) in the operational performance type operating mode performance.
2. Plug in pressure sensor on the machine outlet Clip machine outlet).
3. Through pressing the "+" and "-" key you can adjust the desired pressure setting (green
indicator). This can be altered at any time, even during the operation.
4. adjust the desired vacuum pressure (13, 14)
5. The function is started upon depressing the knee lever. The current actual pressure is
shown through the red indicator.
6. The function is stopped through an additional depression of the knee lever.

Attention:
If no pressure can be built up after ca. 15 seconds, because i.e. the hopper is empty,
then the Vacuum filling machine stops and an error signal appears F 421 (set/actual
pressure deviation is too great).

Figure 25: mask pressure sensor

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4.10 ADJUSTMENT OF THE SECOND MACHINE CONTROLS

1. In the operational mode performance, press key 23 or 24

(depending upon the usage of portioning or twisting off).

2. select program area

3. type in sausage name

4. set the respective amount

5. Press key 21 in the operational mode performance

6. Second machine controls is activated through the on key.

7. The following amounts can be selected with help of the

respective key:

- Start advance and lagging

- Stop Advance/lagging

- Beginning with 2. Portions

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21 17
Figure 26: mask portioning of secondary machine

8. By pressing the operational mode key 21 a second time, the

window opens up, in which " the second machine controls can
be deactivated by pressing "0“. However, this can also be ac-
complished through pressing the withdrawal key (17).

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4.11 SPECIAL FUNCTIONS

The so called Information mask opens after pressing the Info-key (19), which offer the possi-
bility of numerous special functions and set ups.

Info-mask

Figure 27: information mask

Under the column "service information" the current machine operational hours are indicat-
ed. You can also determine how many operational hours and days remain before the next
servicing date for the vacuum filling machine is due.

In the column "machine type" the type of machine employed will be indicated.

Under "accessibility" the machine manufacturer is shown in the left column. On the right,
the address of the REX-appointed dealer and negotiator can be inserted by a trained techni-
cian.

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4.12 SPECIAL FUNCTION "TUBE ALIGNMENT"

After pressing the Info-mask key "tube alignment", a dialog field opens up.

Info-mask

Figure 28: tube alignment

The tube begins rotating once the knee lever is depressed, which allows for an alignment.
The twisting pipe stops upon releasing the knee lever. The function can be abandoned with
the "confirmation key and withdrawal key (17)".

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4.13 TUNE IN SETUP MASK, LANGUAGE SELECTION, TIME AND

DATE

 Setup-Mask

The machine operator can carry out adjustments in the (local time, date, etc.) with the setup
mask. The desired language can also be selected with the language choice. Additional im-
portant information is left there, such as machine number, appliance number, software ver-
sions and free circuit code.

Setup mask

Figure 29: setup mask

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 Language switch over

Through pressing the display field of the selected language, a window opens up in which the
desired language can be selected.

Figure 30: switching languages

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 Installing time and date

Through pressing the date and time display field, a window opens up, in which the desired
date and local time can be set.

Figure 31: setting the date

Figure 32: setting the time

The further adjustments and alterations, such as versions, free circuit code and
screen background lighting can only be carried out through an authorized REX-
appointed dealer.

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4.14 SCREEN ADJUSTMENTS

Pressing the screen adjustment button opens up the adjustment mask.

Adjustment mask

Figure 33: mask screen adjustments

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In the "operation modes" column, the buttons in the operating modes bar can be shown or
hidden:
- Portioning (24)
- Twisting off (23)
- Pressure sensor (22)
- Second clipper pulse
- Weight counter
- Lifting device
- Second machine (21)
- Hanging line
- Mincer

Under the "adjustments” mode in the main mask, it’s possible to decide whether to super-
impose the date (5), the time (4) and the portions /minute and kilo/hour (3).
There is also the possibility of putting in the following start masks:

- Start the machine with the last program

- Start the machine with the filling operation mode

- Start the machine with the portioning mode

- Start the machine with the twisting off mode

- Start the machine with the pressure sensor mode

- Start the machine with the operational mode performance indicator

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Setting the "Logo" column remains reserved for the authorized REX-appointed dealers
and technicians.

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4.15 RECIPE ADMINISTRATION

By pressing "Recipe administration" a mask opens up, in which all the set filling programs
are displayed, sorted, deleted, renamed as well as program specific production dates can be
selected.

Recipe administration mask

Figure 34: mask recipe administration

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Figure 35: editing the recipe data

Pressing the "Edit" and "Statistics" buttons enables you to call up daily production data.

Figure 36: recipe dates

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Other features:

- Deleting programs

- Inserting programs

- Renaming programs

- Copying programs

- Deleting all programs

"Import" and "Export" give you the option of importing various programs from other vacuum
fill machines, or saving existing program data to a storage medium. You must connect a USB
device to the provided interface of the CPU controls located in the control cabinet or at the
X7 socket for the external equipment sockets to do this.

Touching the "More" button allows you to set up program favourites on the respective main
screen.

If you sign in as "Administrator/supervisor" in the "User login" you are able to block various
program parameters. The password is: 4444. (Password can be modified).

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4.16 USER REGISTRATION

The administrator / supervisor can sign in with the password: 4444.

The other users are reserved for authorized REX dealers or service engineers.

4.17 INFO-LOG

The installation of this mask remains reserved for the authorized REX-appointed deal-
ers and technicians.

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4.18 SERVICE PLAN

You may view the relevant service information on this mask.

Figure 37: mask service information

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Figure 38: mask service information 2

You can get more detailed status indicators by touching the Zoom button (+). A suggested
maintenance schedule appears by touching the "Info" button.

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The service plan can be accessed by selecting the "Service list" button. Service work already
carried completed on the modules is displayed here.

Figure 39: mask service plan

The person who did the service work has to confirm all completed maintenance work at the
specified intervals (see chapter 5.4 Maintenance and upkeep).

Attention: After a procedure has been carried out and saved, the service and mainte-
nance tasks interval indicator (8) will be reset on the main screen.

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4.19 STATUS REPORT

Figure 40: status report

In the event of a program error, a description of the error can be entered in the input
field. The report is automatically saved. Your dealer can view and edit this data.

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4.20 METAL DETECTOR

Figure 41: metal detector

Open the "Metal detector" input mask by selecting the parameter "Metal detector" on the cor-
rection input mask.

This dialogue facilitates making changes in the metal detector settings.

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4.21 WEIGHING SYSTEM

You have the option of connecting the REX vacuum filler to a weighing terminal. You are
able to take sample weights for the portions here. If the portion weights are outside the pre-
set tolerances, the controls will automatically correct the weight parameters -4.5.2. Weight
(volume) Target data and correction as well as tolerance ranges can be pre-set specifically to
the recipes and then saved here.

Figure 42: weighing system

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4.22 ALARMS, MALFUNCTION REPORTS

 Error message: hopper steps

After opening the hopper cover and the steps, the controls interrupt the operation and the
following error dialog opens up:

Hopper Steps are folded down, close again after use.

This window closes independently once the hopper cover is closed again and the steps are
folded back up.

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 Other error messages

With every other standing mistake report, the operation of the Vacuum filling machine is in-
terrupted and an alarm mask opens up independently and by pressing the alarm key.

Figure 43: alarm mask 1

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All malfunction reports that occur will be indicated in this alarm mask, including the alarm
status, the time it took place, the alarm class as well as a description of the incident and
standing alarm.

Alarm number including description

Figure 44: alarm mask 2

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4.23 DEFECT REPAIR

By pressing the current disturbance report, it will be marked in blue.

For every alarm, a help key is available, including the possible specific cause and also op-
tions for repairing the defect.

Figure 45: alarm mask 3

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Help -key: After pressing the key, a window opens up with suggestions for possible causes
of the defects, including their repair.

Window with suggestions for possible cause of defect

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After resolving the defect, the solution must be given.

Figure 46: alarm mask 4

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4.24 CONVEYOR HOUSING, SLIDING DRUM AND PRESSURE PLATE

The correct function of the filler determines the installation of the right piece in the proper
sequence.

Figure 47: installation sequence for delivery system

The correct sequence is depicted above.

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Installation
Pos. naming remarks
sequence

Permanently installed on the ma-

1 See remarks Conveyor housing
chine housing

used to seal against meat for the

2 See remarks groove ring main drive, leave it on the sliding
drum for cleaning

3 1 Sliding drum Develop for cleaning

4 2 vane outside Develop for cleaning

5 3 vane inside Develop for cleaning

6 4 vane inside Develop for cleaning

7 5 vane outside Develop for cleaning

4.25 INSERTING CONVEYOR PARTS

- Rub into, or spray the conveyor parts with food-based, edible fats, or
oils
- Insert sliding drum with the help of both leverage keys. The sliding
drum must engage with it in the shank of the input shaft
- Put in the vanes
- close and lock upper part incl. sliding plate

Attention: Due to the cushioned feeder coupling, the upper section can be
opened in any position with the hopper, or be closed. After start-
ing the Vacuum filling machine, the feeding coupling automatical-
ly engages.

 installing the conveyor system

The installation of the conveyor system should only be performed by trained per-
sonnel.

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4.26 HOPPER, FEEDER AND STOPPER

Figure 48: hopper cover with feeder

Installation
Pos. naming remarks
sequence
1 1 Filling hopper Solidly mounted on the upper plate
2 2 Scraper Develop for cleaning
4 4 Stopper (retainer curve) Develop for cleaning

The stopper isn’t necessary when processing a thin, fluid-like mass.

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4.27 OVERVIEW OF FEEDING SYSTEM

This is a qualitative description of the effects on the filling material with various feeding sys-
tems.

Feeding system qualities

Filling hopper with curved increase

feeder and stopper
Better delivery of solid filling meats
(e.g. raw sausage)

Filling hopper with curved Tighter and clearer

feeder without stopper cross section
Weight precision with solid filling meat

Filling hopper without feeder Settlement danger with sensitive

or stopper filling meats (i.e. cooking sausage
or heavily, cut up sausage for
boiling
Reduction

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4.28 INSERTION OF FEEDER, SCRAPER AND ANTI-STOPPER

 installation of feeder

- main switch (Figure 9, page 41) switch on position 0

- press gasket-O-ring and axial face seal ring in the intended nut
- install feeder with the flange facing under into the hopper, and turn until the step
pin engages

 installation of scraper

- put the scraper on the top end of the feeder screw until it clicks into place

Attention: Under no circumstances should the long scraper (2) be used for
cold raw sausage filling meat and rigid filling mass, because this
can lead at any time to a breakage of the scraper in the hopper,
and this way could result in being mixed with the filling meat.
(Danger of breaking the conveyor system!)

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 inserting stopper

With the processing of hard filling meats (grainy, solid and compact) i.e. “raw sausage” type
filling meats:

- Insert stopper in the filling hopper when the Vacuum filling machine is shut down.
- Clamp on with fixing screws on the positions intended for this.

4.29 FASTEN STRAIGHT FILLING TUBE

Filling tubes (2) can easily be connected with the hand locking device (1) in the drain (3) in
the Vacuum filling machine.

1 2 3
Figure 49: fastening straight filling tube

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4.30 INSERTING VACUUM GLASS GAUGE PARTS

1. Secure vacuum tube stub (1) by pressing and twisting into the tube (only use with
thin, liquid-like fillings, such as liverwurst. (The vacuum pump must be shut off while
using the vacuum tube stub.)

2. Press the vacuum lock-housing (2) firmly upwards

2 1
Figure 50: inserting vacuum glass gauge parts

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4.31 INSERTING THE WATER DRAIN

Press the water drain stub (1) into the runoff tube (2) and secure this through turning.

2 1
Figure 51: water drain

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4.32 ATTACHMENT OF THE TWISTING GEAR, TWIST OFF FILLING

TUBE AND INTESINE HOLDING DEVICE

It must be said in advance, that the twist off tube can only be attached in connection with the
twisting gear. The twisting gear serves for the automatic twisting off of natural and synthetic
skins. Depending upon the skill of the operator, it’s possible to hold the linings by hand or
through an intestine holding device. By using a skin holding device, the productivity rate can
be raised.

5 3 6 4 1 2

Figure 52: skin holding device

Attachment
Pos. naming comments
sequence

1 1 Twisting gear Put on its hinges

2 2 Grip locking device Lock firmly in outlet

3 3 Twisting off tuber Fasten at the outlet of twisting gear

4 4 Twisting mother Firmly secure with intended auxiliary

key

5 5 Skin holding device Hang in the hinges of the twisting gear

6 6 skin holder cover Secure skin holder through twisting the

fastener at 180°

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 The following steps must be followed

1. Shut down Vacuum filling machine with

the off key.

2. Twisting gear carefully put on hinges of

swinging mechanism

3. Firmly secure twisting gear with the quick

release in the outlet

4. /5. Press outlet seal plate firmly between twisting gear and grip locking device.

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6. Fasten twisting off tube at the outlet of the

twisting gear. By pressing the lock up but-
ton on the twisting gear, you can secure
the twisting gear against distortion. With
the accessory key, you can secure the
twist filling tube.

7. Hang the skin holding device carefully on a

hinge in the swinging mechanism of the
twisting gear

8. Firmly secure the skin holding device on

the twisting gear.

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9. Insert the skin braking set on the skin

holder

10. Secure jamming valve through twisting on

the skin holding device.

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11 and 12. Depending upon the usage of the artificial or natural linings, the artificial skin roll
can be mounted and disassembled on the skin holding device.
Depending upon the skin caliber used the artificial skin rolls must be installed in-
dividually vertically.

13. Through usage of the tool keys, (accesso-

ries) the skin brake system can be ad-
justed. This influences the solidity of the
filled linings.

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Operation of the vacuum filling

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 Choice of the right twisting tube

- Listing the skin caliber – twisting tube diameter

skin type /caliber - Ø (mm) Equipment of the holding device

Collagen skin

Twisting tube

Twisting tube

Twisting tube
Artificial skin

Skin braking
Natural skin
Kranz skin

device-Set

Jamming
HV-star

valve
320

400
13 13
15 15 14-16
9 9 9 9 9
16 16-18
17 17
19 18-20 16-18 10 10 10 10 10
19 17-23 18-20
11 11 11 11
21 20-22
11-12
23 23-26 18-20
12 12 12 12
20-22
26 26-32 18-20
14 14 14 14 14
20-22
26 28-32 22-24
16 16 16 16 16
28 24-26

26-28
18 18 18 18 18
30 28-30
32
34 28-30 20 20 20 20 20
36 30-32
38 36 32-34
22 22 22 22
40 40 34-36
43 32-35
36-38
43 38 35-37
47 42 37-40
52 40 24 24 24 24 24
42 40-43
45 43-46
58 50 46
Attention: Non-compliance could result in premature wearing down of the conveyor
system.
The manufacturer assumes no warranty claims for neglect .

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4.33 PROCESSING SUGGESTIONS FOR SKINS

- The instructions given by the skin manufacturer regarding the storage

and processing of the skins must be followed exactly.
- The pre-processed natural skins can be pulled up with the skin pulling
device directly on the special squeezing out tip.
Of course, the skins can also be pulled up by hand.

skin types Processing suggestions

Salting Pork skin Only general recommendations.
The special instructions of the manufacture need to be not-
Wet salting

Wet salting
Dry salting

Dry salting

ed.

Pre-processing
  On day before: rinse skins well with cold, squeeze out
somewhat and store overnight cold.
  On processing day: soak skins in warm water +37°C for 60
min.
  Soak skins in warm water  +37°C 30-60 minutes.
    Increase lubrication: Through additional substances e.g.
Sodium bicarbonate (baking soda) amount given 2-3 table-
spoons to
5 Liter water ( +37°C)
    Un-used skins: rinse well, salt and keep cool stored
Draw up (with skin pulling device R2)
  Feed water: slowly dropping
  Fast dropping
  Adjust pressure of the pull up roller  3 to 4 kg and adjust
so that the skins are pulled straight.
   4 to 5 kg already pulled on
3-6 pieces Capacity of the pulling dome
    Pulled out skins: after 10 minutes further process, or store
in water.

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4.34 PRODUCTION

 start production

Figure 53: operational elements vacuum filling machine

The numbers in the parentheses refer to the Figure 3, page 24.

Establishing the professional operation of the Vacuum filling machine take place as follows:

- Following the general safety warnings e.g. according to chapters 1.4 und 4.1.
- fill product in the filling hoper (1)

Attention: Only use products that correspond according to chapter 2.2.1

Operational area and a directed usage!

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- Turn on Vacuum filling machine with the on key (chapter 4.2 Control ele-
ments/function, page 38)
- Select desired program
- Through depressing the knee lever (6) the Vacuum filling machine is put into oper-
ation. Filling meats are delivered through the feeder to the conveyor system.
In the conveyor system a vacuum is available, which depending upon the filling prod-
uct is adjusted at various levels. Through rotation of the sliding drum, the product is
led to the outlet.

 Supervision during the production

The almost malfunction-free production assumes the early recognition of possible disruption
causes.

The person working on the Vacuum filling machine during its operation should therefore ob-
serve both the machine itself, and also the peripheral area. Possible determined abnormali-
ties such as:

- Strange sounds
- Unusual vibrations
- Unsteady running of the Vacuum filling machine
- Clear warming up of the Vacuum filling machine

Immediately report to supervisor!

Attention: While conveyor is in operation, never reach with the hands in the
area around the hopper and conveyor system!
Danger of injury! Danger of finger and limb loss!

 Interruption of production

- Shut down Vacuum filling machine with knee lever (6), in order to replenish the fill-
ing meat, for example.

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 Continuation of production

- Set the desired filling program and restart through depression of the knee lever.

Attention: Never run Vacuum filling machine without filling meats! Without
filling meats the conveyor system runs dry and prematurely
stops. Non compliance means no guarantee through the machine
manufacturer, or their corporation!

 Emergency shut off in dangerous situations

1. Shut down through the main switch (Figure 9, page 41)

Press Main switch immediately if a potential danger exists of injury or damage to

the Vacuum filling machine!

2. shut down through safety switch

Vacuum filling machine shuts down independently, or impedes operation if the

upper portion is not completely sealed off. If the divided hopper or sealed off lad-
der is opened or loosened during operation, then the main motor comes to a
complete stop. There appears an error display "step, hopper is open". (see chap-
ter 4.22 Alarms, malfunction reports)

3. shut down through the motor protection switch in switch box

Engaging the motor protection switch also results with the complete stop of the
main motor. The vacuum pumps and the twisting motor are protected.

Attention: Continuing the operation only after repairing the motor overload.
Otherwise there’s a danger of complete motor damage!

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Operation of the vacuum filling

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 Switching back on after emergency shut off

1. The emergency shut off through main switch (Figure 9, page 41):

 Cause of emergency shut off resolved ( bring person or their hands out of
dangers reach, Allow the Vacuum filling machine to be inspected by skilled
personnel and brought back to normal functioning.)

 Turn on main switch, wait for the controls to start up

 Activate Vacuum filling machine by means of on key (chapter 4.2 Control el-
ements/function)

2. In shutting down through the safety switch, or by independent shutting down of the
Vacuum filling machine:

 Close upper portion or cause of activating the end stroke switch and only al-
low trained personnel to inspect and resolve the situation.

 Activate Vacuum filling machine by means of the on key (chapter 4.2 Control
elements/functions)

3. By shutting down through a non-given malfunction display:

 Call at once an authorized REX appointed dealer and REX technician.

 Establish the cause of the malfunction report and repair it.

 Continuation of operating the Vacuum filling machine can only be performed

by trained REX-Personnel. Through violation, the manufacturer offers no
guarantee.

Attention: Prior to every activation of the Vacuum filling machine, be cer-

tain that:
- No persons are located in a dangerous area of the Vacuum filling
machine
- all safety devices of the Vacuum filling machine are mounted and
intact
- all covers and shields are closed

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4.35 END OF PRODUCTION

The end of production is approaching when:

- the intended amount of the filling meat is processed

- there are no more filling meats available for the foreseeable time
- The Vacuum filling machine must be placed out of service for an indefinite period
resulting from a complicated problem, or for other reasons.

At the end of production the Vacuum filling machine must be immediately shut down. This
takes place effectively in this sequence:

- Shut down Vacuum filling machine by means of the off key (4.2 Control ele-
ments/function)
- Shut down main switch (position "0") (Figure 9, page 41)
Shutting down the main switch is absolutely required for cleaning. The Vacuum filling
machine can of course be turned on once again at the main switch after completion of
cleaning process and be brought in standby-operation.

Die cleaning must be done according to chapter 5 .

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Maintenance

5. MAINTENANCE

5.1 CLEANING AND CLEANING PLAN

 Safety precautions

Prior to beginning the cleaning process the off key must be pressed (4.2 Control ele-
ments/function).

- The main switch must be placed in the position"0"

- Be careful in using a high pressure cleaner (danger of damaging electrical and
mechanical components)
Never point cleaning spray on the following components:
- Operation table (Touch-controls)
- Area of mechanical storage
- Other electrical devices, such as clamps- or cable inlet, unknown device outlets
- Ventilator slot on the floor of the Vacuum filling machine
- All visible seals

Never use abrasive agents on flat metal surfaces, due to threat of adversely effecting the
corrosion protection!

No using cleaning or cleaning agents which contain metallic substances. Possibility of dam-
aging the anti-corrosion protection!

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Maintenance

5.2 CLEANING THE VACUUM FILLING MACHINE

Vacuum filling machines, in which products for human consumption are pro-
cessed, need to be cleaned and disinfected after ending every production, after a
break in operation of > 1-1, 5 hours, but at least 1 x daily. Calcium or protein
build-up must me removed at least 1 x per month with an acidic cleaning agent
e.g., Henkel P3-topax 56" or "Goldschmidt SOMPLEX acid cream", or another
adequate cleaning agent (the naming of specific products is not suggestive of the
expected quality, but simply pointing out the effects of the products).

These measures are essential for the :

- problem free quality of the product

- avoidance of biological un-cleanliness of the product
- filling appropriate hygiene requirements
- Value upkeep of Vacuum filling machine.

The cleaning can alternatively be carried out with alkaloid and acidic solvents.
The appropriate agent alternatively usable or must be selected in correspond-
ence with the material nature of the machine components. Suggestions and op-
eration manual of the supplier of such agents must be followed to the letter!

5.2.1 Material types and cleaning procedures

With the use of cleaning and disinfectant agents, the material tolerance must be
respected. The following chart offers insight into the usable cleaning procedures,
which are subsequently explained in the "cleaning plan".

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Maintenance

5.2.2 Chart: Types of material and cleaning procedures

Important cleaning parts and their allowed cleaning procedures

Parts names according to Possible cleaning proce-

Pos. Material type
Figure 3, page 24 dures

1 Filling hopper Stainless steel Alkaloid/acid

Conveyor parts Figure 47, page Stainless steel Alkaloid/acid

97

Main switch (Figure 9) plastic No chemicals

9 Operation table: keyboard plastic No chemicals

plastic No chemicals

3 Vacuum inspection glass Plastic No chemicals

8 Covers Stainless steel Alkaloid/acid

5 Machine housing Stainless steel Alkaloid/acid

6 Knee lever Plastic Alkaloid/acid

5.2.3 Cleaning agents

The use of high pressure cleaners is recommended with the following accessories:

Lanze with full stream nozzle Conveyor system parts

Lanze with wide spray nozzle For machine housing chart,

page 120/121
Attention!
Do not spray the following
parts:
- Touch-controls
- Switch box
- Electrical compo-
nent devices
- mech. Storage
areas
Container for cleaner With socket on the device

Cont. for disinfection agent With socket on the device

Disinfection agents

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Maintenance

5.2.4 Cleaning for the alkaloid cleaning procedure

Cleaning meth- device/

Work steps Cleaning agent suggestion
ods remedy
Rough clean- Water, manual, water- Begin immediately
ing, removal max. 50-60°C mechanical hose, after end of produc-
of product spatula, tion
remains scraper
Dismantle 2-5 % solution of First a basic pre- High pres-
and clean e.g. rinsing with water sure cleaner,
small parts Henkel: P3-topax max. 60°C, then low pressure
19 foam or apply foaming ma-
Henkel: P3-topax manually , effec- chine or a
66 tive time brush and
Goldschmidt: ~ 15min bucket
SOMPLEX Fat
dissolver
rinse Water of drinking Low pressure Low pres-
quality ~60°C < 30 bar manual sure clean-
ing machine,
water hose
Check for Visual After cleaning as
cleanliness needed
Disinfection 0,5-2 % solution of Spray, foam, High pres- Total Vacuum filling
e.g. effective time sure cleaner, machine and small
Henkel: P3-topax according to low pressure parts (after comple-
99 product data device, tion of all cleaning
Henkel: P3-topax sheet spray gun measures in the ar-
91 ea)
Goldschmidt:
TEGO 2000
TEGO IMC
Clear spray Drinking water Low pressure Low pres- Carry our rinsing ac-
< 30 bar, manual sure –device cording to LMBG §31
, spray gun,
hose with
water
Drying
care z. B. wheat oil Spray /rub in Spray gun Conveyor parts ma-
chine outer area

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Maintenance

Cleaning plan applies only for the machine parts made of stainless steel
(For other material, the approval from the cleaning and disinfection agent manu-
facturer is required.)

The Vacuum filling machine must be treated, according to the cleaning plan, after
the end of every production, after a break in operation of more than 1-1, 5 hours,
but at least 1x daily.

5.2.5 Cleaning for acidic cleaning procedures

Working Cleaning meth- device/

Cleaning agents Suggestions
steps ods remedy
Rough clean- Water, manual, Water hose, Begin immedi-
ing, removal Max. 50-60°C mechanical scraper, spatula ately after end
of product of production
remains
Dismantle 3-6 % solution of e.g. First a basic pre- High pressure Attention! For
and clean Henkel: P3topax 56 rinsing with water cleaning, low parts not made
small parts Goldschmidt: SOM- max. 60°C, then pressure foaming of stainless
PLEX acid foam allow to foam, or machine, spray metal: follow
apply manually, gun or brush for instructions of
effective time removal of calci- the manufac-
15min um deposits turer exactly!
Final rinse Water of drinking Low pressure Low pressure
quality ~60°C <30bar manual cleaning ma-
chine, water
hose
Check for visual As needed after
cleanliness cleaning
Disinfecting 0,5-2 % solution of Spray, foam, High pressure Tot. Vacuum
Henkel: P3-topax 99 effective time cleaner, low filling machine
Henkel: P3-topax 91 according to pressure device, and small parts
Goldschmidt: product data spray gun (after finishing
TEGO 2000 sheet all the cleaning
TEGO IMC procedures in
the room)
Clear rinse Drinking water Low pressure Low pressure Follow acc. to
<30 bar, manual device, spray LMBG §31
pistol, hose
drying
care z. B. wheat oil Spray/ rub in Spray gun Conveyor ma-
chine.-outer
area

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Maintenance

5.2.6 Individual tips for cleaning touch-screen

The surface of the touch screen must be cleaned with a moist, clean, soft cloth with water-
better yet, glass cleaner. The glass cleaner should be sprayed on the cloth rather than direct-
ly on the touch screen surface.

Attention: Filling meat remains which are not removed from the screen can
dry and bring about the disruption of functions.

5.2.7 Individual tips for cleaning the dismantled machine parts

Prior to carrying out the cleaning plan as previously described, dismantle

the filler in this sequence:

- First press the stop key

- Main switch (Figure 9, page 41) bring to position "0"
- When adapters are together, the dismantled them and clean. For this, see the cor-
responding instructions.
- After removal of the connection cable from the clipper outlet (Figure 8, page 41)
the protective cover must be put on
- If a filling tube was worked with, loosen hand lock and remove filling tube
- Open Inspection glass (Figure 3, page 24, Nr. 3)
- Remove water drain (see Figure 51, page 103, Nr. 1) in the inspection glass
- Upper portion (see Figure 3, page 24, Nr. 11) unlock and swing off hopper
- Remove stopper from the hopper
- Remove feeder
- Dismantle pressure plate (Figure 47, page 97) with leverage tool
- valve (Figure 47, page 97) remove individually
- remove sliding drum (Figure 47, page 97) with leverage tool
- Remove filling meat remains from the conveyor system, conveyor housing, vacu-
um canal etc.
- Spray all dismantled parts and Vacuum filling machine with warm water, or spray
with high pressure and steam cleaner
- Dismantle the ball safety ventilator in the Vacuum holder through pulling and recip-
rocal twisting (Figure 50, page 103, Nr. 2) and give basic cleaning with warm water.

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Maintenance

- Clean receiver housing for the ball-safety ventilator

(do not spray in the receiving hole)
- replace ball-safety ventilator in the Vacuum case
- Dry out conveyor housing and rub in food like, and edible fats or oils. Leave hopper
tipped back overnight.
- Wipe down Vacuum filling machine with absorbent cloth and free of cleaning water
(do not use cleaning cloths which leave behind scratches or stains.)
- Rub conveyor parts dry and rub in food like and edible fats, or oils. Store conveyor
parts separately outside the Vacuum filling machine

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Maintenance

5.2.8 Individual tips for the cleaning of non-removable machine parts

Independently and parallel to the cleaning the non-removable parts, is also carrying out the
cleaning of non-removable machine parts. This also applies here In any case:

Figure 54: cleaning the vacuum filling machine

- Prior to fulfilling the cleaning plans:

press the off key.
- Shut off main switch
- Pre-clean outer machine housing, filling hopper, upper part housing, conveyor
housing, pressure plate, valve, and sliding drum as well as storage and keyway of the
main input shaft with warm water and enough tools (high pressure cleaner, brushes,
scraper, spatula, water hose ).
- Give basic cleaning to machine parts, in particular areas in contact with products,
individually with cleaning solvent according to cleaning plan, and with appropriate
tools (brushes, spray gun, low pressure foaming machine).
Strictly follow required effectiveness time of cleansers and disinfectants according to
instructions by their manufacturers!

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Maintenance

- Rinse off all cleaning solvent handled parts with ca. 60-70°C warm wa-
ter of drinking quality. For this a high pressure cleaner, low pressure
cleaning device, spray pistol or water hose is used. Meanwhile, however,
all safety precautions in this chapter must be absolutely adhered to!

- Check all cleaned parts for absolute cleanliness through certain visual
inspection. Repeat the cleaning measures if any product remains are not
removed!

- Disinfecting all handled parts with a disinfectant solvent according to

cleaning plans and with the necessary tools (high pressure cleaner, low
pressure foaming machine, spray gun, brushes etc.).
The effectiveness time on the product data sheet of the manufacturers of
cleaning and disinfectants, and other usage instructions must be followed
exactly!

- Clear rinse all disinfected parts with drinking water.

- Dry all handled parts (possibly with sterile and oil free compressed air)

- Oil all handled parts with a care product according to cleaning plan.

Attention: This cleaning and disinfecting work is extremely important for:

 Trouble free quality of the product

 Avoiding biological un-cleanliness of the product

 Fulfilling required hygienic laws

 Preserving value of the Vacuum filling machine

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Maintenance

5.3 MAINTENANCE AND CARE

 Safety regulations

With all maintenance, inspections and reconditioning work, the regulations

in the chapter s 1.4 and. 4.1 must be observed! In particular, the main
switch must be turned off (position "0") and secured with a lock. It is addi-
tionally recommended that the plug of the electrical cable be pulled from
the socket and the main circuit be turned off and made inaccessible for a
third party!

- Working on electrical components may only be carried out by an elec-

trician.
- Only original "REX" replacement, or exchanged parts are allowed to be
used. Non-compliance voids the guarantee responsibilities of the machine
manufacturer or their corporations and dealer representatives!
- Interference in the original-delivery condition of the machine controls is
strictly forbidden. Under no condition can changes be made to machine
controls or their components. This prohibition also includes the controls
(hard- and software side), the die wiring and the set up of devices. With
non-compliance the guarantees become void from the manufacturer or
their corporation!
- If the cover of the switch box is opened, it is absolutely necessary to
check the cover gasket for tightness and if necessary to revitalize!

5.4 MAINTENANCE AND UPKEEP

5.4.1 Daily maintenance (all 8 working hours)

- Independently from the cleaning plan, the outer machine housing must
be cleaned with a neutral cleaning agent and finally rubbed in with care oil
(appropriate means see chapter 5.2 Cleaning the vacuum filling machine).

- Check the conveyor parts for unscathed and abnormal operation. Re-
place valves with broken corners with original replacement parts at once.

- Visual control of the orders and report devices at the control panel.
Damaged or non-functionally safe parts must be immediately replaced.

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Maintenance

- Check all safety switches (Magnetic switches upper part, safety switch
for the folding hopper steps) on the function. If there should be a shortage
established, then the Vacuum filling machine is to be shut down immedi-
ately and cannot be put back into service before the shortage is repaired.

- Condition of the electric cable, the plug, and the socket must be visually
inspected for damages.

5.4.2 Weekly maintenance (every 40 working hours)

Generally Vacuum filling machine has intended greasing fittings (Figure 55, page
129). These are colored and marked and can be found immediately through
pointers. These cases apply:
greasing according to separate3 greasing instructions. Pre- grease fitting (grease
fitting) ca. 3,0 cm³ brings in fat.. Attention! Only moist edible fat on a synthetic
basis can be used according to USDA H1, such as e.g. Paraliq GA343. other
than fats are not allowed acc. to USDA H1, , because

-These are not permitted for use in food processing in the Vacuum fill-
ing machine.
-By mixing with other types of fat, the danger of "soaping" exists, and
therefore is a potential breakdown in the smearing process.

With damages through non-compliance with this instruction there is no responsi-

bility through the machine manufacturer or their corporation!

5.4.3 6 Month maintenance

(Every 1.000 operational hours, equivalent of 6 Months at 8h/day, but at VERY least once
yearly)

Maintenance can only be carried out through REX-technicians or through trained technicians
of our authorized appointed dealers. The work carried out by the maintenance is listed in the
service mask of our touch-control. The controls hints in intervals to the service work to be
carried out. (Figure 37, page 85)

For the maintenance of possible guarantee claims is a pre-requisite that all services have
been carried out and can be proven through filled out upkeep listed maintenance and these
are saved in the touch screen controls..

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Maintenance

Generally the following interval times are carried out:

- Checking all storages

- Cleaning, checking, necessary changes of the gaskets.
- Checking the conveyor for abrasion
- Check for possible exchange in the conveyor parts if increased wear is
given
- Check all safety and protection devices (see chapter 2.5 Protective de-
vices and their safety function, as well as chapter 1.4 and 4.1)

- Gasket and bearings change of the main motor and oil change of the
vacuum units. Greasing all the bearings and maintenance of the feeder
chain. In doing so the greasing regulations and instructions must be
obeyed exactly!

5.5 GREASING

 Tips for greasing

- The intended grease positions on the Vacuum filling machine have to

be greased regularly with the suggested grease by the manufacturer. This
is a basic requirement for operational free working of the vacuum filling
machine and a greater longevity. By possible guarantee claims, written
proof of regular greasing must be shown.
- Do not use different fats and oils for the same greasing position Danger
of “emulsion”. !
Even within a greasing group the grease types should not be mixed up!

- Check the grease functions. By fresh greasing the old grease squeez-
es out of the bearing position over the pipes at the built in fat outflow posi-
tions. If no recognized fat can be seen, the REX customer service must be
notified immediately.
- All of the grease instructions made are referring to time descriptions
based on a one shift operation (eight hour day). With the exception of skin
holding devices in which there is a higher greasing need in intervals.
Attention! Max. 0, 3 to 0, 5 cm³ grease refilled for grease positioning!

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Maintenance

2 upper part

1 main motor

Figure 55: grease points of the vacuum filling machine

3 Skin holding device

Figure 56: grease point for skin holding device

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Maintenance

 Signs und Symbols for greasing oils, hydraulic fluids and grease according to
DIN 51502

synthetic based oil

Hydraulic oil DIN 51524/2

synthetic based oil mineral based oil

operational oil DIN 51517/3
operating oil DIN 51517/3

Grease on wheat oil or synthetic based oil

Consistency sign numbers NLGI 1 or 2 according to DIN 51818

Required types of fat for greasing

machines in contact with food

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Maintenance

 Manufacturer type of grease chart RVF (excerpt)

Grease Gasket oil Grease oil Greasing fat NLGI 1

DIN 51506 DIN 51517/3 or 2
DIN 51818
Viscosity DIN ISO VG 068 ISO VG 220 NLGI – class 1 or 2
DIN 51519
Viscosity 100 mm²/s at 220 mm²/s at 40°C Walking penetration
40°C 265 - 295 or 310 –
340
Usage Vacuum pump operation Feeder motor,
RB 16 main motor,
built in motor
Filling 0,8 3,0
amount (Li-
ter)
Basis Synthetic based Mineral Synthetic based oil Wheat oil Syn-
oil/ based oil basis thetic
Mineral based oil oil
basis
Signs DIN
51502 Man-
ufacturer
Allowed USDA H1 --- USDA H2 USDA H1 USDA H1 USDA
H1
ARAL Aral Motanol Degol
GM68 BG 220
BP BP Energol Energol
CS68 PM 220
CASTROL Alpha TRIBOL
SP 220 1810/220
ESSO Esso Teresso 46 Spartan Run off oil Carum 330
EP220* S220
FUCHS Geralyn P2
KLÜBER Klüber oil Klüber oil Klüber- Klüber oil Paraliq Klüber
Summit Hy-Syn GEM1- synth 4UH1- synth
SG100 220 GH6-220 220 4UH1
14-151
MOBIL Mobil Mobil grease
gear 630 FM 102
SHELL Shell Talpa G 68 Omala Cassida
220 Grease 2
* Work related filled oil tapes

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Error search and repair

6. ERROR SEARCH AND REPAIR

6.1 CHECK LIST

 Safety precautions

With all maintenance and inspection work the guidelines in chapter 1.4 and.
4.1 must be observed! In particular the main switch must be turned off (po-
sition “0”) and secured with a lock. It is also recommended to pull the plug
out of the socket of the electrical cable and to turn off the net safety and
make it inaccessible for a third person!

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Error search and repair

Malfunction Possible cause Repair

Main motor (Electric mo- Hopper steps not sealed Close off hopper and steps
tor) does not run off
Feeder curve motor gear Feeder curve motor with- Grease feeder curve motor
operation slow out grease (see chapter 5 mainte-
nance)
Filling capacity is not  Not enough filling  Fill hopper
reached meats available for the
conveyor

 Vacuum canal stopped  Clean vacuum canal

with filling meats

 Vacuum pump filter is  Clean filter and ex-

clogged change (see chapter 5
maintenance)
 With solid materials no  Put in stopper
stopper used

 No scraper used  Put in scraper

 Filling material too cold  Do not use filling mate-

or solid rial below -4°C soften
filling meats.

 Vacuum ventilator on  Close vacuum ventila-

the vacuum holder is tor.
open
* In den other cases the technical customer service must be notified.

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Error search and repair

Malfunction Possible cause Repair

Inconsistent weight in Conveyor amount of the Reduced portion capacity

combination with attach- vacuum filling machine is or use a larger feeding
ments. insufficient amount in the vacuum
filling machine. *

Constant pressure not Program is adjusted Properly set program

adjustable wrong; set conveyor reduce feeding amount. *
amount exceeds the max-
imum conveyor capacity

Feeding curve does not Pinion of the sprung clutch Swing the clutch shaft
run shaft is hung up in swing- back and forth with the
ing housing. appropriate tools after the
opening of the swinging
housing. *

Inconsistent portioning in  Room temperature too  Let the vacuum filling

portioning program and low, not less than machine warm up
portioning with twisting +15°C
 Too cold and too solid  Filling temperature
mass should not be under -
4°C.
 No stopper with solid  Put in stopper
(hard) material

 Too high filling speed  Reduce filling speed

 Filling pipe too long or  Use short filling speed

too narrow-Ø with larger.

 Changing twisting posi-  Increase adjustable

tion through falling out relaxing time between
of filling material end of portion and start
of twisting. By cutting
watch out for small
parts of air in the filling
material.

* In den other cases the technical customer service must be notified.

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Error search and repair

Malfunction Possible cause Repair

Poor filling material venti-  Vacuum adjusted too  Adjust a higher vacu-
lation, voids in the filled low um with the "+"-key
wears.
 Vacuum system  Clean water separator
plugged and vacuum pipe.

 Container and cover of  Exchange container

the water separator and cover
non-tight
 Filter of water separa-  Clean filter and ex-
tor is plugged change (see chapter 5
Maintenance)

 No stopper used  Put in stopper

 Filling material too cold  Do not process filling

material under -4°C
 Filling material has too  Better quality work-
much air portions manship by filling
meats manufacturing
 Filling level sinks be-  Do not let filling
low the anti holding amount in hopper sink
curve. below 1/3

 Too low anti holding  Adjust anti holding

pressure at the filling pressure
tube.-

 Filling material falls  Quickly process cut up

apart in the feeding masses. *
wagon and the filling
hopper (resulting from
additives, e.g. fast ag-
ing material)

* In other cases the technical customer service must be notified.

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Error search and repair

Malfunction Possible cause Repair

No consistent separation  Coarse grained mass-  fill in individual portions

of individual portions from es or large pieces put in the passing ends
one another in e.g. with beer sau-
sage
 Irregular clip machine  pay attention to suffi-
speed by pressure air cient air pressure
clip machine.

Greasing/ put in filling ma-  Filling pipe too long, pr  Use possible short
terial fill pipe too narrow Ø filling tube with larger
diameter
 Filling meats too warm  Let filling goods cool
(put aside with down. Supervise cut-
Brühwurst) ting operation

 Filling material too cold  Filling temperature not

under -4°C
 Stopper not used  Use Stopper

 Filling speed too high  Reduce filling speed

(greasing with raw
sausage)

 Vacuum too low  With the "+"-key install

a higher vacuum pres-
sure

 Filling level sinks be-  Do not let filling

low the anti holding amount in hopper sink
curve. below 1/3

 Conveyor too warm  Cool down the con-

veyor with ice on the
temperature of filling
material. *

* In other cases, the technician, or customer service must be called.

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Error search and repair

 Filling- and Portioning problems RVF 327, 327 S, 330, 330 S

Problem Possible cause repairs

Porous cross-
Weight incon-
Grease prob-

Interruption

Tips on the
Ventilation

chart end
sistency

problem

problem
lems

cut

   Stopper not used 1 Use Stopper

 Stopper used Remove stopper

    Vacuum too low 1 Increase Vacuum

     Filling speed too 1,2 Reduce filling speed

high

     Filling tube too 1,2 Shorter filling tube

long

     Filling tube too 1,2 Wider filling tube

narrow

    Filling level in the Refill earlier

hopper too low

 Use of feeding dismantle

curve

  Too much air in Use restrictor

filling material

 Vacuum filling with When filling without vacuum,

thin fluid material put stopper in the vacuum
tube of inspection glass, also
turn off withdrawal
use filling tube for thin fluid
material, pre-inject at filling
begin for the ventilation of the
conveyor and the filling tubes.

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Error search and repair

Problem Possible cause repairs

Weight incon-
Grease prob-

Porous cross

Interruption

Tips on the
Ventilation

chart end
sistency

problem

problem
lem

cut

    Vacuum canal is 1 clean

stuffed with filling
material

 adjusted non ten- Chose longer non tension

sion time too short time

  Filling material too Cool filling material

warm

   Filing material in 1 Warm up processed filling

the minus area too material
cold.

 Specific weight too 3 Fill hopper full, change weight

inconsistent in weight correction mask.

    Standing time be- 4 Shorten standing time

tween cutting time
and filling of the
raw sausage is too
long.

 Too hard cut up Cut filling material according

filling material. to instructions

 Cut up filling mate- Change cutting process

rial too warm

    Air proportion too Use sharp cutting knife

great through dull
cutting knife.

  Chamber in the Enlarge chamber; use pump

conveyor too rotor with less wings
small.

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Error search and repair

 Suggestions:

1. Pulsing filling output, strong greasing and inconsistent weight result from insufficient
adding of filling material.

2. High filling pressure leads to:

excessive leaking mass, clogging of the vacuum system, poor ventilation, weight in-
consistencies and grease effect.

3. Different composition of filling material and processing on numerous cutters with dif-
ferent technical conceptions can lead to extreme specific weight inconsistencies.

4. With a longer standing time there is the danger of the filling material unbinding, espe-
cially by use of fast aging material. (E.g. GDL).

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Putting out of service

7. PUTTING OUT OF SERVICE

7.1 SHUTTING DOWN THE VACUUM FILLING MACHINE

 Release and dispose of all used oils from diverse components of the vacuum filling ma-
chine (hydraulic aggregates, vacuum pumps and motors).
With the disposal of used oils, all environmental regulations must be observed.

 The vacuum filling machine must be disposed in compliance with all specific
legal disposal laws of the specific country.

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Explanations

8. EXPLANATIONS

8.1 GIVING OVER DECLARATION

The company: _________________________________

_________________________________
_________________________________
Customer -Nr. _________________________________
The Vacuum filling machine
Type________ Mach. Nr.____________
The Vacuum filling machine was
At: ________ from:_________________ installed
At: ________ from:_________________ presented
Operation overtaken.
By the presentation / being put into operation all safety measures and safety precautions according to
the operation manual of the Vacuum filling machine are explained and commented on. The following
persons were shown:
________________________________ ____________________________

_____________________________ __________________________
The machine operation, servicing, and upkeep were declared and commented on through the opera-
tion manual. The following persons were shown:
_________________________________ ____________________________

______________________________ __________________________
In presenting the Vacuum filling machine with products, the following persons were shown and worked
in:
__________________________________ ____________________________

_______________________________ __________________________
The operation manual for the vacuum filling machine
Type: _________________ Nr. ____________________
Was given over on: ___________________
Protocol executed on: _________________________

________________________________ ___________________________

(Signature /stamp customer authorized) (Signature of the installer/performer)

Please send back the signed original to the manufacturer /representative

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Explanations

8.2 CONFORMITY DECLARATION

according to Machinery Directive 2006/42/EC
Name and address of manufacturer:

REX-Technologie GmbH & Co. KG

Irlachstr. 31, A-5303 Thalgau

Category, type and brand or trademark:

REX vacuum filler RVF 327/330
No: 10032711 -10032713 and 10033011-10033013
The device complies with the following directives:
Framework directive 89/109/EEC,
harmonised internationally in accordance with Agreement RD 14A/1-38 of 24.11.2000 in the
status of Ordinance 1935/2004 of 27.10.2004, supplemented by Directive 92-631 of 8.7.1992 and
Ordinance 2023/2006 of 22.12.2006

Inspection for foodstuff authenticity in accordance with Directives 82/711/EEC, 87/572/EEC,

93/8/EEC and 97/48/EC,
EU Machine Directive (2006/42/EC),
EU Low Voltage Directive (2006/95/EC),
Framework Directives 89/391/EEC together with 89/655/EC,
EMV-Directive 2014/30/EU,
Pressure Equipment Directive 1997/23/EC,
Plastics are in accordance with Directive 2002/72/EC in conjunction with Directive 90/128/EEC
in the form of 96/11/EC.
The risk analysis was conducted:
in accordance with DIN EN ISO 12100: 2013 together with EN ISO 14121-1

Risk analysis
Risk analysis number: M 2014 126 from 10.10.2014
The norms and regulations complied with in the risk analysis can be found in the attached list.

Inspection report, which confirmed the risk-free operation:

Inspection site: A.S.S.-experts kurz ges.m.b.H.
Neualmerstr. 37, A-5400 Hallein
Date and number of test certificate: 15.10.2014, M 2014 127
Issued in Thalgau on 15.10.2014
Manufacturer: Inspection site:

REX-Technologie GmbH & Co. KG A.S.S-experts kurz ges.m.b.H.

Christian Haas (managing director) Dir. Prof. Dipl.-Ing. Franz Kurz (inspecting body)
……………………………………….. …………………………………….
(Signature of the managing director under trade law) (Signature)

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Explanations

List of the applied ordinances and norms:

Ordinances complied with during production:

ORDINANCE (EC) number 1935/2004, materials for contact with foodstuffs

ORDINANCE (EC) number 2023/2006, manufacturing procedure for materials for contact
with foodstuffs

Derived norms to be applied:

EN ISO 12100:2013 in conjunction with EN ISO 14121-1, safety related design

EN 62061:2010, functional safety
EN ISO 13849-1:2009 (EN 954-1), safety related parts during steerings
EN 60204-1:2009 electrical equipment
EN 12463:2011, filling machines and auxiliary machines for foodstuffs
EN 1672-2:2009, general design of foodstuff machines
EN ISO 13857:2008, dangers and safety margins in case of machines
EN 842:2009, optical danger signals
EN ISO 14159:2008, hygiene requirements and machine safety
EN 55011:2011, wireless disruptions in the case of machines
EN 61000-3-2/AC:2011, electromagnetic capacity - harmonics
EN 61000-3-3/AC:2014, electromagnetic capacity - upper values
EN61000-6-2/AC:2011, electrical magnetic tolerance - noise immunity
EN60950-1:2014, data processing and data interfaces
EN 61140:2007 protection against electric shock
EN 61310-1:2008, display and use of machines - optical, acoustic
EN 61310-2:2008, display and use of machines - identification
EN 61310-3:2008, display and use of machines - control devices
EN 62310-3:2008, static transfer systems - operation and inspection

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Explanations

8.3 NOTES

page 144 of 144 Version 1.5