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CONTINUOUS VACUUM 
FILLER 
Model 
RS 501 
RS 503 
RS 505 
INSTRUCTION 
MANUAL 
 
 
 
 
 
 
 
 
RISCO S.P.A. 
Workhouse and offices: Via della Statistica, 2 - 36016 THIENE-VICENZA-ITALY 
 Revision 3C-CUS 
 
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This page has been left blank intentionally. 
 
 
 
 
 
 
 
 
 
 
 
 
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1 “CE” DECLARATION AND MARK 
1.1 “CE” Declaration 
The original copy of the “CE” Declaration, in countries where it is required, is given to the customer 
together with the instruction manual. 
1.2 “CE” Mark 
The “CE” mark certifies the conformity of the machine to the essential requisites of safety and health 
required by the Machine Directive. 
The marking consists of a black screen-printed plate with the following dimensions: base 90 mm, 
height 58 mm and thickness 1 mm. 
This plate is applied on the machine in the position indicated in Fig. 1 and attached with four rivets. 
The following information is indicated in English on the plate in a legible and indelible manner: 
• the logo, name and address of RISCO 
• the “CE” mark 
• the machine model 
• the serial number 
• the year of fabrication 
• the power supply in volts, with the number of phases (Ph) and the frequency (Hz) 
• the control voltage 
• the power rating 
• the weight of the machine 
 
Fig. 1: "CE" plate and its position 
 
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2 ORGANISATION OF THE CONTENTS AND METHOD OF 
CONSULTATION 
2.1 How to read the manual 
This manual is composed of 128 pages. 
The manual must be read in its entirely and perfectly understood. If you have any doubts 
regarding the comprehension of any part, please contact RISCO for clarification (see contact 
information on the front cover of the manual). 
The way the manual is structured facilitates consultation. It is sufficient to examine the Table of 
Contents (see Cap.3 -TABLE OF CONTENTS) and find the subject you are interested in, and then 
consult it on the respective page or chapter. 
 
For example: 1.2 indicates Chapter 1 ,section 2 
• 1 identifies Chapter 1-““CE” dECLARATION AND MARK “; 
• 2 identifies section 2 of Chapter 1 ““CE” Mark“. 
Boldface type: highlights important terms or phrases in the text. 
Italics: used for the captions of figures and tables. 
The figures and tables are numbered in increasing order independently from the chapter in which 
they are included. In the event that the binding of the manual breaks, it is always possible to 
reconstruct the order of the pages using the page number or the order of the chapters and sections 
with the respective numbers. 
Any notes or comments made by the user should be written in the dedicated spaces provided in 
the manual. 
2.2 Frequently used symbols and terms 
The symbols and terms that are often used in this manual are explained in the following sections. 
 
 
Symbol or 
term 
Explanation 
 
GENERIC DANGER 
 
GENERIC OBLIGATION 
 
OBLIGATION TO READ THE MANUAL 
 
MACHINE OFF 
Before performing any type of servicing operation and/or adjustment on the machine, it is 
obligatory to switch off all power sources (electrical, pneumatic, hydraulic, etc.), making 
sure that the machine is actually stopped and that no accidental start-up can occur. For the 
procedure in detail, see Sect.18.6. 
 
 
 
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IT IS FORBIDDEN TO LEAVE FILLER SWITCHED ON 
UNATTENDED 
If - for any reason - the filler has to be left unattended, it is 
compulsory to firstly switch it off. For the detailed procedure see 
Par.18.6. 
 
HIGH VOLTAGE DANGER 
 
HOT SURFACE DANGER 
Danger zone Any zone within and/or near a machine in which the presence of 
an exposed person constitutes a risk to personal safety and 
health. 
Exposed person Any person situated wholly or partially within a danger zone. 
Table 1: Safety signs and terms 
 
THE GENERIC DANGER SYMBOL AND THE TEXT IN UPPER-CASE LETTERS ON A 
GREY BACKGROUND CALL THE READER’S ATTENTION TO THE PRECAUTIONS 
GIVEN IN THE MANUAL 
 
MAKE SURE YOU UNDERSTAND AND MEMORISE THE MEANING OF EACH SYMBOL 
AND TERM BEFORE CONTINUING TO READ THE MANUAL. 
2.3 Operators “authorised” to use and service the machine: symbols and description 
The symbols indicated below are placed at the beginning of a chapter and/or section to indicate 
which operator is "authorised" for the use and servicing of the machine based on the specific 
technical-professional competence required for the type of operation in question. 
 
 
THE “AUTHORISED” OPERATOR MUST ONLY PERFORM ON THE MACHINE THE 
OPERATIONS THAT FALL WITHIN HIS SPECIFIC AREA OF COMPETENCE. 
 
Symbol Operator 
 
(O) MACHINE OPERATOR: 
A professionally trained operator, at least 18 years old, in respect for the legislation in force in 
the country of use, qualified to perform the following operations on the machine: 
• switch-on 
• operation 
• switch-off 
Operates exclusively: 
• in absolute respect for the instructions given in this manual. 
• with the safety devices engaged. 
 
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Symbol Operator 
 
(M) MECHANICAL / HYDRAULIC / PNEUMATIC MAINTENANCE TECHNICIAN: 
A qualified technician, enabled to perform operations exclusively on mechanical / hydraulic / 
pneumatic organs to carry out adjustments, maintenance, and/or repairs. 
Can work with the safety devices disengaged (upon approval of the safety manager). 
Does not work on electrical systems with live voltage. 
Works in absolute respect for the instructions given in this manual or any other specific manual 
supplied exclusively by RISCO. 
 
(E) ELECTRICAL MAINTENANCE TECHNICIAN: 
A qualified technician (electrician having the technical-professional requisites required by the 
regulations in force), enabled to perform operations exclusively on electrical devices to carry out 
adjustments, maintenance, and/or repairs, also in the presence of live voltage. 
Can work with the safety devices disengaged (upon approval of the safety manager). 
Works in absolute respect for the instructions given in this manual or any other specific manual 
supplied exclusively by RISCO. 
 
(T) RISCO TECHNICIAN: 
A qualified technician provided by RISCO and/or by the authorised reseller to carry out the 
technical service requested, operations of special maintenance and/or operations not described in 
this manual that required a specific knowledge of machine. 
 
(R) MACHINE SUPERVISOR 
A person with the necessary professional competences to coordinate the machine operators, the 
mechanical/hydraulic/pneumatic technicians, and the electrical technicians. 
• Ensures that all the “authorised” operators have read and understood the manual and that 
they have it on hand. 
• Ensures that all the “authorised” operators understand and apply the safety rules provided 
in the manual. 
• Ensures that all the “authorised” operators wear and use their personal protective 
equipment. 
• Establishes when and which “authorised” operators can access the machine. 
• Assigns and coordinates the personnel in charge of installing the machine. 
• During the operations of installation, routine maintenance, special maintenance, and repair, 
he ensures that only the personnel strictly necessary for such operations are located in the 
areas subject to accident risks. In the event of machine malfunction or breakdown, he 
communicates the status of the machine to all the “authorised” operators and disconnects 
all types of power supply to the machine. 
• Decides when the assistance of the RISCO technician is required. 
Table 2: Operators authorised for machine use and maintenance 
 
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3 TABLE OF CONTENTS 
1 “CE” DECLARATION AND MARK 3 
1.1 “CE” Declaration .....................................................................................................................31.2 “CE” Mark ...............................................................................................................................3 
2 ORGANISATION OF THE CONTENTS AND METHOD OF CONSULTATION 4 
2.1 How to read the manual ...........................................................................................................4 
2.2 Frequently used symbols and terms.........................................................................................4 
2.3 Operators “authorised” to use and service the machine: symbols and description..................5 
3 TABLE OF CONTENTS 7 
4 INDEX OF FIGURES 11 
5 INDEX OF TABLES 13 
6 OVERVIEW 15 
6.1 Scope and limits of this manual .............................................................................................15 
6.2 Copyright ...............................................................................................................................15 
6.3 Limitations to the dissemination of the manual .....................................................................15 
6.4 Identification of the machine .................................................................................................15 
6.5 Method for ordering a new copy of the manual.....................................................................16 
6.6 Technical service ...................................................................................................................16 
6.7 Preface to the general safety rules .........................................................................................16 
6.8 Personal protective equipment (PPE) ....................................................................................16 
6.9 General safety rules for all personnel ....................................................................................17 
6.10 General safety rules for the mechanical maintenance technician ..........................................18 
6.11 General safety rules for the electrical maintenance technician..............................................18 
7 PRESENTATION OF THE MACHINE AND TECHNICAL DATA 19 
7.1 Name of the machine .............................................................................................................19 
7.2 Names of the main components .............................................................................................19 
7.3 Machine dimensions ..............................................................................................................22 
7.4 Technical data ........................................................................................................................22 
7.5 Knee lever switch...................................................................................................................23 
7.6 Optional devices.....................................................................................................................23 
7.6.1 Multiple socket for external connections .....................................................................23 
7.6.2 FRL compressed air unit ..............................................................................................23 
7.7 Optional accessories recommended by RISCO ....................................................................24 
7.8 Noise ......................................................................................................................................25 
7.9 Products used for processing .................................................................................................25 
8 INSTALLATION 27 
8.1 Installation personnel .............................................................................................................27 
8.2 Machine delivery ...................................................................................................................27 
8.3 Packing...................................................................................................................................27 
8.4 Storage methods.....................................................................................................................27 
8.5 Machine movement and handling..........................................................................................28 
8.5.1 Lifting with a crane ......................................................................................................28 
8.5.2 Lifting with a forklift ...................................................................................................29 
8.6 Physical characteristics of the installation site.......................................................................29 
8.7 Positioning .............................................................................................................................29 
8.8 Levelling the machine............................................................................................................30 
8.9 Electrical hook-up..................................................................................................................30 
8.10 Pneumatic hook-up ................................................................................................................31 
8.11 Testing and start-up................................................................................................................32 
9 OPERATION AND USE 33 
9.1 Permitted use..........................................................................................................................33 
9.2 Non-permitted use..................................................................................................................33 
 
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9.3 Directives and standards of reference.................................................................................... 33 
9.4 Safety systems adopted.......................................................................................................... 33 
9.5 Safety signs............................................................................................................................ 35 
9.6 Residual risks for the operator............................................................................................... 35 
9.7 Information on the residual risks ........................................................................................... 39 
10 INSTRUCTIONS FOR ASSEMBLY 41 
10.1 Fitting the vacuum suction filter............................................................................................ 41 
10.2 Fitting the hopper parts.......................................................................................................... 41 
10.3 Fitting the extruder cone........................................................................................................ 42 
10.4 Fitting the filling pump unit .................................................................................................. 43 
10.5 Closing the hopper plate ........................................................................................................ 44 
11 FILLER OPERATING MODES 45 
11.1 Knee lever switch operating modes....................................................................................... 45 
11.2 Machine operating modes...................................................................................................... 45 
11.3 Special machine functions ..................................................................................................... 46 
12 OPERATING INSTRUCTIONS: MACHINE START-UP 49 
12.1 Adjusting the position of the knee lever................................................................................ 49 
12.2 Controls to perform prior to switch-on.................................................................................. 49 
12.3 Presentation of the control panel ...........................................................................................51 
12.4 Machine switch-on ................................................................................................................ 52 
12.5 How to enter values ............................................................................................................... 53 
12.6 How to correct the values entered ......................................................................................... 53 
12.7 Modifying/setting operating parameters with the pump in operation ................................... 55 
12.8 Functions common to all operating modes............................................................................ 55 
12.8.1 Vacuum pump.............................................................................................................. 55 
12.8.2 Knee lever switch ........................................................................................................ 55 
12.9 Adjustments common to all the operating modes ................................................................. 56 
12.9.1 Adjusting the speed of the filling pump ...................................................................... 56 
12.9.2 Adjusting the rotor return ............................................................................................ 56 
13 OPERATING INSTRUCTIONS: OPERATION IN CONTINUOUS MODE 57 
13.1 Selecting the continuous mode .............................................................................................. 57 
13.2 Selecting the desired continuous mode ................................................................................. 57 
13.3 Indications provided by the control panel for continuous mode ........................................... 58 
13.4 Starting the machine in continuous mode ............................................................................. 59 
14 OPERATING INSTRUCTIONS: OPERATION IN PORTION MODE 61 
14.1 Selecting portion mode.......................................................................................................... 61 
14.2 Appearance of the display for portion mode ......................................................................... 61 
14.3 How to scroll from a display upper row to the subsequent ones........................................... 62 
14.4 First display adjustment row ................................................................................................. 62 
14.4.1 Adjusting the speed of the filling pump ...................................................................... 62 
14.4.2 Adjusting the rotor return ............................................................................................ 62 
14.4.3 Adjusting the portion weight ....................................................................................... 62 
14.4.4 Adjusting the pause time between one portion and the next ....................................... 63 
14.4.5 Adjusting the speed of the twister (optional)............................................................... 63 
14.4.6 Pause time and twister speed ....................................................................................... 63 
14.5 Second display adjustment row ............................................................................................. 64 
14.5.1 Adjusting the first piece increase................................................................................. 64 
14.5.2 Adjusting the clipper anticipation/portion anticipation ............................................... 64 
14.5.3 Adjusting the piece counter ......................................................................................... 65 
14.5.4 Programming block ..................................................................................................... 65 
14.6 Third display adjustment row................................................................................................ 65 
14.6.1 Adjustment of filling pump start-up delay................................................................... 65 
 
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14.6.2 Adjustment of clipping machine delay ........................................................................66 
14.6.3 Adjustment of first programmed piece correction .......................................................66 
14.6.4 Adjustment of last programmed piece correction ........................................................66 
14.6.5 Adjustment of connection time first piece increase/reload pieces count .....................67 
14.7 Indications provided by the control panel for portion mode..................................................67 
14.8 Starting the machine in portion mode....................................................................................68 
14.9 Connecting a weigher ............................................................................................................68 
14.9.1 Communication data between weigher and filler.........................................................69 
15 OPERATING INSTRUCTIONS: PROGRAMS AND PASSWORDS 70 
15.1 Recalling a program in continuous mode operation ..............................................................70 
15.2 Recalling a program in portioning mode operation ...............................................................70 
15.2.1 Programs for automatic weight correction...................................................................71 
15.3 Giving a name to a program...................................................................................................72 
15.4 Modifying a program .............................................................................................................72 
15.5 Programming block................................................................................................................73 
16 OPERATING INSTRUCTIONS: GRINDER CONTROLS (RISCO RS 503) 75 
16.1 Risco RS 503 Filler ................................................................................................................75 
16.2 How to access the grinder socket controls for continuous mode...........................................75 
16.3 How to access the grinder socket controls for portion mode.................................................76 
16.4 Grinder speed setting .............................................................................................................76 
16.5 Information provided by the control panel during grinder operation ....................................76 
16.6 Starting the filler with the grinder fitted ................................................................................77 
16.7 Utility for replacing the grinder plate/knife block .................................................................77 
17 OPERATING INSTRUCTIONS: LOADING THE PRODUCT IN THE HOPPER USING THE LIFT 79 
17.1 Danger zone around the machine during the product loading operations..............................79 
17.2 Filling the cart ........................................................................................................................80 
17.3 Inserting the cart on the trolley ..............................................................................................81 
17.4 Hydraulic lift control keys .....................................................................................................82 
17.5 Unloading the product in the hopper .....................................................................................83 
17.6 Removing the cart from the trolley........................................................................................84 
18 OPERATING INSTRUCTIONS: RUNNING AND SWITCHING OFF THE MACHINE 85 
18.1 Inspecting the hopper.............................................................................................................85 
18.2 Correct use of the collapsible platform..................................................................................8518.3 Vacuum restrictor inserted in the filter block suction............................................................87 
18.4 Emergency stop......................................................................................................................87 
18.5 Switching off the machine in emergency conditions .............................................................87 
18.6 Switching off the machine .....................................................................................................88 
19 CLEANING THE MACHINE 89 
19.1 General provisions on cleaning..............................................................................................89 
19.2 Equipment trolley...................................................................................................................89 
19.3 Disassembling the filling pump unit ......................................................................................90 
19.3.1 Opening the hopper plate .............................................................................................90 
19.3.2 Disassembling the extruder cone .................................................................................91 
19.3.3 Disassembling the feeder .............................................................................................91 
19.3.4 Disassembling the filling pump unit ............................................................................92 
19.4 Cleaning the filler ..................................................................................................................93 
19.4.1 Cleaning the inside of the filter block ..........................................................................93 
19.4.2 Caution in the use of high-pressure washing equipment .............................................94 
19.4.3 Cleaning and disinfecting the machine and its disassembled parts..............................94 
19.4.4 Cleaning and disinfecting the filter-valve ....................................................................95 
19.4.5 Detergents and disinfectants ........................................................................................95 
19.5 Reassembling the machine following cleaning......................................................................95 
 
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20 MAINTENANCE 97 
20.1 General provisions for Maintenance...................................................................................... 97 
20.2 Maintenance signalled by the control panel .......................................................................... 98 
20.3 Summary table of routine maintenance ................................................................................. 98 
20.4 Safety checks ....................................................................................................................... 100 
20.5 Air filter maintenance.......................................................................................................... 100 
20.6 Compensation plate maintenance ........................................................................................ 100 
20.7 Vacuum pump maintenance ................................................................................................ 101 
20.7.1 Checking and filling the vacuum pump oil................................................................ 101 
20.7.2 Replacement of vacuum pump oil ............................................................................. 102 
20.7.3 Replacement of vacuum pump extraction filter......................................................... 103 
20.8 Hopper plate maintenance ................................................................................................... 104 
20.9 Disassembly of the control panel ........................................................................................ 106 
20.10 Checking the oil level in the filling pump reduction unit.................................................... 106 
20.11 Topping-up oil in the filling pump reduction unit............................................................... 107 
20.12 Replacement of the oil in the filling pump reduction unit................................................... 107 
20.13 Check functionality and restoration of the level/ replacement of the oil in the lifting cylinder 
hydraulic control unit..................................................................................................................... 108 
20.14 Checking and greasing of the lifting cylinder hinge ........................................................... 108 
20.15 Checking and greasing of the cart safety lock..................................................................... 109 
20.16 Periodic check of lifting system .......................................................................................... 109 
20.17 Access to the electric control board..................................................................................... 109 
20.18 Eventual thickening of the hopper unit................................................................................ 110 
20.19 Extraordinary maintenance.................................................................................................. 110 
21 TROUBLESHOOTING 111 
21.1 Anomalies signalled by the control panel............................................................................ 111 
21.2 Anomalies signalled by the control panel: fuses ................................................................. 112 
21.3 List of alarms/anomalies...................................................................................................... 112 
21.4 Troubleshooting................................................................................................................... 114 
22 DISPOSAL OF NOXIOUS SUBSTANCES 119 
23 DEMOLITION OF THE MACHINE 120 
24 RISCO WARRANTY SYSTEM 121 
25 LIFTING INSTRUCTIONS APPLIED TO THE PACKAGE 122 
26 SYMBOLS THAT CAN BE FOUND ON THE PACKAGES 123 
27 OILS AND LUBRICANT GREASES 124 
27.1 Filling pump transmission reduction unit oil....................................................................... 124 
27.2 Greasing of components inside the filling pump................................................................. 124 
27.3 Greasing of components outside the filling pump............................................................... 124 
27.4 Vacuum pump oil ................................................................................................................ 124 
27.5 Lifting cylinder hydraulic control unit oil ........................................................................... 124 
28 ATTACHMENTS 125 
29 NOTES 126 
 
 
 
 
 
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4 INDEX OF FIGURES 
Fig. 1: "CE" plate and its position..........................................................................................................3 
Fig. 2: names of the main components.................................................................................................19 
Fig. 3: names of the main components.................................................................................................20 
Fig. 4: names of the main components.................................................................................................21 
Fig. 5: names of the main components.................................................................................................21 
Fig. 6: names of the main components.................................................................................................21 
Fig. 7: machine dimensions..................................................................................................................22 
Fig. 8: position of the FRL unit............................................................................................................23 
Fig. 9: accessories recommendedby RISCO ......................................................................................24 
Fig. 10: transporting the machine with marine packing.......................................................................28 
Fig. 11: transporting the machine with the wooden pallet ...................................................................29 
Fig. 12: extracting the machine body from the pallet (after having removed the hopper) ..................29 
Fig. 13: maximum height adjustment of each foot ..............................................................................30 
Fig. 14: safety systems adopted ...........................................................................................................34 
Fig. 15: arrangement of the safety signs ..............................................................................................35 
Fig. 16: residual risks ...........................................................................................................................36 
Fig. 17: residual risks ...........................................................................................................................37 
Fig. 18: fitting the filter valve ..............................................................................................................41 
Fig. 19: fitting the revolving feeder .....................................................................................................41 
Fig. 20: fitting the fixed counter-feeder ...............................................................................................42 
Fig. 21: fitting the extruder cone..........................................................................................................42 
Fig. 22: fitting the internal components of the filling pump ................................................................43 
Fig. 23: operator position for closing/opening the hopper plate ..........................................................44 
Fig. 24: cycle of operation in portion mode with insertion of pause ...................................................46 
Fig. 25: knee lever adjustment .............................................................................................................49 
Fig. 26: filter block lid closed ..............................................................................................................50 
Fig. 27: extruding cone must be fitted .................................................................................................50 
Fig. 28: control panel with machine off ...............................................................................................51 
Fig. 29: digital panel with RISCO logo...............................................................................................52 
Fig. 30 : control panel with machine set on continuous operation.......................................................52 
Fig. 31: vacuum pump icons and key...................................................................................................55 
Fig. 32: adjustments common to all the operating modes....................................................................56 
Fig. 33: control panel with machine set on continuous operation........................................................57 
Fig. 34: indications on the control panel for continuous mode............................................................58 
Fig. 35: position of the operator for filling ..........................................................................................59 
Fig. 36: control panel with machine set on portion operating mode....................................................61 
Fig. 37: display of the three different display upper rows in portion mode.........................................62 
Fig. 38: first line of settings in portion mode.......................................................................................62 
Fig. 39: second adjustment row portion mode .....................................................................................64 
Fig. 40: third adjustment row portion mode.........................................................................................65 
Fig. 41:indications on the control panel for portion mode...................................................................67 
Fig. 42: indication of the weight supplied by the weigher...................................................................69 
Fig. 43: recalling a program in continuous mode operation ................................................................70 
Fig. 44: recalling a program in portioning mode operation .................................................................71 
Fig. 45: active panel lock signal...........................................................................................................73 
Fig. 46: control panel with machine preset to continuous operation for RISCO RS 503 ....................75 
Fig. 47: control panel with machine preset to portion operation for RISCO RS 503 ..........................76 
Fig. 48: partial disassembly of the grinder components ......................................................................78 
Fig. 49: ejection of the plate/knife block from the grinder ..................................................................78 
 
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Fig. 50: definition of danger zone around the machine ....................................................................... 80 
Fig. 51: danger zone around the machine............................................................................................ 80 
Fig. 52: inserting the cart on the trolley............................................................................................... 81 
Fig. 53: positions of the cart safety lock.............................................................................................. 82 
Fig. 54: cart stop position in the automatic descent............................................................................. 82 
Fig. 55: position of the operator for controlling lifting ....................................................................... 84 
Fig. 56: notification microswitch of foot-board and/or hopper activated............................................ 85 
Fig. 57: using the collapsible interlocked platform ............................................................................. 86 
Fig. 58: suction cap.............................................................................................................................. 87 
Fig. 59: equipment trolley.................................................................................................................... 90 
Fig. 60: disassembling the extruder cone ............................................................................................ 91 
Fig. 61: disassembling the fixed counter-feeder.................................................................................. 91 
Fig. 62: disassembling the revolving feeder ........................................................................................ 92 
Fig. 63: disassembling the components inside the filling pump.......................................................... 92 
Fig. 64: filter block internal compartment ........................................................................................... 93 
Fig. 65: elements with potential for movement during the washing phase ......................................... 94 
Fig. 66: maintenance indication........................................................................................................... 98 
Fig. 67: air filter maintenance............................................................................................................ 100 
Fig. 68: compensation plate measurement......................................................................................... 100 
Fig. 69: plate replacement..................................................................................................................101 
Fig. 70: vacuum pump maintenance.................................................................................................. 101 
Fig. 71: vacuum pump maintenance.................................................................................................. 102 
Fig. 72: replacement of oil separator filter ........................................................................................ 103 
Fig. 73: hopper parts dismantling ...................................................................................................... 104 
Fig. 74: rotating feeder support dismantling...................................................................................... 104 
Fig. 75: dismantling pinion device .................................................................................................... 104 
Fig. 76: plate central bush dismantling.............................................................................................. 105 
Fig. 77: rotating feeder body dismantling.......................................................................................... 105 
Fig. 78: panel disassembly................................................................................................................. 106 
Fig. 79: check oil level in the reduction unit ..................................................................................... 106 
Fig. 80: reduction unit oil filler cap ................................................................................................... 107 
Fig. 81: reduction unit oil discharge cap ........................................................................................... 107 
Fig. 82: lifting cylinder hydraulic control unit .................................................................................. 108 
Fig. 83: greasing the lifting cylinder hinge........................................................................................ 108 
Fig. 84: access to the electric control panel....................................................................................... 109 
Fig. 85: supports and hopper plate thicknesses ................................................................................. 110 
Fig. 86: anomaly signal...................................................................................................................... 111 
Fig. 87: lifting instructions applied to the packaging ........................................................................ 122 
Fig. 88: symbols that can be applied to the packages........................................................................ 123 
 
 
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5 INDEX OF TABLES 
Table 1: Safety signs and terms .............................................................................................................5 
Table 2: Operators authorised for machine use and maintenance..........................................................6 
Table 3: symbol –mandatory PPE – type of use ..................................................................................17 
Table 4: main components ...................................................................................................................20 
Table 5: main components of the hydraulic lift ...................................................................................20 
Table 6: technical data for Risco 500 Series ......................................................................................22 
Table 7: optional accessories recommended by RISCO .....................................................................24 
Table 8: safety systems adopted...........................................................................................................34 
Table 9: danger symbols and precautions for use ................................................................................35 
Table 10: residual risks ........................................................................................................................39 
Table 11: knee lever switch operating modes ......................................................................................45 
Table 12: machine operating modes ....................................................................................................46 
Table 13: special machine functions ....................................................................................................48 
Table 14: controls to perform prior to switch-on .................................................................................50 
Table 15: control panel keys ................................................................................................................51 
Table 16 : entering parameter values ...................................................................................................53 
Table 17 : correcting the values entered ..............................................................................................54 
Table 18: adjusting the machine for use in continuous mode..............................................................59 
Table 19: setting the machine for operation in portion mode ..............................................................68 
Table 20: configuration of plate/knife ejection utility icon .................................................................77 
Table 21: lift control keys ....................................................................................................................83 
Table 22: layout equipment trolley ......................................................................................................90 
Table 23: legend of maintenance codes ...............................................................................................98 
Table 24: routine maintenance .............................................................................................................99 
Table 25: faulty fuse signal ................................................................................................................112 
Table 26: fan magnet-circuit breaker alarm.......................................................................................113 
Table 27: magnet-circuit breaker alarm .............................................................................................113 
Table 28: filling pump activation and motor alarms..........................................................................113 
Table 29: twister activation and motor alarms...................................................................................113 
Table 30: grinder activation and motor alarms ..................................................................................114 
Table 31: troubleshooting ..................................................................................................................118 
Table 32: symbols that may be present on the case ...........................................................................123 
Table 33: manual attachments............................................................................................................125 
 
 
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Notes 
 
 
 
 
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6 OVERVIEW 
6.1 Scope and limits of this manual 
The subject of this manual is the operation, use and maintenance of the 500 Series continuous 
vacuum fillers 
RISCO RS 501 - RISCO RS 503 - RISCO RS 505 
The manual is not a tool for professional training. Please note that the instruction manual never 
substitutes for the user’s experience. For certain maintenance operations that are particularly 
complicated, the manual only serves as a memorandum of the main operations to be performed for 
operators with adequate and specific professional training. 
Do not make your own interpretation of the instructions given in the manual, but clarify any doubts 
you may have by contactingRISCO directly. 
This manual is to be considered an integral part of the machine and must be saved until the final 
demolition of the machine. 
In the event that the machine is transferred to another user, it must be accompanied by the manual. 
If the manual gets lost, please request a new copy from RISCO. 
 
 
READ THIS MANUAL CAREFULLY BEFORE TRANSPORTING, INSTALLING, AND 
USING THE MACHINE OR CARRYING OUT ANY MAINTENANCE OPERATIONS. KEEP 
THE MANUAL IN GOOD CONDITION AND ALWAYS ACCESSIBLE TO THE 
“AUTHORISED” OPERATORS. 
 
RISCO DECLINES ANY RESPONSIBILITY FOR DAMAGE CAUSED TO PERSONS, 
ANIMALS, AND THINGS BY THE FAILURE TO OBSERVE THE RULES AND 
REGULATIONS GIVEN IN THIS MANUAL. 
6.2 Copyright 
The copyright regarding this INSTRUCTION MANUAL remains in the possession of RISCO. All 
the information (text, drawings, diagrams, etc.) in the manual is reserved. No part of this manual may 
be copied and disseminated (completely or partially) by any means of reproduction (photocopies, 
microfilm, or other) with the written authorisation of RISCO. 
6.3 Limitations to the dissemination of the manual 
This manual may not be disseminated or transmitted to third parties. Its use is authorised only to the 
customer’s company. 
6.4 Identification of the machine 
To enable RISCO to identify the machine, the following information must be transmitted: 
• the machine model 
• the serial number 
• the shipping date 
All this information is shown on the machine identification plate of Fig. 1 (see Sect. 1.2). 
 
Continuous Vacuum filler 500 Series 
 
Pag. 16 / 128 
6.5 Method for ordering a new copy of the manual 
The customer may ask RISCO for a new copy of the instruction manual. In the request, please 
identify the machine as specified in Sect. 6.4 and attach a copy of the invoice or bill of sale. 
6.6 Technical service 
Routine and periodic maintenance must be performed according to the instructions contained in this 
manual. 
Any special maintenance, replacements, overhauling, and repairs of the machine that become 
necessary must be carried out by the RISCO Technical Service, contacting RISCO and 
identifying the machine as specified in Sect.6.4 
• Any replacement of components of the machine must be carried out using exclusively Original 
RISCO Spare Parts. 
• Through our Technical Service, RISCO is available for any periodic and/or special 
maintenance on the machine as well as for any type of overhauling or repair. 
 
PARTIAL OR TOTAL FAILURE TO OBSERVE THE PROVISIONS ESTABLISHED FOR 
PERIODIC MAINTENANCE, THE USE OF NON-ORIGINAL SPARE PARTS, AND ANY 
OTHER MODIFICATION MADE TO THE MACHINE WITHOUT THE WRITTEN 
AUTHORISATION OF RISCO, INVALIDATES THE GUARANTEE DEFINED BY 
CONTRACT AND EXEMPTS RISCO FROM ANY AND ALL RESPONSIBILITY FOR 
DAMAGE TO PERSONS AND/OR THINGS CAUSED BY THE MACHINE. 
 
6.7 Preface to the general safety rules 
 
 
The employer of the company where the machine is installed must thoroughly inform all the 
operators on the accident risks and in particular the noise-related risks, the personal protective 
equipment required, and the general safety rules established by both the international laws and 
regulations and those in force in the country in which the machine is used. 
 
TO PREVENT ACCIDENTS, ALL THE OPERATORS MUST RESPECT THE 
CURRENT SAFETY REGULATIONS, BOTH INTERNATIONAL AND THE 
NATIONAL REGULATIONS IN THE COUNTRY IN WHICH THE MACHINE IS 
USED 
6.8 Personal protective equipment (PPE) 
 
 
 
IT IS MANDATORY FOR ALL THE “AUTHORISED” OPERATORS AND THE 
PERSONNEL INVOLVED IN INSTALLATION, MAINTENANCE, AND REPAIR TO 
USE PERSONAL PROTECTIVE EQUIPMENT (PPE) IN COMPLIANCE WITH THE 
CURRENT REGULATIONS AND REQUIRED BASED ON THE RISKS RELATED TO 
THE TYPE OF USE (SEE TABLE 3). 
 
 
 
 
 
Continuous Vacuum filler 500 Series 
 
 
Pag 17 / 128 
 
 
 
IT IS MANDATORY FOR THE “AUTHORISED” OPERATORS AND THE PERSONNEL 
INVOLVED IN INSTALLATION, MAINTENANCE, AND REPAIR TO: 
! USE THE PPE PROVIDED TO THEM IN COMPLIANCE WITH THE INFORMATION 
AND TRAINING (CORRECT USE AND PRACTICAL USE) PROVIDED BY THE 
EMPLOYER. 
! IMMEDIATELY ADVISE THE MACHINE SUPERVISOR OF ANY DEFECT OR 
PROBLEM FOUND IN THE PPE PROVIDED TO THEM. 
! MAINTAIN THE PPE IN GOOD CONDITION AND ENSURE THEIR HYGIENIC 
CONDITIONS BY PROPER MAINTENANCE, REPAIR, AND WHERE NECESSARY, 
REPLACEMENT. 
 
Symbol Mandatory PPE Types of use 
 
HAND PROTECTION 
Gloves for foodstuff use and 
gloves for protection from 
chemical and mechanical risks. 
Gloves for foodstuff use: during use of the machine. 
It is prohibited to use gloves of any type when the following 
accessories are used on the machine: twister a1 (see Fig. 9) 
and automatic hand a2 (see Fig. 9). 
Gloves to be used in the presence of chemical or 
mechanical risk: during machine maintenance, in particular 
in the cleaning phase. 
 
FOOT PROTECTION 
Safety shoes, waterproof, anti-
bacterial with anti-static, acid-
proof, and non-skid rubber sole. 
During the use and maintenance of the machine. 
 
BODY PROTECTION 
Sterile work clothing, waterproof 
jacket and trousers. 
Sterile work clothing: during use of the machine. 
Waterproof jacket and trousers: during machine 
maintenance, in particular in the cleaning phase. 
 
EAR PROTECTION 
Soundproofing earphones. 
During the use and maintenance of the machine, when the 
level of daily noise exposure exceeds 80 dBA. 
 
FACE PROTECTION 
Visor. 
During the machine cleaning phase. 
 
EYE PROTECTION 
Protective goggles. 
May be necessary during the mechanical maintenance 
operations. 
Table 3: symbol –mandatory PPE – type of use 
6.9 General safety rules for all personnel 
• Look after the work space around the machine, which must be free from obstacles and objects 
that can limit freedom of movement, and must be clean and adequately lighted. Minimum 
indispensable illumination to guarantee perception of the single signs: from 280 to 350 lux. 
Maximum illumination to prevent stroboscopic effects or glare for the operator. 
 
 
 
Continuous Vacuum filler 500 Series 
 
Pag. 18 / 128 
• Make sure that all protective devices and safety guards are in place, that all the safety devices are 
present and efficient and that they have not been tampered with. 
• The machine supervisor must ensure that any non-functional safety devices are immediately 
replaced or repaired, and must prohibit machine operation until the repair/maintenance is 
completed. 
• Eliminate any condition that may be a safety risk before using the machine and always notify the 
machine supervisor of any irregularity of operation. 
• Tampering with or replacing parts of the machine not expressly authorised by RISCO is strictly 
prohibited. 
• It is prohibited to carry out any modifications to adapt devices/objects not foreseen by RISCO. 
• The use of accessories, tools, consumable materials or spare parts other than those recommended 
by RISCO and/or described in this manual may constitute a danger for operators and/or damage 
the machine. 
• The electrical switchbox must always be kept closed. 
• Any modification of the machine not expressly authorised by RISCO relieves RISCO from any 
civil or criminal liability. 
 
IT IS STRICTLY FORBIDDEN TO REMOVE OR TAMPER WITH THE SAFETY 
DEVICES FITTED ONTO THE MACHINE (SEE PAR. 9.4). 
RISCO DECLINES ALL RESPONSIBILITY FOR ANY INJURIES TO PERSONS OR 
ANIMALS AND DAMAGE TO THINGS CAUSED BY REMOVING AND/OR 
TAMPERING WITH THE SAFETY DEVICES FITTED ONTO THE MACHINE. 
 
6.10 General safety rules for the mechanical maintenance technician 
 
 
• Before performing any operation of installation, routine or special maintenance, all the power 
sources must be disconnected: electrical, pneumatic, hydraulic, etc. 
• After each operation of maintenance or adjustment, make sure that no tools or foreign bodies 
remain amongst the moving parts of the machine to prevent damage to the machine and/or injury 
to the personnel. 
• Do not use benzene or flammable solventsas a detergent. Always use authorised commercial 
solvents that are non-flammable and non-toxic. 
• Do not use compressed air for cleaning the machine parts. In the event that it is impossible to use 
other systems, protect yourself with goggles with side guards and limit the pressure to a 
maximum of 2 bar. 
6.11 General safety rules for the electrical maintenance technician 
 
 
• Before performing any operation of installation, routine or special maintenance, all the power 
sources must be disconnected: electrical, pneumatic, hydraulic, etc. 
• After each operation on the electrical switchbox, close it and block it with the respective screws 
before switching the power back on and starting up the machine. 
 
 
 
 
Continuous Vacuum filler 500 Series 
 
 
Pag 19 / 128 
7 PRESENTATION OF THE MACHINE AND TECHNICAL DATA 
7.1 Name of the machine 
The 500 Series continuous vacuum fillers are named as follows: 
RISCO RS 501 - RISCO RS 503 - RISCO RS 505 
The 500 Series machines must be used by one operator only. 
7.2 Names of the main components 
 
Fig. 2: names of the main components 
pos fig Name pos fig Name 
- - Instruction Manual 16 4 Hopper 
1 2 Hopper plate 17 4 Fixed counter-feeder 
2 2 Socket for twister (optional) 18 4 Revolving feeder 
3 2 Filling cone 19 5 Filling pump 
4 2 Moving ring nut 20 5 Extractor 
5 2 Vacuum suction filter block 21 5 Upper cam gasket 
6 2 Multiple socket for external connections 
(optional) 
22 5 Upper cam 
7 2 Knee lever switch 23 5 Vane 
8 2 Hopper plate blocking lever 24 5 Rotor 
3 
4 
5
6 
7
8
9
10
29 
1115 
2 
1 
30 
40 (Rs503)
 
Continuous Vacuum filler 500 Series 
 
Pag. 20 / 128 
9 2 Filler case 25 5 Hopper plate seal 
10 2 Control panel 26 6 Switchbox and electrical controls 
11 2 Front guard 27 6 Vacuum pump 
12 3 Lockable master switch 28 6 Open hopper plate support 
13 3 Collapsible interlocked platform 29 2 Guard attachment screws 
14 3 Rear guard 30 2 Hopper mirror 
15 2 Adjustable feet 40 2 Grinder coupling 
Table 4: main components 
 
pos fig Name pos fig Name 
31 3 Trolley for cart 36 3 Lift tie rod 
32 3 Cart safety lock 37 6 Lift cylinder 
33 3 Trolley rotation hinge 38 6 Lift cylinder hydraulic control unit 
34 3 Lift arm 39 3 RISCO cart capacity 200 litres 
35 3 Lift arm rotation hinge 
Table 5: main components of the hydraulic lift 
 
 
Fig. 3: names of the main components 
13 
14 
34 
39 
31
35 
12 
36 
33 
32
 
Continuous Vacuum filler 500 Series 
 
 
Pag 21 / 128 
 
Fig. 4: names of the main components 
Fig. 5: names of the main components 
 
 
Fig. 6: names of the main components 
17 
18 
16 
20
21
22
23
24
19
25 
28
26 
37
27
38
 
Continuous Vacuum filler 500 Series 
 
Pag. 22 / 128 
7.3 Machine dimensions 
 
Fig. 7: machine dimensions 
7.4 Technical data 
Value Characteristic Unit of measurement RS 501 RS 503 RS 505 
Hourly production kg/h 
(lb/h) 
up to 6500 
(up to 14330) 
up to 6500 
(up to 14330) 
up to 10000 
(up to 22050) 
Weight of portions g from 1 to 24000 from 1 to 24000 from 1 to 32000 
Hopper capacity l 
Cart capacity l 
350 
200 
Filling pump motor kW 5.9 5.9 5.9 
Twister motor kW 1.6 1.6 1.6 
Grinder motor kW - 3.3 - 
Vacuum pump motor kW 1.5 1.5 1.5 
Lift control unit motor kW 0.75 0.75 0.75 
Total installed power kW 11.00 14.00 11.00 
Power supply voltage V See the “CE” plate (see Fig. 1) 
Pneumatic power supply 
(optional) 
bar 6 
Machine weight kg 
(lb) 
920 
(2030) 
1060 
(2340) 
1000 
(2210) 
Machine weight with 
simple packing (see 
Sect.8.3). 
kg 
(lb) 
1090 
(2410) 
1230 
(2720) 
1170 
(2560) 
Overall dimensions mm See Fig. 7 
Table 6: technical data for Risco 500 Series 
 
 
Continuous Vacuum filler 500 Series 
 
 
Pag 23 / 128 
7.5 Knee lever switch 
When the machine is switched on, the knee lever switch 7 (see Fig. 2) is the only control organ that 
permits the start or stop of the filling pump. 
7.6 Optional devices 
One or more of the following optional devices can be fitted on 
the machine: 
• twister socket 2 (see Fig. 2). 
• multiple socket for external connections 6 (see Fig. 2). 
• FRL unit (see Fig. 8). 
If the above-mentioned devices are not present, the 
corresponding holes on the case are not present or are closed 
with screwed-on covers sealed with silicone. 
The presence or absence of the above-mentioned devices does 
not change: 
• the basic functionality of the machine. 
• the name of the machine given in Sect.7.1. 
• the validity of this instruction manual. 
 
Fig. 8: position of the FRL unit 
7.6.1 Multiple socket for external connections 
The signal that controls the machines (clipper, tying machine, etc.) connected to the filler comes 
from this 10-pole socket 6 (see Fig. 2). 
The wiring diagram of the socket is provided in the enclosure 49012001del Cap. 28-A of this 
manual. 
 
THE CORRECT INTERFACING OF THE FILLER WITH ANOTHER MACHINE VIA THE 
BLANK SOCKET IS THE RESPONSIBILITY OF THE CUSTOMER (EMPLOYER). AN 
INCORRECT CONNECTION BETWEEN THE FILLER AND ANOTHER MACHINE MAY 
CONSTITUTE A SERIOUS DANGER TO OPERATORS AND/OR DAMAGE BOTH 
MACHINES. 
THE RISCO TECHNICAL ASSISTANCE SERVICE CAN PROVIDE ALL THE DATA 
NECESSARY FOR THE CORRECT CONNECTION OF OUR FILLER TO OTHER 
MACHINES. 
 
RISCO DECLINES ANY RESPONSIBILITY FOR DAMAGE TO PERSONS, ANIMALS, OR 
THINGS CAUSED BY ERRORS OF CONNECTION BETWEEN OUR FILLER AND OTHER 
MACHINES. 
7.6.2 FRL compressed air unit 
The machine in question can use a casing spinner (see Sect.7.7 -Optional accessories 
recommended by RISCO) that requires pneumatic power. In this case, the FRL 
filter/regulator/lubricator unit (see Fig. 8) is required. 
Connect the air feed pipe coming from the compressor or from the pneumatic system to the 
coupling of the FRL. Use a feed pipe with internal diameter of at least 6 mm. 
The air pressure is already calibrated by RISCO at about 4 bar to give the pneumatic motor an 
optimal speed. 
 
Continuous Vacuum filler 500 Series 
 
Pag. 24 / 128 
7.7 Optional accessories recommended by RISCO 
The machine described in this manual may be equipped with certain optional RISCO accessories. 
Contact our Sales Office to find out how these accessories can improve the functionality and 
productivity of the filler. 
For the use and installation of the accessories, refer to the instruction manuals provided with them. 
Please note that in order to use the accessories, the machine must be equipped with the necessary 
optional devices described in Sect. 7.6. 
For the machine described in this manual, RISCO recommends the accessories listed in the 
following table: 
Position Description Optional device required 
a1 Twister Twister socket 
a2 Automatic hand for Twister Twister socket 
a3 Casing spinner FRL unit 
a4 Casing spinner FRL unit 
a5 Grinder RS 503 only 
Table 7: optional accessories recommended by RISCO 
 
THE USE OF ACCESSORIES DIFFERENT FROM THOSE RECOMMENDED BY RISCO 
MAY CONSTITUTE A DANGER FOR OPERATORS AND/OR MAY DAMAGE THE 
MACHINE. 
RISCO DECLINES ALL RESPONSIBILITY FOR DAMAGE TO PERSONS, ANIMALS, AND 
THINGS CAUSED BY THE USE ON THE FILLER OF ACCESSORIES DIFFERENT FROM 
THOSE SHOWN IN TABLE 7. 
 
Fig. 9: accessories recommended by RISCO 
a1 
a3 
a2
a4
a5 
 
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Pag 25 / 128 
7.8 Noise 
The machines described in this manual have been designed and constructed to reduce noise pollution 
to the minimum. 
The measurement of noise on the machine as shown below was made in proximity to the knee lever 
switch at a height of 1.5 m from the floor. 
Equivalent level (eqL) measured during filling operation in portion mode: 
• with twister 76 dbA 
• without twister 70 dbA 
When the machines are used for work in an environment where the daily exposure of operators to 
noise exceeds 80 dbA, the employer must apply all the measures necessary to safeguard the health of 
the operators as specified by the laws in force (Directive 86/188/EEC). 
In particular,in case of need the operator must use personal protective equipment (see Sect.6.8) for 
ear protection. 
7.9 Products used for processing 
 
USE ONLY THE FOLLOWING PRODUCTS: 
! GROUND MEAT OR SIMILAR PRODUCT. 
! NATURAL OR SYNTHETIC CASING. 
RISCO DECLINES ALL RESPONSIBILITY FOR DAMAGE TO PERSONS, ANIMALS, AND 
THINGS CAUSED BY THE USE OF THE FILLER WITH PRODUCTS OTHER THAN 
THOSE INDICATED. 
 
 
 
 
Continuous Vacuum filler 500 Series 
 
Pag. 26 / 128 
Notes 
 
 
 
 
Continuous Vacuum filler 500 Series 
 
 
Pag 27 / 128 
8 INSTALLATION 
8.1 Installation personnel 
 
 
 
 
THE MACHINE INSTALLATION OPERATIONS MUST BE CARRIED OUT BY QUALIFIED 
PERSONNEL HAVING SUITABLE TECHNICAL TRAINING AND EXPERIENCE. 
 
IT IS MANDATORY FOR THE INSTALLATION PERSONNEL TO USE THE PERSONAL 
PROTECTIVE EQUIPMENT (PPE) IN COMPLIANCE WITH THE REGULATIONS IN 
FORCE AND ACCORDING TO THE RISKS RELATED TO THE TYPE OF USE. SEE SECT. 
6.8 - PERSONAL PROTECTIVE EQUIPMENT (PPE). 
8.2 Machine delivery 
All the material is thoroughly checked by RISCO prior to shipping. 
Upon receiving the machine, make sure that it has not suffered damage during transport or that any 
packing has been tampered with, with consequent removal of parts from inside. 
Should there be any damage or missing parts, notify the shipper and RISCO immediately, producing 
photographic documentation. 
In addition, please verify that the supply corresponds to the order specifications. 
8.3 Packing 
The packing methods are defined in conjunction with the customer in relation to the distance and 
means of transport chosen. 
The packing methods are the following: 
• machine without packing 
• packing on wooden pallet with covering in sturdy cardboard 
• packing on wooden pallet, sides and cover forming a wooden cage 
• packing on wooden pallet, sides and cover forming a wooden crate. 
If the wood is requested smoked, ask for the certificate and stamping of the treatment. 
The outer part of the packing may bear the symbols as per Chapter 26. 
8.4 Storage methods 
If the machine is not used immediately upon arrival, it should be stored in such a way that none of 
the packing materials are exposed to harsh weather conditions. The machine must be stored in a dry 
place, free from moisture and dust. 
Minimum admissible temperature: - 5°C. 
 
 
Continuous Vacuum filler 500 Series 
 
Pag. 28 / 128 
8.5 Machine movement and handling 
 
The Instruction Sheet for Transport and Lifting attached to the packing (see Ch.25) must be read and 
understood by the personnel assigned to loading, transporting and unloading the machine. 
 
! IT IS MANDATORY THAT ALL THE OPERATIONS OF MACHINE PACKING, 
LIFTING, LOADING, TRANSPORT AND UNLOADING BE CARRIED OUT BY A 
"SPECIALISED SHIPPING COMPANY" WITH QUALIFIED PERSONNEL AND 
SUITABLE MEANS IN COMPLIANCE WITH THE SAFETY REGULATIONS IN 
FORCE. 
! THE MACHINE SUPERVISOR MUST ENSURE THAT WITHIN THE RANGE OF 
ACTION OF THE OPERATIONS OF SHIPPING AND HANDLING – OUTSIDE AND 
INSIDE THE WORK SITE WHERE THE MACHINE WILL BE INSTALLED – THERE 
ARE ONLY THE PERSONS ABSOLUTELY NECESSARY FOR THESE OPERATIONS. 
RISCO DECLINES ANY RESPONSIBILITY FOR DAMAGE TO PERSONS, ANIMALS, 
OR THINGS CAUSED BY THE FAILURE TO OBSERVE THIS SAFETY RULE. 
! USE LIFT MEANS AND EQUIPMENT IN COMPLIANCE WITH THE REGULATIONS 
IN FORCE THAT ENABLE THE LIFTING WITHOUT RISKS OF A WEIGHT GREATER 
THAN THE GROSS WEIGHT OF THE MACHINE INDICATED IN TABLE 6. 
! DURING THE LIFTING (RAISING/LOWERING) AND TRANSPORT OPERATIONS, DO 
NOT PERFORM ANY BRUSQUE MANOEUVRES THAT COULD JEOPARDISE THE 
STABILITY OF THE LOAD. 
! WHATEVER TYPE OF LIFTING AND HANDLING SYSTEM IS USED, THE MACHINE 
MUST ALWAYS BE TRANSPORTED IN THE VERTICAL POSITION. EVEN IF IT IS 
PACKED IN A CRATE, THE MACHINE MUST NEVER BE OVERTURNED OR SET ON 
ITS SIDES. 
! FOLLOW THE INDICATIONS PROVIDED BY THE SYMBOLS ON THE CRATE (SEE 
CH.26), IN PARTICULAR THOSE SHOWING THE POSITION OF THE CENTRE OF 
GRAVITY OF THE CRATE. 
! TRANSPORT THE MACHINE WITHOUT PACKING ONLY AND ALWAYS 
SUPPORTED FROM THE BOTTOM. 
 
8.5.1 Lifting with a crane 
• Take care in positioning the hooking or harnessing 
systems (see Fig. 10). 
• With cardboard packing, arrange the hooking or 
harnessing systems so that they do not exert force on the 
packing material. 
• Make sure that the harness straps do not strike against 
and/or damage the components of the machine. 
• To decide how to position the harnessing, follow the 
indications given by the symbols shown on the crate (see 
Ch.26). 
• Make sure that the length of the harnessing is such that 
the angle of each strap with respect to the vertical 
direction is less than 45°. 
• Be extremely careful in lifting the machine and 
subsequently setting it on the ground. 
 
Fig. 10: transporting the machine with 
marine packing 
 
Continuous Vacuum filler 500 Series 
 
 
Pag 29 / 128 
8.5.2 Lifting with a forklift 
• To decide how to position the forks, follow the indications given by the symbols on the crates 
(see Ch.26). 
• Establish beforehand the path to be followed, making sure that it is free from any obstacles. 
• Position yourself with the lift truck facing the crate and very slowly insert the forks under the 
pallet (see Fig. 11). The forks must be longer than the crate. 
• Slowly lift the machine and transport it to the chosen site. 
• Very carefully lower the machine to the floor and remove the forks. 
• Only after having moved the hopper 16 (see Fig. 12) from the pallet, carefully extract the body of 
the machine from the pallet as shown in Fig. 12. 
 
Fig. 11: transporting the machine with the wooden 
pallet 
 
Fig. 12: extracting the machine body from the 
pallet (after having removed the hopper) 
8.6 Physical characteristics of the installation site 
This machine does not require a particular installation site. 
It can operate in any industrial environment with characteristics in compliance with the regulations in 
force for the Food Processing Industry. 
It requires a support surface that can support the weight of the machine (Table 6-Sect. 7.4) on the 
four feet used for setting it on the floor. 
 
THE RISCO RS 501, RS 503 AND RS 505 FILLERS ARE NOT SUITABLE FOR 
OPERATING IN ENVIRONMENTS WITH EXPLOSIVE ATMOSPHERE OR FIRE RISK. 
8.7 Positioning 
The machine must be installed in an industrial environment that is enclosed, covered, and sufficiently 
illuminated, respecting the minimum positioning measurements. 
The filler and the machine operator must stand on the same support surface, absolutely free from any 
steps or other impediments (e.g. raised raceways or cable channels) that could trip the operator. 
In particular, when positioning the machine make sure that there is: 
• a clear space on the side of the rear guard 14 (see Fig. 2) to enable easy performance of 
maintenance operations (see Ch.20) and repairs. 
• at least 1-2 m free in the front part for the operations of product loading, machine operation, 
control and adjustment. 
16
 
Continuous Vacuum filler 500 Series 
 
Pag. 30 / 128 
• on the product outfeed end, sufficient space so that the operator can easily perform the filling 
operation or make the connection with a machine in series (for example, a clipper) or any 
accessories. 
• on the rear part, a sufficient space for easily moving the cart 39 (see Fig. 3) and allowing its 
insertion on the trolley 31 (see Fig. 3). 
 
WHEN POSITIONING THE RISCO RS 501, RS 503 AND RS 505 FILLERS NEAR OTHER 
OPERATOR-CONTROLLED MACHINES, IT IS IMPERATIVE TO TAKE INTO ACCOUNT 
THE DANGER AREA AS DEFINED IN SECT.17.1-CH.17. 
 
8.8 Levelling the machine 
 
 
 
Check that all the setting points of the machine are 
in contact with the floor and weight-bearing. 
Placing a level on the upper part of the hopper 
plate 1 (see Fig. 2), check the levelling of the 
machine. 
To level the machine, proceed as follows: 
• Using a manual forklift system, raise the 
machine a few centimetres. 
• Insert a screwdriverin the hole A (see Fig. 
13) situated on each foot 15 (see Fig. 2) and 
adjust its height by tightening or loosening it. 
• Set the machine back no the floor, check that 
it is level and that all the feet are in contact 
with the floor and weight-bearing Fig. 13: maximum height adjustment of each 
foot 
 
 
IN ADJUSTING EACH FOOT, ABSOLUTELY DO NOT EXCEED THE HEIGHT 
INDICATED IN FIG. 13 – SECT. 8.8 
 
8.9 Electrical hook-up 
 
 
 
IN CONNECTING THE MACHINE TO THE ELECTRICAL SYSTEM, THE CUSTOMER 
(EMPLOYER) MUST: 
! GUARANTEE THAT THE ELECTRICAL POWER SYSTEM AND THE EARTH 
SYSTEM ARE IN COMPLIANCE WITH THE REGULATIONS IN FORCE IN THE 
COUNTRY WHERE THE MACHINE IS USED. 
 
A 
 
Continuous Vacuum filler 500 Series 
 
 
Pag 31 / 128 
 
THE CUSTOMER (EMPLOYER) MUST: 
! MAKE SURE THAT THE ELECTRICAL POWER SYSTEM TO WHICH THE MACHINE 
IS CONNECTED SATISFIES THE TECHNICAL CHARACTERISTICS INDICATED ON 
THE “CE” IDENTIFICATION PLATE (SEE SECT. 1.2-“CE” Mark.). 
! GUARANTEE A VARIATION OF THE POWER SUPPLY VOLTAGE WITHIN THE 
LIMITS OF ± 10% OF THE RATED VOLTAGE. 
RISCO DECLINES ANY RESPONSIBILITY FOR FAILURES AND ANOMALIES DUE 
TO VOLTAGE VARIATIONS GREATER THAN THE LIMITS INDICATED. 
! VERIFY THAT THE CROSS-SECTION OF THE CABLES AND THE LINE SWITCH 
ARE SIZED FOR A PASSAGE OF CURRENT CORRESPONDING TO THE POWER 
ABSORBED BY THE MACHINE (SEE SECT. 6.4 AND SECT. 7.4). 
! PROVIDE A THREE-PHASE CIRCUIT BREAKER UPSTREAM FROM THE MACHINE 
THAT IS SUITABLE TO THE POWER ABSORBED BY THE MACHINE (SEE 
SECT.7.4), IN ADDITION TO EFFECTIVE MEANS OF PROTECTION AGAINST 
OVERCURRENT OR DIRECT CONTACTS. 
! PROVIDE FOR FITTING A PLUG ON THE POWER CABLE COMING FROM THE 
MACHINE. THE PLUG MUST BE SUITABLE TO THE CHARACTERISTICS OF THE 
SYSTEM AND OF THE MACHINE, AND IN COMPLIANCE WITH THE 
REGULATIONS IN FORCE. 
THE CONNECTION DIAGRAM FOR THE POWER CABLE IS PROVIDED IN THE 
WIRING DIAGRAMS. 
! PROVIDE FOR THE CONNECTION OF THE MACHINE WITH THE EARTH SYSTEM. 
IT IS PROHIBITED TO HOOK THE FILLER TO THE MAINS WITHOUT CONNECTING 
IT TO EARTH. 
! FOR THE EXECUTION OF THE ELECTRICAL HOOK-UPS, IT IS ADVISABLE TO 
FOLLOW THE GENERAL RULES OF INSTALLATION FOR THE PREPARATION AND 
INSTALLATION OF ELECTRICAL SYSTEMS. SEE THE CEI 64-8 STANDARDS (IEC 
364). 
 
8.10 Pneumatic hook-up 
 
The pneumatic hook-up is necessary for using the casing spinner (see Sect.7.7 ). 
Connect the air feed hose coming from the compressor or from the pneumatic distribution system to 
the 1/4" coupling provided on the optional filter/regulator/lubricator unit (FRL)(see Fig. 8). 
Use a feed hose with internal diameter of at least 6 mm and make sure the air pressure entering the 
FRL unit is not less than 5 bar. 
 
THE CUSTOMER (EMPLOYER) MUST: 
! CONNECT THE FRL UNIT TO THE AIR DISTRIBUTION SYSTEM BY MEANS OF A 
QUICK DISCHARGE COCK, WHICH MAKES IT POSSIBLE TO DISENGAGE THE 
PNEUMATIC SUPPLY RAPIDLY, DISCHARGING THE PRESSURE OF THE SYSTEM 
UPSTREAM FROM THE COCK. 
! SUPPLY THE FRL UNIT WITH CLEAN AIR, FREE FROM IMPURITIES, IN 
COMPLIANCE WITH THE DIN ISO 8573-1 STANDARD. 
 
 
 
Continuous Vacuum filler 500 Series 
 
Pag. 32 / 128 
8.11 Testing and start-up 
 
 
The machine is tested at the RISCO factory before being delivered to the customer. 
 
BEFORE TESTING, THE CUSTOMER (EMPLOYER) MUST PERFORM THE 
INSTALLATION OPERATIONS DESCRIBED IN THE PREVIOUS SECTIONS. 
The TESTING AND START-UP comprises the verification that every component and working unit 
of the machine are functioning correctly. If the testing outcome is positive, the first start-up can be 
carried out. 
 
THE CUSTOMER (EMPLOYER) MUST TAKE ALL THE MEASURES NECESSARY SO 
THAT THE COMPANY EMPLOYEES MAY NOT FOR ANY REASON ACCESS THE 
MACHINE INSTALLATION SITE UNTIL FINAL TESTING AND PREPARATION FOR 
START-UP ARE COMPLETED. 
 
THE MACHINE TESTING AND START-UP ARE CARRIED OUT: 
! BY THE SPECIALISED TECHNICAL PERSONNEL OF RISCO (OR OF THE 
RESELLER/AGENT) IN THE PRESENCE OF THE MACHINE SUPERVISOR AND THE 
OPERATORS “AUTHORISED” FOR THE USE AND MAINTENANCE OF THE 
MACHINE. 
OR 
! BY THE MACHINE SUPERVISOR (CUSTOMER), AFTER HAVING READ AND 
FULLY UNDERSTOOD EVERY PART OF THIS INSTRUCTION MANUAL. 
 
 
Continuous Vacuum filler 500 Series 
 
 
Pag 33 / 128 
9 OPERATION AND USE 
9.1 Permitted use 
RISCO RS 501, RS 503 and RS 505 – CONTINUOUS VACUUM FILLERS 
to be used for filling a natural or artificial casing with a meat-based food product for the purpose of 
producing salami, sausages, frankfurters or similar products. 
 
THE MACHINE IS DESIGNED TO BE USED BY ONLY ONE (1) OPERATOR, WHO MUST 
BE PROFESSIONALLY TRAINED AND WHO IS AT LEAST 18 YEARS OF AGE, IN 
RESPECT FOR THE CURRENT LEGISLATION IN THE COUNTRY WHERE IT IS USED 
9.2 Non-permitted use 
any use different from that stated in the previous section (Sect. 9.1) and not considered in this 
manual is to be considered: 
N O T A D M I S S I B L E 
 
IT IS STRICTLY PROHIBITED TO INSTALL, USE, AND SERVICE THE MACHINE IN ANY 
WAY THAT IS NOT DESCRIBED IN THIS MANUAL. 
9.3 Directives and standards of reference 
The machine in question has been designed and constructed taking into account the assessments 
resulting from a thorough analysis of the risks and aimed at achieving, in consideration of the current 
state of the art, the objectives established by the essential safety and health requirements of the 
"Machinery Directive". 
9.4 Safety systems adopted 
The RISCO RS 501, RS 503 and RS 505 fillers are equipped with a series of fixed protective 
devices and safety systems that delimit the working range of the operator in order to guarantee his 
safety. 
The safety systems adopted on this machine are shown in Fig. 14 and described in Table 8. 
Ref .Fig. 14 Description 
A Microswitch for hopper plate 1 (see Fig. 2) opening: it instantaneously blocks 
the operation of the filler pump and all the revolving parts of the machine 
whenever the hopper plate 1 is opened. 
B Hopper plate blocking lever 8 (see Fig. 2) 
C Master switch 12 (see Fig. 3) lockable yellow red disconnecting switch. 
D Collapsible interlocked platform 13 (see Fig. 3) for inspection of the hopper. 
use of the platform triggers a microswitch that stops the machine. 
E Fixed front guards 11 (see Fig. 2) and rear guards 14 (see Fig. 3) that 
hermetically seal the machine body. 
F Upper cam 22 (see Fig. 5) for concealing the conveyor vanes 23 (see Fig. 5) 
during their passage in the discharge zone. 
 
Continuous Vacuum filler 500 Series 
 
Pag. 34 / 128 
G Electrical switchbox 26 (see Fig. 6) inside the machine, enclosed in an 
container with a removable cover, closed with four locks which can be opened 
by means of the appropriate key supplied; the box 26 is secured to the machine 
structure by means of screws. 
L Cart safety lock 32 (see Fig. 3): impedes the movement of the cart 39 (see Fig. 
3) during the loading operations of the foodstuff to be filled. 
Table 8: safety systems adopted 
 
 
 
 
Fig. 14: safety systems adopted 
 
 
IT IS STRICTLY FORBIDDEN TO REMOVE AND/OR TAMPER WITH THE SAFETY 
DEVICES FITTED ONTO THE MACHINE (SEE TABLE 8). 
 
IT IS OBLIGATORY TO CHECK CONSTANTLY THAT ALL THE SAFETY DEVICES 
PRESENT ON THE MACHINE ARE IN GOOD WORKING ORDER AND OPERATING 
EFFECTIVELY. 
A 
B 
C
D
E E 
G 
F 
L 
 
Continuous Vacuum filler 500 Series 
 
 
Pag 35 / 128 
9.5 Safety signs 
The machine is equipped with a series of safety signs in the form of self-adhesive labels. Fig. 15 
shows how the signs are arranged. 
The full meanings of the symbols shown in Fig. 15 are described in Table 9. 
Deteriorated signs must be replaced. New ones may be requested as spare parts from RISCO. 
 
 
Fig. 15: arrangement of the safety signs 
 
Ref. Fig. 
15 
Description Symbol Code for 
reordering 
N Symbol for “BURN DANGER” 
 
10056024 
P Symbol for “ELECTROCUTION DANGER” 
 
10056019 
Table 9: danger symbols and precautions for use 
 
 
IT IS STRICTLY PROHIBITED TO REMOVE AND/OR DAMAGE THE