ULINE Instant Bubble Roll Machine User Guide

SAFETY

BEFORE OPERATING THIS MACHINE:

1. Read and thoroughly understand this guide.

2. Read and understand all safety instruction labels attached to the system.

3. Be sure the system is plugged into a properly rated, grounded outlet.
   WARNING! Failure to properly ground the system could create an electrical shock hazard.
   WARNING! Do not remove the guards or access covers.
   WARNING! Risk of entrapment ­ Keep fingers, loose hair, clothing and jewelry away from the edge seal roller when material is feeding, inflating and sealing.
   WARNING! Hot Surface ­ Edge seal roller will become hot during use.
   WARNING! Do not use the material as a flotation device, toy or pillow.

4. Inspect at regular intervals to ensure that:

   • Component cables are not cut, broken or damaged.
   • All controls and indicators function properly

5. Airborne Noise Emission:

   • This machine does not exceed 80 decibels during normal operation. Please check to make sure you comply with your local health and safety requirements.

6. Environmental Conditions:

   • Storage temperature: Machine and material rolls ­ 32°-110°F (0°-43°C).
   • Operating temperature: Machine and material rolls ­ 60°-110°F (16°-43°C).

OVERVIEW

SYSTEM DESCRIPTION

The H-4008 Instant Bubble Roll Machine creates on-demand air-filled cushioning material from a compact/uninflated pre-formed roll of material. The inflated material chain is perforated into sections and can easily be separated by the operator as needed.

There are 3 modes of operation:

MANUAL MODE

• Press the start key to begin producing air-filled material and the stop key to end production.

BATCH MODE

• Dispense a programmed length of inflated material.

ROLL WINDER MODE

• Requires optional roll winder (H-4621) and stand (H-4620).
• Dispense a roll of inflated material.

ELECTRICAL POWER REQUIREMENT

WARNING! Use of extension cord will increase the levels of static, resulting in operational problems.

Inflatable Cushioning System: 115 VAC
Receptacle Type: NEMA 5-15R
A/C Voltage: 100-120 VAC 50/60 Hz
Phase: Single Phase Grounded
Current: 15A Service 4.0A

NOTE: The use of non-Sealed Air materials will cause production problems, may damage the equipment and will reduce the quality of the packaging protection.

SYSTEM COMPONENTS

1. ON/OFF Power Switch This circuit breaker switch controls power to the system and is located on the back of the system.

2. Emergency Stop Switch (E-Stop) This emergency stop switch stops all feeding, inflating and sealing functions.

3. Main Power Cord Plug this cord into a properly rated receptacle ­ see Electrical Power Requirements.
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4. Control Panel This panel with LCD display and keys is used to operate, program and diagnose the system ­ see Operation.

5. Material Mandrel This mount provides an unwind position for the material roll.

6. Edge Seal Assembly This replaceable component wheel creates an edge seal to seal air in the material ­ see Replacing the Edge Seal.

SYSTEM SETUP

1. Uncrate the machine.
2. The installation area should have a sufficient amount of clear, dry and level space for your packaging application, operation and service of machine.
3. Verify that the required electrical power receptacle is installed at the desired machine location.
4. Load the material roll.

LOADING THE MATERIAL ROLL

1. Load the material roll onto the material mandrel. (See Figure 1)

   • Hold the new material roll so that the open end is facing towards the control panel.
   • Slide the roll fully onto the mandrel so that the end of the core is contacting the collar.
     

2. Feed the material into the system. (See Figure 2)

   • Lower the clamp handle to open the edge seal assembly.
   • Thread the material over the blue directional roller and under the black bar.
   • Spread the open end of the material and wrap around the inflation nozzle (bent metal tube) and the material “flapper.
   •  Thread between the two wheels on the edge seal assembly.
     

3. Close the clamp and make a few feet of inflated cushioning material. (See Figure 3)

   • While maintaining tension on the material, raise the clamp handle to close the edge seal assembly.

NOTE: If the material is not inflating and/or sealing after 8″ (20cm), re-feed the material. (Step 2).

OPERATORS MENU

To enter the Operator’s Menu, press and hold the Up/ Down arrows ( / ) for 5 seconds.

Film Type Selection Available to the Operator

• ON allows the operator to select film types.
• OFF does not allow the operator to select film types.

Roll Size Adjustment

• Adjust the diameter of the roll when using the optional roll winder arm. (H-4621)
• 20″-40″ (50cm-100cm) diameter. · 2″ (5cm) increments. Batch Size Adjustment Available to the Operator
• ON allows the operator to adjust batch sizes. · OFF does not allow the operator to adjust batch sizes.

FILM CODE SETTINGS

FILM CODE SETTING

ITEM NO.

|

DIMENSIONS

|

FILM CODE

S-19738| Medium Premium (1/2″ inflated) 12″ x 2,050′ Perf 12″| RK8R
S-19739| Medium Premium (1/2″ inflated) 24″ x 2,050′ Perf 12″| RK8G
S-19740| Large Premium (3/4″ inflated) 12″ x 1,250′ Perf 12″| NJ8R
S-19741| Large Premium (3/4″ inflated) 24″ x 1,250′ Perf 12″| NJ8K
S-19742| XL Premium (1″ inflated) 12″ x 1,167′ Perf 12″| AO8C
S-19743| XL Premium (1″ inflated) 24″ x 1,167′ Perf 12″| AO8Q

NOTE: The factory default film setting is S-19740, film code NJ8R.

CHANGE THE FILM CODE SETTINGS

1. Press the up and down arrows and the reset button at the same time to access the menu. (See Figure 4)
   

2. Use the arrow buttons to move the cursors on either side of the screen to Engineering. Press the select button on the left to select Engineering. (See Figure 5)
   

3. Use the arrow keys to move the cursor to Film Type. Press the SELECT button on the left to select Film Type. (See Figure 6)
   

4. Use the arrow keys and SELECT button to set each digit to match the film code for the corresponding item number. After the last digit has been set, press the SELECT button to save the film code. (See Figure 7)
   

OPERATION

PRODUCING AIR-FILLED MATERIAL IN BATCH MODE

1. Select Batch Mode.
   • Press and hold the start key for 5 seconds to enter Batch Mode.
2. Adjust the batch length.
   • Using the Up/Down arrows  , set the batch length in feet.
3. Press the start key.
   • Press the start key to begin batching.
   • Press the stop key to pause batching.
     

PRODUCING AIR-FILLED MATERIAL IN ROLL WINDER MODE

1.  Press the winder release button.
   • Press the winder release button to lower the roll winder.
2.  Set the roll diameter.
   • Press and hold the Up/Down arrows  for 5 seconds to enter Operator’s Menu.
   • Scroll to Menu 2 Roll Size.
   • Using the Up/Down arrows  , set the diameter from 20″-40″ (50cm 100cm) in 2″ (5cm) increments.
   • Press SELECT.
   • Press (//) reset to return to the Ready window.
3. Create a 3′ (1m) length of inflated material.
   • Using the start key, create a 3′ (1m) length of inflated material.
   • Using the stop key, stop the system
4. Slide the leading edge of the inflated material into the winder slot
5. Start the roll winder.
   • Toggle the winder start button to start/stop the roll winder.
6. Remove the finished roll of inflated material
   •  The winder will automatically stop once the roll reaches the programmed diameter.
   • Tear at a perforation and slide the roll off of the winder.

MAINTENANCE AND REPAIR

PREVENTATIVE MAINTENANCE

Monthly

• Blow off all dust and debris from the system.
• Check for any unusual wear on components.
• Check for any unusual wear or buildup on the side of the seal assembly.

REPLACING THE EDGE SEAL

Materials required:

• H-4008-SEALR   Edge Sealer

NOTE: The system must be ON for the following procedure. Ensure components are cool before proceeding.

1. Lower the clamp handle to open the edge seal.
2. Push the release button (in the center of the edge seal wheel) in while pulling the edge seal wheel and black plastic gear straight out approximately .25″ (6mm). (See Figures 8 and 9)
3. Pull the edge seal wheel away from the black plastic gear. (See Figure 10
4. Install the new edge seal:
   • Align the three (3) connection pins on the new wheel with the three (3) receptacle holes in the seat.
   • Push the release button in while pushing the wheel fully against the black plastic gear.
   • Do not load film. Raise the clamp handle to close the edge seal.
5. Load film, press (//) reset key, then start key to calibrate the new edge seal ­ 3′ (1m) of uninflated material will automatically feed out.
   Figure 8
   
   Figure 9
   
   Figure 10
   

TROUBLESHOOTING

NO POWER TO THE SYSTEM :

PROBLEM

|

CAUSES

|

RECOMMENDATIONS

---|---|---
There is no power to the system and the control panel display is OFF.| System is off.

Main power cord is unplugged at the outlet.

Facility power supply is interrupted. Electrical component failure.

| Turn the main power switch to the ON position.

Verify the main power cord is plugged into a properly rated outlet – see Electrical Power Requirements.

Verify facility power supply – see Electrical Power Requirements.

Contact Uline Customer Service.

DISPLAYED FAULT MESSAGES :

DISPLAYED MESSAGE

|

CAUSES

|

RECOMMENDATIONS

---|---|---

01 E-Stop Pressed| E-Stop switch pressed.| Twist E-Stop to release.

03 Clamp Open| Edge seal clamp is open.| Hinge the clamp handle up to close

the edge seal and press reset key.

08 Check Film Path| Out of film. Material roll is improperly loaded.| Load

new roll – see Loading the Material Roll. Reload roll as required – see Loading the Material Roll.

17 Edge Seal Fault| Edge seal wheel is missing or not fully seated. Edge seal

failure.| Check condition of edge seal and verify that it is fully seated. Replace as required – see Replacing the Edge Seal. Contact Uline Customer Service.

43 Check Inflation| Material roll is improperly loaded at the nozzle. Faulty

material. Electrical or mechanical failure.| Reload roll as required – see Loading the Material Roll. Load new material – see Loading the Material Roll. Return material roll – contact Uline Customer Service. Contact Uline Customer Service.

51 Check Web Control| Flapper is out of film skirt. Flapper is faulty, worn

or missing.| Reload roll as required – see Loading the Material Roll. By hand, pull the flapper out of its mount and fully insert a new one.

PROBLEMS WITH MAKING INFLATED MATERIAL :

PROBLEM

|

CAUSES

|

RECOMMENDATIONS

---|---|---
The material will not advance – the control panel is ON.| Material roll is empty. Material roll is improperly loaded. Electrical or mechanical failure.| Load a new roll as required – see Loading the Material Roll. Reload roll as required – see Loading the Material Roll. Contact Uline Customer Service.
The material advances and edge seals are present, but the material does not fill with air.| Material roll improperly loaded. The material layers are not properly wrapped around the inflation nozzle. Faulty material. Electrical or mechanical failure.| Verify that the open end of the material is facing in towards the inflation nozzle – see Loading the Material Roll. Load new material – see Loading the Material Roll. Return material roll – contact Uline Customer Service. Contact Uline Customer Service.
The material advances and fills with air, but the material does not seal properly.| Material roll improperly loaded. Faulty edge seal. Faulty material. Seal power out of adjustment. Electrical or mechanical failure.|  Reload material roll – see Loading the Material Load. Check condition of edge seal on the material. Check condition of edge seal and verify that it is fully seated. Replace as required – see Replacing the Edge Seal. Contact Uline Customer Service. Load new material – see Loading the Material Roll. Return material roll – contact Uline Customer Service. Remove, re-install and calibrate the edge seal – see Replacing the Edge Seal. Contact Uline Customer Service. Contact Uline Customer Service.
The inflated material leaks air.| Material roll improperly loaded. Faulty edge seal. The operator is pulling the inflated material directly out of the system before the inflated material can cool. Faulty material. Seal power out of adjustment. Electrical or mechanical failure.| Reload material – see Loading the Material Roll. Check condition of edge seal on the material. Check condition of edge seal and verify that it is fully seated. Replace as required – see Replacing the Edge Seal. Contact Uline Customer Service. Do not attempt to pull inflated material from machine. Contact Uline Customer Service. Load new material – see Loading the Material Roll. Return material roll – contact Uline Customer Service. Remove, re-install and calibrate the edge seal – see Replacing the Edge Seal.

Contact Uline Customer Service. Contact Uline Customer Service.

The inflated material has an inconsistent air-fill amount.| Material roll improperly loaded. Faulty material. Electrical or mechanical failure Material has been affected by storage conditions.| Reload material roll – see Loading the Material Roll. Load new material roll – see Loading the Material Roll. Return material roll – contact Uline Customer Service. Contact Uline Customer Service. Refer to storage conditions under Safety.

PROBLEMS WITH THE ROLL WINDING :

PROBLEM

|

CAUSES

| RECOMMENDATIONS
---|---|---
The roll winder will not wind inflated material.| The winder is stopped. The winder is not plugged in. Obstruction blocking the winder or the roll. Electrical or mechanical failure.| Press the winder start button – see Producing Air-Filled Material in Roll Winder Mode. Verify that the roll winder is plugged in to the bottom of the machine. Verify the roll can wind free of obstruction. Contact Uline Customer Service.
The roll is a different diameter than expected.| The diameter setting is set incorrectly. Material roll is empty Electrical or mechanical failure.| Verify diameter setting – see Producing Air-Filled Material in Roll Winder Mode. Load a new roll as required – see Loading the Material Roll. Contact Uline Customer Service.

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