Pregis AirSpeed Turbo Air Cushion Machine Owner’s Manual

Pregis AirSpeed Turbo Air Cushion Machine

LANGUAGES OF OPERATION DISCLAIMER

It is illegal to operate this machine in an EU member state if this (or any other related) manual is not written in that State’s language. If a translated version is needed, contact Pregis to order the manual. The original version of this manual is in English and denoted “Original Instructions” in the top right corner. All translated versions are denoted “Translation of Original Instructions” in the same location

SPECIFICATIONS

Machine
Weight: 25.4 lbs / 11.5 kg Overall Size (L x W x H): 16.7 x 15.3 x 12.6 in / 424 x 389 x 320 mm
Power: 120/230 VAC, 5.0/2.6 A, 60/50 Hz Production Speed: 100 feet per minute / 30.5 meters per minut

Sound Test Declaration

The equivalent sound pressure level Leq at the operator station is XX dB(A).

OPERATING SAFETY

AirSpeed® Turbo Air Cushion Machine

Operator safety and the safety of others in the work area depend on the operator using common sense,
good judgment and reasonable care while operating the machine. The Safety, Operation and Maintenance manual, and warning labels affixed to the machine, provide notification of specific potential hazards.

Safety

The following instructions are only a guideline and should be considered a supplement to your plant’s comprehensive safety program. Your company’s policy supersedes these guidelines if at any time the two contradict each other.

1. Read and understand the manual. If after reading the manual you have questions, get answers before working with the machine.
2. Read and understand all the danger, warning, and caution statements in the manual and on the signs attached to the equipment.
3. Never deface or remove factory installed warning decals. If a decal ever becomes lost, damaged, or illegible, report this condition to a supervisor and obtain a replacement decal.
4. Keep the work area clean and uncluttered. Walking surfaces should always be free of packing material and debris to prevent a slipping or tripping hazard.
5. Ensure that all covers, guards, and other safety devices are in place. Never remove a safety device for any reason.
6. Follow the manufacturer’s recommended startup procedure.
7. Never leave the equipment unattended while operating. Shut the machine off if you must leave the work area.
8. Keep body parts and clothing away from moving components. Ties, scarves, long hair, and gloves are especially dangerous.
9. Understand what will happen when you operate the various controls.
10. Understand the proper web path and the safe method for threading the web.
11.  Learn the safe procedure for clearing the machine of web wraps or jams.
12. Exercise extreme care whenever it is required to inspect or adjust the machine while it is in motion. NEVER reach into the machine for any reason while it is in motion
13. Understand which adjustments are operator adjustments; only trained and qualified service personnel may maintain/clean any electrical and or mechanical part of the machine.
14. Never operate or work around equipment if you are under the influence of alcohol, drugs or medications that can make you less alert or affect your judgment.
15. The machine shall be used in a facility adequately ventilated for air renewal

Warning Labels

The Operating Safety section of this manual, the Operator manual, and warning labels affixed to the machine provide notification of specific potential hazards.
Safety signs are used to alert operating and maintenance personnel to potential hazards. The machine
manual also calls attention to potential hazards with statements describing the hazard. Warning labels used on the machine are depicted below

Electric Shock
Hot Surface
Refer to Instruction Manual
Hand Entanglement, Rollers

The meanings of the warning labels and the potential hazards they represent must be clearly understood before attempting to operate or maintain the machine. If, at any time, a warning label on the machine becomes lost, damaged, or illegible, contact Pregis to order replacement signs.

SCOPE AND LIMITS

AirSpeed® Turbo
Air Cushion Machine

Introduction

The Pregis AirSpeed® Turbo produces panels of air-filled packing cushions in any quantity, as needed. The ability to create packing cushions on demand saves storage space and reduces packaging material waste.
Supported film rolls have a maximum size of the following:

Use of the machine for any purpose – other than stated – may cause severe injury to the operator and/or damage to the machine.

Inputs and Outputs

Compatible Accessories
For a list of accessories compatible with the AirSpeed® Turbo, see the Pregis Systems Catalog.

Dismantling

Upon dismantling of this system at the end of its service life, please follow the local recycling laws and regulations in effect at that time

GENERAL OPERATION

Setting up the Machine

Mounting Options

The machine can be mounted either horizontally, vertically, or on a “C” frame.
Horizontal mounting utilizes a baseplate and a floor stand with casters for ease of movement. Place the machine on the baseplate and stand and secure with (2) M8 x 1.25 x 30mm bolts at the holes labeled BE and (2) M6 x 1.0 x 30mm bolts at the holes labeled D.
Optionally, the machine can be mounted vertically on a frame with an attached bin, called a “C” frame. The “C” frame is mounted on casters for ease of movement.
Vertical mounting also utilizes a baseplate to assist in mounting to a vertical plane. This configuration is ideal for use with overhead delivery systems.

Installing Feet and Mounting Hardware

To install the feet (SAP# 1027857, 1027881) or mounting hardware (SAP# TBD), reference the figure below

Power On
Plug the AC power cord into the back of the machine. Insert power cord into a suitable outlet. Power the machine on or off using the Power Switch on the rear of the machine. See Section 3.2.

DO NOT POWER ON MACHINE UNTIL IT IS SECURED.

Changing Film

Loading Film

Removing Film

Starting the Machine

Initial Startup
Upon startup, the machine will require user interaction to warm up. Once this step is complete, the
machine will be ready to run film.

Running Film

To run film through the machine, first follow all prior steps outlined in Section 4. To start the machine, press the physical or touchscreen Start/Stop button. See Section 5.2.

ADVANCED OPERATION

Home Screen

Each item displayed below is described in the Table of Symbols, located in Section 5.2.

RFID Recipe Overview
The recipe (preset operating parameters) for each film type is automatically loaded from the RFID tag on the roll. Air Level and Temperature settings are adjustable within a predefined range. See Section 5.4.

Table of Symbols

machine is in Sleep Mode. See Section 4.3
| Wake from Sleep Button| Use this button to wake the machine from Sleep Mode. See Section 4.3.
| Progress Bar| Function progress is displayed on the right side of the screen for various processes, including Wake from Sleep.
| Start/Stop Button| Use this button to Start the machine. While the machine is running, this turns into a Stop button able to stop the machine if pressed. See Section 5.1.
| Start/Stop Button (Physical)| The physical Start button performs similarly to the touchscreen button. It is located near the lower right corner of the front panel. See Figure 11 in Section 4.2.
| Jog Indicator and Button
Jog Button (Physical)| The Jog button is used to load film. Hold the touchscreen Start/Stop button for 3 seconds access the Jog feature. Alternatively, use the physical Jog button.
| Back Button| The Back button allows the user to return to the Home Screen.
| Fill Mode Button| This button brings up the Fill Mode menu. Depending on fill mode, length/time per run can be set be pressing the Run Time/Length button. See Section 5.3.
| Run Time/Length Buttons| Once a mode is selected in the Fill Mode menu, length/time per run can be set by pressing either indicator. See Figure 18 in Section 5.3.
| Run Time/Length Indicator| Once Run Time or Length is selected in the Fill Mode menu, the appropriate indicator will display on the Home Screen.
| Seal Temperature Indicator and Button| By selecting the Seal Temperature button, one can adjust the sealing temperature. Once set, the Seal Temperature Indicator will blink until the machine is ready.
| Wait Symbol| The Start/Stop button will turn into a Wait symbol while a temperature change is in progress. See Section 5.1
| Air Level Button| By selecting the Air Level Button, one can adjust the air level. See Section 5.1.
| Production Speed Button| By selecting the Production Speed button, an authorized user can adjust the production speed. This setting is not customer adjustable. See Section 5.1.
| RFID Film Type Indicator| This indicates the detected RFID Film Type and is located to the right of the Fill Mode button. See Section 5.1.
| Enter/Delete Key| When changing a value via the Keypad, use the Enter Key to save the displayed value. The Delete button can be used to erase numbers as needed.
| Keypad and Level Visualize| When changing a setting such as Fill Mode, Seal Temperature, or Air Level, use the keypad to change the value. The Level Visualizer will display the range of acceptable values
| Bin Mode Toggle| If the machine is attached to a bin, this setting will be enabled. This setting is not customer adjustable.
| Bin Mode Indicator| This indicates that Bin Mode is enabled when/if the machine is attached to a bin.
| Bin Empty/Full Indicator| While in Bin Mode, indicators will activate if the bin is empty or full.
| Winder Enable| This indicates that Winder Mode is enabled when/if the machine is attached to a winder.
| Winder Idle / Threading Indicator| While in Winder Mode, indicators will activate if the winder is idle or threading.

Fill Mode Adjustments

Pressing the Fill Mode button brings up the Fill Mode Selection menu.

Air Level and Temperature Adjustment

Pressing the Air Level button and Seal Temperature button opens the Blower Setting and Seal Drum Setting menus, respectively.

TROUBLESHOOTING

Error Codes

Material not properly threaded onto air tube
Material is jammed| Replace with full roll. See Section.
Ensure material is properly threaded onto air tube. See Section 4.2.
Clear jam if possible. See Section 6.2
460| RFID Error: No Tag| No RFID tag detected| Rotate roll of material. Verify material type. Load an alternate roll of material.
462| RFID Error: Invalid Material| RFID tag detected is not for the Turbo Machine| Verify material type. Power cycle the machine. Load an alternate roll of material.
464| RFID Error: Bad Tag Status| RFID tag detected is not readable| Rotate roll of material. Power cycle the machine. Load an alternate roll of material.
466| RFID Error: Bad Checksum| RFID tag detected has a bad checksum| Rotate roll of material. Power cycle the machine. Load an alternate roll of material.
468| RFID Error: No Recipe| RFID tag detected has no recipe on the Turbo Machine| Load an alternate roll of material. Load latest recipe set
470| RFID Tag Error: Invalid Tag| Invalid number of Blocks on RFID Tag, may be corrupted| Rotate roll of material. Power cycle the machine. Load an alternate roll of material.

*Note: Error 136 may present during power surges or lightning events. This is expected behavior.
Power cycle the machine to restore operation in this event.

Errors

Errors displayed that are not described above should be resolved by attempting the following steps.
(For Error 136 start with item 2.)

1. Clear the error. Remove the machine from sleep or start a cycle.
2.  Locate the power switch on the rear of the machine and restart the machine. Start a cycle after allowing the machine to heat.
3. Power off the machine and remove the power cord for 30 seconds. Plug back in the power cord and repower the machine. Start a cycle after allowing the machine to heat.
4. If a problem persists, call Technical Services at 886-904-6979.

Clearing Jams

In the event the machine jams, first break the web. Then, attempt to advance the material through the machine with the Jog button. If the jam persists, power off the machine. Attempt to remove the jammed material with your hands by pulling the film backwards, opposite to the feed direction. Do not remove the safety covers. Do not attempt to cut away material.
If the jam persists, call Technical Services.

Other Items

Depending on machine settings, material production may be less than optimal. Refer to the following to rectify the most common issues.

Wrinkled Seal
If the material leaves the machine with a large wrinkle in the seal – specifically in the cross-machine direction – ensure the roll of material is properly seated on the spindle. The inner core should be seated against the flange on the spindle. Decreasing machine temperature/fill may also remedy this issue. See Figure 6 in Section 4.2.
If the problem persists, call Technical Services.
Jamming at Startup
When loading material through the machine, ensure that the film is jogged all the way through.
See Section 4.2.1.
If the problem persists, call Technical Services.
Pillow Pops Off Air Tube
In the event a pillow comes off the air tube before being sealed, gets punctured by the air tube, or gets lodged and breaks a perforation, ensure the roll of material is properly seated on the Spindle. The inner core should be seated against the flange on the spindle. Decreasing machine fill may also remedy this issue. See Figure 6 in Section 4.2.
If the problem persists, call Technical Services.

Flat Pillows
If pillows exit the machine underinflated, first increase the inflation setting. Optionally, increase the sealer temperature. Ensure the film’s air channel is correctly threaded onto the air tube. Ensure the roll of material is seated against the flange on the spindle. See Section 4.2.
If the problem persists, call Technical Services.
Tearing at Seal
If the sealer is too hot, the sealer may burn through the material and air retention may be low.
Decrease the sealer temperature.
See Section 5.4.
If the problem persists, call Technical Services.
Perforation Failure
If the perforation breaks consistently, check to ensure the film is not rubbing on any object as it leaves the roll. Ensure the roll is properly seated. See Figure 6 in Section 4.2.
If the problem persists, call Technical Services.

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