AirSpace G6 Air Pillow Machine User Manual

AirSpace G6 Air Pillow Machine

Safety Precautions

• Always make sure the power is disconnected before touching any electrical part of the machine.
• In case of an emergency, ___
• During the installation and set up, the machine should be off and the power should be disconnected.
• Before doing any work on the machine, the machine should be turned off, disconnected and completely cooled down.

Technical Data

AIRSPACE G6  SPECIFICATIONS

AIR PILLOW FILM OPTIONS

Product| G4080875UP| G408107SUP| G408050~| G4080801| G4000S12| G4080812| 641004 2| 64100612| G4101012| 64080518| G4100618
---|---|---|---|---|---|---|---|---|---|---|---
Mil thic kntss| 0.75 MIL| 1 MIL| 1.2 Mil| 1.8 Mil
Sin| 8×8| 8×10| 8″ X 5″| 8″ X8| 8 X 5.,| 8″ X 8| 10• X 4•| 10″ X 6′| 1 0″ x 10″‘| 8″x5″| 10″ X 6•
Roll Length| 4750| 4750′| 3500′| 3500′| 2s50| 2850′| 2300′| 2300′| 2300′| 1925′| 1525′

BUBBLE-ON-DEMAND FILM

• Makes a 12″ x 12″ inflated bubble-on-demand sheet

FIVE MODES OF OPERATION

• Continuous Mode – dispenses pillows constantly
• Count Mode – dispenses a specific number of pillows
• Keypad Mode – dispenses 4, 8, 12, 15 or 20 pillows using discrete length buttons
• Foot Pedal Mode – allows machine control using an operator foot pedal
• Photo-Eye Mode – allows machine control using a vision sensor

TOUCH SCREEN FUNCTIONALITY

• Bilingual touch screen interface saves settings for quick changes between films
• Reset button changes settings to factory original for ease of troubleshooting
• Fine Tune Screen permits for small adjustments to the motor speed, fan speed and temperature
• Password protected screen reduces unauthorized changes

Machine Components

Key:

A: On/Off switch
B: Connector for optional foot switch or photo eye
C: USB Connector
D: Main Screen
E: Clamp Lever
F: Nozzle
G: Film Roller
H: Guide Roller
I: Power Cord Connector

AIRSPACE G6 – Operator

Air Pillow and Bubble on Demand Quick Start User Guide

#1

• Using a Philips screwdriver, position the roller in the back screw hole.
• Place the film on the roll holder.
• If you are using printed film, make sure the printed information is facing you; if you are NOT using printed film, make sure the channel is on the left.
  

#2A

• For air pillows, flip the roller stop so the blue tab is visible
  

#2B

• For bubble film, flip the roller stop so the yellow tab is visible
  

#3

• Rotate the clamp lever counterclockwise to release
  

#4

• Thread the film around the inflation tube
• To access the film channel opening, take the film and rub your fingers together to separate
  

#5

• Pull the film through
  

#6

• Rotate the clamp clockwise to lock down film
  

#7

• Plug the machine in and turn it on with the On/Off switch. Plug in optional accessories (photo eye or foot switch) as indicated.
  

#8

• The Main Screen will appear.
• If top of screen is red, the machine is not running.
• If the top of the screen is green, the machine is running

EZ Air Quick Start Supervisor Guide

Thread the film as indicated on the diagram.* (Make sure the information on the film is facing you.)

Plug in the machine and turn it on and see the MAIN SCREEN.

Press the AIRSPACE G6 logo.
The PASSWORD screen will appear.

On the PASSWORD SCREEN, Enter the code “2244”.
The SETTINGS screen will appear.

The SETTINGS SCREEN allows you to customize your job to meet your film characteristics and operational need.

Press:

• SPEED to select run speed.
• FILM to indicate the specs of the film being used
• MODE to select various run options
• FINE TUNE to adjust to motor speed, fan speed and temperature
• BACK to return to the Main Screen

SPEED SCREEN: Choose the appropriate setting.

| Pillows on Demand (POD)| Bubble on Demand (BOD)
---|---|---
FAST| 100’ per minute| 40’ per minute
NORMAL| 70’ per minute| 30’ per minute

EZ Air Quick Start Supervisor Guide – Film Selection

FILM TYPE SCREEN:

• PILLOW selects Pillow Film.
• BUBBLE selects Bubble film.

After selecting film type, you will be brought to the Film Width Screen.

FILM WIDTH SCREEN: Choose the appropriate film width:

PILLOW

• 8” Wide
• 10” Wide
• 12” Wide

BUBBLE

• 12” Wide
• 15” Wide

If Pillow Width is selected: You will be prompted to select the Pillow Perforation Width.

If Bubble Width is selected: You will be prompted to select the Film Thickness.

FILM PERFORATION WIDTH: Choose the appropriate distance between perforations. (Pillow Film Only)

8” WIDE PILLOW

• 4” Perforation
• 5” Perforation
• 8” Perforation
• 10” Perforation
• 12” Perforation

10” WIDE PILLOW

• 4” Perforation
• 6” Perforation
• 8” Perforation
• 10” Perforation
• 14” Perforation

12” WIDE PILLOW

• 4” Perforation
• 8” Perforation
• 12” Perforation

After selecting film perforation distance, you will be prompted to select film thickness.

FILM THICKNESS SCREEN: Choose the appropriate film thickness.

• 0.75 mil
• 0.80 mil
• 1.00 mil
• 1.20 mil
• 1.80 mil

Once film settings are complete, you will be returned to the main screen. Press the Green Button to Start your job

For assistance and questions contact Customer Service, 8 a.m. to 5 pm EST at 800-926-3700. After hours, leave a message.

User Screens

Main Screen

• Green button starts the machine
• Red button stops the machine
• Press the AIRSPACE G6 logo at the bottom of the screen to access the machine setting menus
  

Password Screen

• Enter the Password 2244 to access the setup menu
• “Back” button takes you to the Main Screen
  

Settings Screen

• “Speed” button selects the run speed for the machine
• “Film” button selects the film being used
• “Mode” button selects the operation mode for the machine
• “Fine Tune” button accesses the settings for the selected speed and film type
• “Back” button takes you to the Main Screen
  

SPEED SCREEN

• “Fast” is a factory preset, which can be adjusted in the Fine Tune menu.
• Pillow on Demand preset is 100’ per minute
• Bubble on Demand preset is 40’ per minute
• “Normal” is a factory preset, which can be adjusted in the Fine Tune menu.
• Pillow on Demand preset is 70’ per minute
• Bubble on Demand preset is 30’ per minute
• “Slow” is a factory preset, which can be adjusted in the Fine Tune menu.
• Pillow on Demand preset is 40’ per minute
• Bubble on Demand preset is 25’ per minute
  

FILM TYPE SCREEN

• PILLOW selects Pillow Film.
• BUBBLE selects Bubble film.
  

After selecting film type, you will be brought to the Film Width Screen.

FILM WIDTH SCREEN: Choose the appropriate film width:

PILLOW

• 8” Wide
• 10” Wide
• 12” Wide

BUBBLE

• 12” Wide
• 15” Wide

FILM PERFORATION WIDTH: Choose the appropriate distance between perforations. ( Pillow Film Only )

8” WIDE PILLOW

• 4” Perforation
•  5” Perforation
• 8” Perforation
• 10” Perforation
• 12” Perforation

10” WIDE PILLOW

• 4” Perforation
•  6” Perforation
• 8” Perforation
• 10” Perforation
• 14” Perforation

12” WIDE PILLOW

• 4” Perforation
• 8” Perforation
• 12” Perforation

FILM THICKNESS SCREEN: Choose the appropriate film thickness.

• 0.75 mil
• 0.80 mil
• .00 mil
• 1.20 mil
• 1.80 mil

MODE SCREEN

Note: See mode descriptions section for more details about different modes

• “Count” button selects the count run mode. When this button is pressed, you can select the number of air pillows you want to dispense in the count mode.
• “Continuous” button selects the continuous run mode
• “Keypad” button selects the Keypad run mode
• “Photoeye-Count” button selects the Photoeye triggered count run mode. When this button is pressed, you can select the number of air pillows you want to dispense in the count run mode.

FINE TUNE SCREEN

• Press the number above “Motor Speed” to select the motor speed fine tune. Then adjust the number up or down using the arrows.
• Press the number above “Blower Speed” to select the fan speed fine tune. Then adjust the number up or down using the arrows.
• Press the number above “Temperature” to select the seal temperature fine tune. Then adjust the number up or down using the arrows.
• “Enter” goes back to the Settings Menu
• “Service” goes to a service screen

SERVICE SCREEN

• “Total Film Feet” is the linear feet of material the machine has dispensed
• “Total On/Off Cycles” is the number of times the machine has started and stopped running
• “Settings” navigates you to the photo-eye delay and accessories screen. Accessories gives the choice to use a photoeye, or foot switch, Photo-eye delay let you fine tune the delay of the Photo-eye operation.
• “Reset” changes the fine tune setting to the factory setting for a given speed and film choice
• “Reset All” changes all the fine tune settings to the factory settings
• “Back” goes back to the settings menu

PHOTO EYE DELAY SCREEN

• “Start Delay” is the delay of time to begin operating the machine after the photo-eye has been triggered to start.
• “Stop Delay” is the delay of time to halt operation of the machine after the photo-eye has been triggered to stop.

Machine Run Modes

Continuous Run Mode

How to Enter the Mode

Select the “Continuous” button in the MODE menu and, if connected, disconnect the photo eye or the foot switch.

How the Machine Runs

When the green button on the main menu is pressed, the machine runs until the red button is pressed.

Count Run Mode

How to Enter the Mode

Select the “Count” button in the modes menu and, if connected, disconnect the photo eye or the foot switch

How the Machine Runs

When the green button on the main menu is pressed, the machine runs until either the red button is pressed, or the user-defined number of pillows have been dispensed from the machine.

Keypad Run Mode

How to Enter the Mode

Select the “Keypad” button in the modes menu and, if connected, disconnect the photo eye or the foot switch

How the Machine Runs

Press the number button to dispense that predetermined number of air pillows. For example, pressing the green “20” button dispenses 20 air pillows.

Foot Switch Continuous Run Mode

How to Enter the Mode

Select the “Continuous” button in the modes menu and connect the foot switch to the back of the machine.

How the Machine Runs

When the foot switch is pressed, or the green button in the main menu is pressed, the machine runs until the foot switch or the red button is pressed.

Foot Switch Count Run Mode

How to Enter the Mode

Select the “Count” button in the modes menu and connect the foot switch to the back of the machine.

How the Machine Runs

When the foot switch or the green button is pressed, the machine runs until either the foot switch is pressed, the red button is pressed, or the user- defined number of pillows have been dispensed from the machine.

Photo Eye Continuous Run Mode

How to Enter the Mode

Select the “Continuous” button in the modes menu and connect the photo eye sensor to the back of the machine.

How the Machine Runs

When the green button in the main menu is pressed, the machine runs until the photo eye sees an air pillow. Then it pauses until the air pillow is removed. If the air pillow is removed, the machine runs again until the photo eye sees another air pillow. When the red button in the main menu is pressed, the machine is stopped.

Factory Machine Settings

Temperature Settings

These are factory settings preset into the machine. When a given speed and film thickness is chosen, a film seal temperature is automatically selected. These setting can be adjusted in the Fine Tune menu.

Blower Speed Settings

These are factory settings preset into the machine. When a given speed and film type is chosen, a film blower speed is automatically selected.
These setting can be adjusted in the Fine Tune menu.

Pillow

Bubble

Maintenance

Changing Belts

1. Turn off the machine and unplug the power cord from the machine.

2. Remove the two screws (A) holding on the upper heater block cover
   

3. Remove the two screws (B) holding on the lower heater block cover.

4. Remove the two covers from the machine.

5. Raise the upper heater block by moving the clamp lever (C) into the up position.
   

6. Pull the rear belt guide roller (D) forward and pull off the old belts.

7. Put the new belts on by putting the belt on the front roller (E) first and then onto the back roller (D) with the roller pulled forward.
   

8. Attach the upper lower side covers.

Changing the Blade

1. Turn off the machine and unplug the power cord from the machine.

2. Remove the three screws (A) holding on the left side of the housing.
   

3. Remove the small screw (B) on the machine frame.
   

4. Locate the blade between the circuit board and blower hose, and remove the screw (C).
   

5. Note the orientation of the blade before removal, and make sure to align the new blade in the same manner that the old blade was removed.

6. When installing new blade, make sure front of blade is seated below the outer surface of the nozzle. Failure to perform this may result in the film not cutting and cause clogs in the machine.

7. Reinstall covers, and test machine function.
   

Changing the Upper and Lower Heater Blocks

1. Turn off the machine and unplug the power cord from the machine.

2. Remove the belts from the machine, following the maintenance guide for changing belts. (Page 18)

3. Remove two 5mm socket head screws on upper heater block (A) along with retainer plate.
   

4. Pull out the upper heater block, carefully, until yellow wires are visible (B).
   

5. Remove two 2mm socket head screws (C) from upper heater block, and remove wires from terminals. The upper block is now free for removal.
   

6. Once the upper block is removed, the lower block can now be removed. To remove the lower block, simply lift from below the lower block until it is free from the locating posts. (D)
   

7. Turn the lower block upside down to remove the 2mm socket head screws holding the red wires to the lower block. (E)
   

8. The lower block is now free for removal. Installation for replacement heater blocks is the reverse of removal.

Machine Error Codes

• Check that the heater clamp is down
• This error will clear when the clamp is in the down position.

The film roll is not moving. This can be due to no film on the roller or in the feed rollers.|

• Check the roller has material on it.
• Check the film is fed correctly onto the nozzle
• Check the film is being pulled all the way through the heating element block and the feed rollers.

The heating element is not heating. Please check wiring.|

• Check all wires going to the heating elements.
• If no loose wire is seen, call Better Packages Service for assistance
• Once the problem has been fixed, turn the machine off and then on

Over temperature condition has been detected. Check temperature sensor and heater block.|

• Check for signs of over temperature, burnt belts, etc.
• If signs of burnt belts are present, Call POLYAIR Customer Service for assistance.*
• If no sign of burnt belt is present, replace Upper Heater Block.

Temperature reading out of range. Check temperature sensor.|

• Replace Upper Heater Block.
• Call POLYAIR Customer Service for assistance.*

Motor rotation has been stopped. Check for film jam.|

• Check feed roller for a film jam.
• If no film jam is seen, Call POLYAIR Customer Service for assistance.*

Broken Belt or Belt Switch Activated|

• Replace both upper and lower belts.

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