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Koch Ultravac 250, Owner'S Manual

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Koch Ultravac 250 Owner'S Manual Download Page 36

8 6 0 1 0 8 • Q

MAIN: 816-753-2150

TOLL FREE: 800-777-5624

INTERNET: kochequipment.com

E-MAIL: [email protected]

S C H E M A T I C S   •   P A G E   5 . 7

 Gas Flush Pneumatic Diagram

VACUUM 
PORT

SEAL BAR

GAS NOZZLE

VACUUM 

GAUGE

SOL-2

SEAL

1

2

3

GAS INLET

V-1

QUICK

EXHAUST

ATMOSPHERE

A

R

P

SOL-3

GAS

2

1

SOL-1

VENT

OUT

IN

ATMOSPHERE

VACUUM PUMP

INLET

Summary of Contents for Ultravac 250

Page 1: ...Ultravac 250 Vacuum Chamber Packaging Machine 860108 Revision Q Date 01 2009...

Page 2: ...on 3 7 MAINTENANCE Prior to Cleaning 4 1 Cleaning Recommendations 4 1 Vacuum Pump Maintenance 4 2 Seal Bar Maintenance 4 2 Reading the Indicators 4 3 Troubleshooting 4 4 Supervisor Menu on Digital Pan...

Page 3: ...26mm 32 5 in Working Height D 365mm 14 375 in Seal Bar Length 406mm 16 in Chamber Length E 505mm 19 875 in Chamber Width F 422mm 16 625 in Chamber Height G 171mm 6 75 in Between Seal Bar and Back of C...

Page 4: ...ne Failure to follow operating instructions could result in personal injury or damage to equipment WARNING WARNING Explosion hazard Do not use a gas with an oxygen content greater than 22 with gas flu...

Page 5: ...kaging M A P to review the safety of your application Gas Flush In order to ensure proper shelf life of the food product packaged in this machine you must contact a reputable food technologist or spec...

Page 6: ...ipment grounding conductor can result in a risk of electric shock The equipment grounding conductor outer surface is green with or without yellow stripes If repair or replacement of the cord or plug i...

Page 7: ...ifferent type of electric circuit the reconnection should be made by qualified service personnel and after the reconnection the appliance should comply with all local codes and ordinances Grounding Pi...

Page 8: ...Connection The machine is equipped with a regulator for air assisted sealing The hose barb will accept 1 4 in I D hose The recommended air supply is 75 p s i at 6 c f m The maximum regulator setting...

Page 9: ...he pouch Keep the product and the product residue away from the seal area of the pouch Place the product as far into the pouch as possible Maintain an equal amount of the product above and below the s...

Page 10: ...dial Seal impulse is the length of time the seal bar is turned on and can range from 0 to 2 seconds The impulse time is controlled by the Seal Potentiometer Koch Equipment recommends an initial setti...

Page 11: ...feature turned on these programs cannot be inadvertently changed The VACPLUS option allows the operator to run the pump from 0 to 20 seconds after the set vacuum level is achieved The Gas Flush optio...

Page 12: ...that was run will be the current program shown in the window To set the operating parameters for the program shown press the MENU key VACUUM is set to vacuum using the UP and DOWN Arrow Keys The rang...

Page 13: ...zard Do not use a gas with an oxygen content greater than 22 with gas flush option If the machine is equipped with the gas option it can be turned on or off by pressing the UP or DOWN arrow keys Press...

Page 14: ...S NO PROGRAM YES NO Selecting a New Program From the Main Menu use the UP and DOWN Arrow Keys to select a new program Press the UP Arrow to switch to program 2 or any of the ten programs New parameter...

Page 15: ...eal Option Gas Flush Option Gas flushing is the introduction of an inert gas into the chamber after the vacuum stage is finished Gas can be used as a filler to prevent crushing of the product after se...

Page 16: ...8 6 0 1 0 8 Q MAIN 816 753 2150 TOLL FREE 800 777 5624 INTERNET kochequipment com E MAIL info kochequipment com O P E R A T I O N P A G E 3 8 THIS PAGE LEFT BLANK INTENTIONALLY...

Page 17: ...CAUTION CAUTION Cleaning agents Do not get the cleaning agents in eyes on skin or on clothing Always wear rubber gloves goggles and protective clothing when contact is likely Consult product manufactu...

Page 18: ...nd the spring at this time loosen the set screw and remove the old spring retainer and spring and install the new ones Adjust the spring retainer to allow a 1 8 in gap between the spring retainer and...

Page 19: ...icator lights correspond to the operating devices and should turn on and off in the following sequence when the machine lid is closed 1 Vacuum Pump C 1 2 Gas Flush Valve SOL 3 optional 3 Seal Bladder...

Page 20: ...ntake screen in vacuum pump hose barb for blockage pieces of bags labels bone etc Longer vacuum cycle times Check intake screen in vacuum pump hose barb for blockage No gas flush optional If indicator...

Page 21: ...ck seal bar connection points and clips for corrosion and proper tension The red seal light on the front panel either does not light for the proper length of time to 1 second or does not light at all...

Page 22: ...seal to cool down and take set The range is 1 to 8 seconds Press the MENU key SECURITY can be turned on by selecting YES If security is on the operator menu will be read only and the operator will not...

Page 23: ...n simply opening the vacuum valve for a continuous vacuum the valve is opened and closed repeatedly until the chamber reaches the set vacuum level Press the MENU key The vacuum reached by pulsing the...

Page 24: ...alve for a continuous vent the valve is opened and closed repeatedly until the chamber vents back to atmosphere pressure Press the MENU key The vacuum reached by pulsing the vent valve before the vent...

Page 25: ...alve for a continuous vent the valve is opened and closed repeatedly until the chamber vents back to atmosphere pressure Press the MENU key The vacuum reached by pulsing the vent valve before the vent...

Page 26: ...MENU key If the loop is set greater than 1 the control can be set to exit the loop on either the last gas cycle or the last vacuum cycle prior to sealing The DOWN arrow key indicates NO and the UP arr...

Page 27: ...achine between the pump and front edge of the chassis Slide the machine over to the edge of the table with the hole over the edge of the table Position an oil collection pan underneath this hole CAUTI...

Page 28: ...grip nut on the rear of the machine Remove the cord from the cable clamps on the bottom of the chamber Disconnect the cord from the control panel 4 Route the new power cord through the cord grip on th...

Page 29: ...for further maintenance A maintenance log will clearly show oil changes daily inspections Teflon tape replacement and so on A master copy has been provided on page 4 14 please create a copy and store...

Page 30: ...mp Contactor for 220 VAC C 2 Seal Impulse Contactor for double seal bar Overloads and Fusing OL 1 Vacuum Pump Motor Overload F 1 Seal Bar Fuse F 3 Control Power Fuse Control Modules MCC Master Control...

Page 31: ...gle Phase Analog Digital Control Panel H1 MASTER CONTROL CIRCUITBOARD X2 X3 ELEMENT SEAL 48V SOLENOID LID SWITCH LS 1 TRANSFORMER T1 SEAL SOL 1 VENT VALVE SOLENOID VALVE SEAL SOL 2 110V H4 110V H2 H3...

Page 32: ...log Digital Control Panel H1 MASTER CONTROL CIRCUITBOARD X2 X3 ELEMENT SEAL 48V SOLENOID LID SWITCH LS 1 TRANSFORMER T 1 SEAL SOL 1 VENT VALVE SOLENOID VALVE SEAL SOL 2 220V H4 220V H2 H3 VALVE SOLENO...

Page 33: ...VALVE SOLENOID VALVE SEAL SOL 2 VALVE SOLENOID SOL 3 GAS 18 17 16 15 14 13 11 12 10 SINGLE PHASE 110 V VACUUM PUMP 2 LINE GND NEU GRD 1 M 1 CHASSIS GROUND OL 1 THERMAL 9 8 7 6 4 5 3 2 1 19 IMPULSE CON...

Page 34: ...WITCH LS 1 TRANSFORMER T 1 SEAL SOL 1 VENT VALVE SOLENOID VALVE SEAL SOL 2 220V H1 220V H3 H2 VALVE SOLENOID SOL 3 GAS 18 17 16 15 14 13 11 12 10 SINGLE PHASE 220 V VACUUM PUMP 2 LINE GND NEU GRD 1 M...

Page 35: ...T kochequipment com E MAIL info kochequipment com S C H E M A T I C S P A G E 5 6 Non Gas Flush Pneumatic Diagram VACUUM PORT SEAL BAR VACUUM GAUGE SOL 1 VENT ATMOSPHERE IN OUT VACUUM PUMP INLET SOL 2...

Page 36: ...uipment com E MAIL info kochequipment com S C H E M A T I C S P A G E 5 7 Gas Flush Pneumatic Diagram VACUUM PORT SEAL BAR GAS NOZZLE VACUUM GAUGE SOL 2 SEAL 1 2 3 GAS INLET V 1 QUICK EXHAUST ATMOSPHE...

Page 37: ...ft 840170 Teflon Tape 7 ft 860220 Lid Gasket 3 ft 860950 Backup Strip 1 ea 860337 Fuse GMC 1 Amp 1 ea 860045 Fuse MDA 10 Amp for 110VAC with Single Seal Bar or 220VAC with Double Seal Bar 2 ea 860338...

Page 38: ...g Transformer T 2 Single Seal Bar 860044 Sealing Transformer T 2 Double Seal Bar 8 866716 Screw M5x10 Slotted Panhead 9 866604 Cord Grip PG13 5 10 860291 Brass Hex Nut 3 8 in 24 11 860109 Fitting Dual...

Page 39: ...8 6 0 1 0 8 Q MAIN 816 753 2150 TOLL FREE 800 777 5624 INTERNET kochequipment com E MAIL info kochequipment com P A R T S P A G E 6 3 Pump and Chassis Diagram...

Page 40: ...l Bladder Assembly 3 860074 Seal Bar Standoff 4 860973 Fiberglass Insulator Strip 5 860034 Sealing Element 6 860035 Cutting Wire optional 7 860170 Teflon Tape 8 860033 Brass Electrical Contact 9 86027...

Page 41: ...8 6 0 1 0 8 Q MAIN 816 753 2150 TOLL FREE 800 777 5624 INTERNET kochequipment com E MAIL info kochequipment com P A R T S P A G E 6 5 Seal Bar Diagram...

Page 42: ...ssembly 7 861322 Hinge Block 8 860150 Shaft Stainless Steel Tube 1 4 in x 11 in Long 9 860027 Gas Spring 10 860026 Anchor Block 11 860028 Ball Stud 10mm 12 860073 Gas Spring Disconnect 13 860252 Screw...

Page 43: ...8 6 0 1 0 8 Q MAIN 816 753 2150 TOLL FREE 800 777 5624 INTERNET kochequipment com E MAIL info kochequipment com P A R T S P A G E 6 7 Lid and Hinge System Diagram...

Page 44: ...ally Closed 220VAC 2 860123 Bracket 3 866273 Fitting Aluminum Elbow 4 860532 Quick Exhaust Valve V 1 5 860535 Close Nipple 1 8 in 6 860530 Hose Barb 1 8 in x 1 4 in Straight 7 860107 Fitting Hose Tee...

Page 45: ...8 6 0 1 0 8 Q MAIN 816 753 2150 TOLL FREE 800 777 5624 INTERNET kochequipment com E MAIL info kochequipment com P A R T S P A G E 6 9 Gas Flush Components Diagram...

Page 46: ...60832 Gauge 2 in Vacuum 6 860837 Decal Front Panel 7 860843 Potentiometer Control Panel 8 860045 Fuse MDA 10 Amp for 110VAC with Single Seal Bar or 220VAC with Double Seal Bar 861192 Fuse MDA 8 Amp fo...

Page 47: ...8 6 0 1 0 8 Q MAIN 816 753 2150 TOLL FREE 800 777 5624 INTERNET kochequipment com E MAIL info kochequipment com P A R T S P A G E 6 1 1 Analog Control Panel Diagram 2 11 5 3 4 6 1 7 8 12 10 9 14 13...

Page 48: ...nel 110 Volt for 110 volt two seal bar machines 861115 Digital Panel 220 Volt for 220 volt machines 2 860316 Main Power On Off Switch SW 1 4 860045 Fuse MDA 10 Amp for 110VAC with Single Seal Bar or 2...

Page 49: ...166 Vacuum Valve and Screws 220 Volt 2 860188 Vacuum Block Spacer 3 860192 Vacuum Block Cover 4 866844 Screw M6x20 Flat Socket Head 5 860838 Valve Quick Exhaust for gas flush machines replace elbow in...

Page 50: ...4 Miscellaneous Machine Parts Parts List and Diagram Item No Koch Part No Description 1 860049 Filler Plate Set for one seal bar machine 860125 Filler Plate Set for two seal bar machine 2 840051 Stain...

Page 51: ...S P A G E 6 1 5 Pump Filter Option Parts List and Diagram Item No Koch Part No Description 1 861197 Filter Vacuum 3 4 in NPT 2 861198 Filter Element for 861197 3 861199 Piping 3 4 in NPT 90 Elbow M F...

Page 52: ...INSTALLATION AND OPERATING MANUAL R5 Series Model 0021 Single Stage Rotary Vane Vacuum Pump...

Page 53: ...Filter 3 3 Exhaust Filter 3 4 Vacuum Inlet Filter 3 5 Maintenance Chart 3 6 Overhaul Kit Filter 4 0 TROUBLESHOOTING 5 0 LIMITED STANDARD WARRANTY Exploded View Drawings of Pumps Parts Lists for Pumps...

Page 54: ...for connection to your system 1 2 Location The pump must be installed in a horizontal position on a level surface so that the pump is evenly supported on its rubber feet Allow at least one foot five f...

Page 55: ...e each pump should have its own manual or automatic operated shut off valve or positive action check valve The built in anti suck back valve should not be used as a shut off valve for the vac uum syst...

Page 56: ...lug Ref 88 making sure that the gasket Ref 89 is in place and properly seated and secured Some pumps are equipped with an exhaust pressure gauge as an integral part of the oil fill plug 2 0 OPERATION...

Page 57: ...ooled Pumps optional Water cooled pumps are cooled by circulating the oil through a shell and tube type heat exchanger The cir culation of the pump oil through the shell is created by vacuum in the pu...

Page 58: ...s ballast open on RA pumps the water will be purged from the oil If the oil is dark colored it is con taminated or carbonized and must be changed Depending on the severity of the contamination a thor...

Page 59: ...p as part of the oil fill plug This gauge has a green field and a red field A pressure within the green field would indicate normal pressure Any pressure in the red field for a continuos period of tim...

Page 60: ...off pressure can be measured by using a good quality cap sule gauge 4 1 1 Possible Cause Contaminated oil is by far the most common cause of not reaching the ultimate pressure Remedy Shut off pump aft...

Page 61: ...setting fuses are burned or wire is too small or too long causing a voltage drop to the motor Remedy Check correct supply voltage check overload settings in motor starter for size and setting accordi...

Page 62: ...il return valve Ref 275 is stuck open on RA RB pumps Proper function is that when blowing into check valve it should close When applying vacuum on it check valve should open Remedy Free or replace the...

Page 63: ...2 Possible Cause Automotive type oil filter clogged and pump does not receive enough oil not applicable on 0010 0012 0016 or 0021 Remedy Change automotive oil filter 4 6 3 Possible Cause Not enough oi...

Page 64: ...n the product has been properly installed used in a normal manner and serviced according to the operating manu al This warranty shall not extend to products that have been misused neglected altered or...

Page 65: ...Illustration of R5 0012 0021 Series 15...

Page 66: ...elbow fitting 222 Hydraulic straight fitting 223 Hydraulic straight fitting 224 Hydraulic elbow fitting 231 Oil tubing 240 Cooling coil 251 Valve plate 252 Valve guide 253 O ring Viton 254 Inlet check...

Page 67: ...0 62 1 phase motor data 2 kW 0 75 0 90 Volts 115 230 RPM 1750 3330 Frame R80N E8F2B3 Amps 10 7 0 Approx oil capacity Qts 0 5 0 5 0 5 0 5 7 14 16 42 44 Inlet connection NPT inch 3 4 1 hose 3 4 3 4 2 3...

Page 68: ...6 13 Miscellaneous Machine Parts 6 14 N No Gas Flush 4 4 Non Gas Flush Pneumatic Diagram 5 6 No Vacuum 4 4 Number of Programs 4 6 O Oil 2 3 6 1 Oil Drain Plug 4 11 Oil Filler Cap 4 11 Opening Chamber...

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