safety, operation, and maintenance pregis airspeed 5000...

SAFETY, OPERATION, AND MAINTENANCE

Pregis AIRSPEED 5000

AIR CUSHION MACHINE

(Part No. 136309)

01-01-06

SECTIONINSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NUMBER

1 SAFETYOPERATING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1SAFETY ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

2 OPERATIONINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1OPERATOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2MANAGEMENT INTERFACE SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

3 MAINTENANCESEALING BELT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

4 TROUBLESHOOTINGTROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

TABLE OF CONTENTSP5000 AIR CUSHION MACHINE (136309)

TABLE OF CONTENTS

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Operator safety and the safety of others in the workarea depends on the operator using common sense,good judgement and reasonable care while operat-ing the machine. The Safety, Operation andMaintenance manual, and warning labels affixed tothe machine, provide notification of specific poten-tial hazards.

NOTE: Refer to the Safety Alerts instruction foradditional safety-related information.

Safety

The following instructions are only a guideline andshould be considered a supplement to your plant'scomprehensive safety program. Your business' pol-icy supercedes these guidelines if at any time thetwo contradict each other.

1. Read and understand the manual. If after read-ing the manual you have questions, getanswers before working with the machine.

2. Read and understand all of the danger, warn-ing and caution statements in the manual andon the signs attached to the equipment.

3. Never deface or remove factory installedwarning decals. If a decal ever becomes lost,damaged or illegible, report this condition to asupervisor and obtain a replacement decal.

4. Keep the work area clean and uncluttered.Walking surfaces should always be free ofpacking material and debris to prevent a slip-ping or tripping hazard.

5. Ensure that all covers, guards and other safetydevices are in place. Never defeat a safetydevice for any reason.

6. Follow the manufacturer's recommended start-up procedure.

7. Never leave the equipment unattended whileoperating. Shut the machine off if you mustleave the work area.

8. Keep body parts and clothing away from mov-ing components such as nip rolls, power trans-mission components, sealing belts, etc. Neverreach into the machine for any reason while itis in motion.

9. Understand what will happen when you oper-ate the various controls.

10. Understand the proper web path and the safemethod for threading the web.

11. Learn the safe procedure for clearing themachine of web wraps or jams.

12. Exercise extreme care whenever it is requiredto inspect or adjust the machine while it is inmotion. NEVER reach into the machine forany reason while it is motion.

13. Understand which adjustments are operatoradjustments; contact a maintenance person tomake all other adjustments.

14. Never operate or work around equipment ifyou are under the influence of alcohol, drugsor medications that can make you less alert oraffect your judgement.

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OPERATING SAFETYPREGIS AIRSPEED 5000AIR CUSHION MACHINE

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Operator safety and the safety of others in the workarea depends on the operator using common sense,good judgement and reasonable care while operat-ing the machine. The Safety, Operation andMaintenance manual, and warning labels affixed tothe machine, provide notification of specific poten-tial hazards.

Safety signs are used to alert operating and mainte-nance personnel to potential hazards. The machinemanual also calls attention to potential hazardswith statements describing the hazard. Both thesafety signs on the machine and the warnings in themanual use signal words to identify the seriousnessof the potential hazard. These signal words areDanger, Warning and Caution.

The meanings of the signal words and the level ofpotential hazards they represent must be clearlyunderstood before attempting to operate or main-tain the machine. If, at any time, a safety sign onthe machine becomes lost, damaged or illegible,contact Pactiv to order replacement signs at nocharge.

SAFETY ALERTSPREGIS AIRSPEED 5000AIR CUSHION MACHINE

An definitely hazardous situation that, ifnot avoided, will result in serious injury ordeath.

A potentially hazardous situation that, ifnot avoided, could result in serious injuryor death.

A potentially hazardous situation that, ifnot avoided, may result in minor injury (ormachine damage).

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Introduction

The Pregis AIRSPEED 5000 (Figure 1) producesair-filled packing cushions in any quantity, as need-ed. The ability to create packing cushions ondemand saves storage space and reduces packagingmaterial waste.

Packing cushions are created in strings of individ-ual cushions. The string can be torn apart at perfo-rations cut between each cushion. The perforationrepeats can be 6" or 8" on film webs 8.88" or10.88". Cushions are created at a constant rate ofup to 50 feet per minute (fpm) of film feed. Theamount of cushions created per minute will varywith the film cushion size.

Operation

The film web is a continuous tube in which thereare pairs of cross seals, with a perforation placedbetween them, spaced every four to eight inches.The cross seals stop 0.56"-0.62" from one edge ofthe film. This creates a gap or tube, in the filmdirection, along that edge of the film.

INTRODUCTIONPREGIS AIRSPEED 5000AIR CUSHION MACHINE

Figure 1PACTIV Air 5000 System

DO NOT OperateWith GuardsRemoved!

Electrical shock or unexpected machinemovement can cause injury. DO NOToperate machine with guards removed orcovers open.

For your safety, follow your company’slockout/tagout policy as required for eachtask.

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The film is loaded onto the unwind shaft with theseal gap edge facing the inside. The film is thenrouted around the outside of a spring-loaded roller.This roller maintains film tension by controllingthe amount of braking applied to the unwind shaft.The seal gap edge of the film is then guided overthe end of the air injection tube. The air injectiontube extends through the seal section, and past theoutfeed nip rollers. See Figures 2 and 3.

INTRODUCTION - P5000

UnwindShaft

FilmRoller

Air Injection Tube

Belt TensionerRoller

GuideRollers

Guide Rollers

UpperSealing Belt

Lower Sealing Belt

SeeFigure 5

See Figure 3 forInterior View

Figure 2Front/Side View - DO NOT Operate With Guards Removed!

Air Injection Slot

Infeed Nip Rollers

Outfeed Nip Rollers

Diverter Rollers

CoolingFan

SealingGuard/Clamp

CoolingFan


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A proximity sensor and grooved wheel assemblyare mounted on the inside of the machine enclo-sure. This assembly acts as a counter for detectingfilm feed. The sensor and wheel assembly aremounted on a length of spring steel.

The wheel protrudes through a slot in the frame tocontact the air injection tube. (Figure 3) An o-ringin the wheel groove provides the traction requiredfor the moving film to turn the wheel.

Holes in the wheel are detected by a proximity sen-sor and processed by the PLC to determine filmfeed. This counter also acts as a “Film Run Out” or“Web Break” detector. The machine stops whenthe counter stops.

An upper and lower teflon sealing belt are eachrouted around a set of guide rollers, a spring-loadedtensioning roller, and nip rubber rollers. Film ispulled from the roll by the infeed and outfeed nips.See Figure 2.

Figure 3Film Feed Counter (Inside View)

Wheel

Proximity Sensor

UnwindShaftBrake

UnwindShaft

FilmRoller

TensionSpring

Film RollerBracket

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The lower roller of both the infeed and outfeed nipsare directly-driven by electric motors. Gears aremounted on the upper and lower roller shafts insidethe frame. A cam is hand-turned to push the upperroller down in contact with the lower roller. Gearson both rollers mesh so that the upper roller is driv-en by the lower roller. In addition to pulling film,the nips also drive the sealing belts. See Figure 4.

When unloaded, the nip upper roller is spring-loaded to retract away from the lower roller. Whenthe nip is opened, the drive gears remain partiallymeshed. This aids in gear alignment when the nipis closed again.

A self-contained air compressor (Figure 4) gener-ates the air flow and pressure used to inflate thecushions. Just downstream of the infeed nip, air isinjected into the cushions through a slot in the airinjection tube. The edge of the inflating cushionthen travels through pairs of seal belt diverterrollers before entering the sealing section. Thebelts are diverted away from each other to create anopening for the air to blow into the cushion withminimal resistance. See Figure 2.

The film is captured between the upper and lowersealing belts as it travels through the sealing sec-tion. The sealing head assembly is spring-loaded.The sealing wire presses down against the inside ofthe upper sealing belt. This downward pressureforces the sealing belts, with the web sandwichedbetween, against the lower platen.

Figure 4Inside View from Top

Outfeed NipDrive Motor

Infeed NipDrive Motor

See Figure 6

AirCompressor

See Figure 3

NipOpen

NipClosed

LubeCam

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The lower platen consists of a self-aligning alu-minum block covered on top with a layer of soft sil-icone and then a strip of heat-resistant, stiff plastic(Durit™). See Figure 5.

A sealing guard/clamp and block are mounted out-side of the sealing head and platen. The upperguard/clamp is spring-loaded against the lowerblock. This helps to hold the sealing belts and filmtogether during sealing. See Figure 2.

The guard/clamp also isolates the cushion air fromthe seal so the hot seals are not stressed. While thefilm is being driven and sealed, a knife blade issimultaneously cutting open the outside seal gapedge. The film edge must be slit open to allow it toexit off the air injection tube. The knife blade ispartially inserted into a slot in the air injection tube.The blade is located at approximately the center ofthe sealing section. See Figure 6.

The web of inflated and sealed cushions are pulledthrough the sealing section by the outfeed nip. Asthe web passes out from between the sealing belts,a pair of fans blow air at the cushion seals. This airflow helps to cool and set the seal while guiding thecushions out of the machine. The fans also providemachine cooling, drawing air from inside themachine cabinet. See Figure 2.

Figure 5Film Sealing

Figure 6Slitter Blade (Inside View)

SealingWireLower

Platen

(Upper Sealing Guard/Clamp removed for clarity)

AirInjection

Tube

SealingWire

Lower Block

Air InjectionTube

OutfeedNip

UpperRoller

SealingWire

Slitter Blade

SealingBelts

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Controls

NOTE: Refer to Figure 1 unless noted other-wise.

1. Operator Interface ScreenUsed to monitor, select and adjust the air cush-ion machine operating parameters.

2. (Up/Down) ArrowsUsed to navigate through various displayscreens. Screens may be password-protectedand accessible only by maintenance personnel.

3. +/- (Plus/Minus)Used to increase or decrease quantity, such asthe length of film run or sealing wire tempera-ture. When pressed and released, they act asmomentary buttons, changing the value inincrements of one (1). When pressed and held,the value changes in larger increments.

4. STARTUsed to run the machine during normal opera-tion.

5. STOPUsed to stop the machine.

6. JOGUsed to run the machine slowly (preset speed)to feed the film through for web thread-up.

7. Reset ( / / )Used to clear fault messages and allow themachine to run. Press to return to the Readyto Run screen.

8. Nip Open/Close LeverA nip control lever is located on each end ofthe machine, one each for the infeed and out-feed nips. Turn lever in the direction indicat-ed on the cabinet to open or close the nip.

OPERATOR CONTROLSPREGIS AIRSPEED 5000AIR CUSHION MACHINE

Figure 1Operator Control Panel (Outfeed End)

2 1

4 765

3

8

9

OPERATOR CONTROLS - P5000

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9. Inflation Gauged RegulatorUsed to set the cushion air inflation pressurewhile running. The air compressor alwaysputs out 5 psi. The regulator bleeds off excessair. Refer to the air pressure label on themachine for the approximate setting (psi) forthe cushion size being run.

NOTE: Settings on the air pressure label areintended as initial guides only. Actualsettings may vary for requirements.

10. Power SwitchUsed to turn electrical power to the machineOn or Off. Located next to power supply cord.See Figure 2.

11. Footswitch (Option)Used as a remote control for starting and stop-ping. Duplicates the function of the controlpanel START and STOP buttons. Connectedwith a 10' long cable to either of the inputinterface ports (Figure 2) on the end of themachine. See Figures 3 and 8.

12. Remote Control (Option)Used as a remote control for starting and stop-ping. Duplicates the function of the controlpanel START and STOP buttons.

The remote control kit contains a radio trans-mitter mounted inside the air cushion machine,a length of antenna wire, and the handheldpendant. (See Figure 4) The antenna wire,hanging out of the machine, allows the remoteto operate at up to a 30' range.

Figure 2Infeed End View

Figure 3Optional Footswitch

11

8

10Input Interface

Ports


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NOTE: Electrical interference (radio-frequencynoise), as generated by an AC motor,tends to reduce the effective range ofthe remote control. Usually, only theoperation the cushion machine air com-pressor affects the operation of the radioremote control. This causes the STOPrange of the remote control to be lessthan its START range.

Operator Interface Touchscreen

The operation of the Interface Screens are separat-ed into three (3) levels of security defined by pass-words that allow access only to specific personnel.

The access levels are defined as:

OperatorManagementTechnician

Each level of access allows varying access to thefollowing screens:

Main (Ready to Run)MACHINE SETUP

PasswordSeal Temperature

Use the Up/Down arrow ( ) buttons to select aspecific line/function. The cursor ( ) moves to theselected line.

Use the Plus/Minus (+/-) buttons to change theActual value, or accept the line/function choicewhich routes you to the applicable screen.

Main (Ready to Run)This screen allows the operator to select themachine operating mode. See Figure 5.

The three (3) operating modes include:

Normal OperationThe machine is started and runs continuouslyuntil manually stopped, or film supply isdepleted. Machine operation is controlled bythe control panel START and STOP buttons,and/or the remote foot pedal and/or the hand-held radio control. See Figure 5.

Figure 4Remote Control Pendant

Figure 5Main screen - Normal Operation

12


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Automatic Stopafter xx ft.

Used to manually select a length of film to run.The machine will stop once the proximity sen-sor detects the set film length has been run.The quantity of cushions created for the select-ed film length will vary with the cushion size.See Figure 6.

Use the arrow ( ) buttons to move to thelength selection line. The film length run is setwith the Plus/Minus (+/-) buttons anywherefrom 1 to 99 feet or meters. The length set willbe the same on both the Automatic Stop(Figure 6) or Fill The Basket (Figure 7) screen.

Fill The Basketwith xx ft.

Used to select a length of film to automatical-ly run once the collection basket/bin is low. Asensor mounted above the bin detects when thebin is low, after which the selected length offilm is then run. See Figure 8.

After the sensor initially detects the bin as low,there is a four second delay before the cushionmachine is started. This prevents the cushionmachine from pulsing on and off.

Once the preset length of film has been run,the Main screen “RUNNING” messagechanges to “PAUSED”, and the machine stops.See Figure 7.

NOTE: The bin sensor interface cable plugsinto either input port on the back of thecushion machine. See Figures 2 and 8.

Figure 6Main screen - Automatic Stop

Figure 8Optional Cart and Bin

Cart

Bin

BinSensor

InputInterface

Ports

Footswitch

Figure 7Main screen - Fill The Basket


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Setup the MachineSelecting this function brings up the Passwordscreen (Figure 9), where a security password mustbe entered before proceeding to the next screen.

Seal TemperatureSelecting this function routes you directly to theSeal Temperature screen. See Figure 10.

NOTE: Management may protect the seal tem-perature setting by requiring a passwordto be entered before allowing access tothe Seal Temperature screen. If so, thePassword screen (Figure 9) will appear.

MACHINE SETUP Screens

All MACHINE SETUP screens list the current set-ting, or selection for the specific parameter, as theActual value. The range of possible values forActual are listed next at Minimum and Maximum.If applicable, the unit of measure for the values islisted at Units.

PasswordUsed to enter the password required to gain accessto specific screens. (Figure 9) Once the correctOperator password is entered, with the Plus/Minus(+/-) buttons, press the Up arrow ( ) button toaccept the password and proceed to the SealTemperature screen.

NOTE: Once you leave the Password screen,the password value shown at Actualreturns to the default of zero (0).

Seal TemperatureUsed to set the sealing (wire) temperature. (Figure10) Once an Actual value has been entered (+/-)and accepted ( ), the Password screen appears.Press the Plus (+) button to return to the previousscreen, in this case Seal Temperature. Press theRESET (/ /) button to return to the Ready to Runscreen.

Figure 10Seal Temperature screen

Figure 9Password screen

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The operation of the Interface Screens are separat-ed into three (3) levels of security defined by pass-words that allow access only to specific personnel.

The access levels are defined as:

OperatorManagementTechnician

The passwords for both the Operator andManagement levels may be changed at theTechnician level. The Technician level passwordhas been programmed within the software and cannot be changed on-screen.

The first, basic level of access is defined as theOperator, and these screens are covered within theOperator Controls instruction. These screensinclude the following:

Main (Ready to Run)MACHINE SETUP

PasswordSeal Temperature

All MACHINE SETUP screens list the currentvalue or selection for the specific parameter head-ing as the Actual value. The range of possible val-ues for Actual are listed next at Minimum andMaximum. If applicable, the unit of measure forthe values is listed at Units.

The second level of access is defined asManagement. This level includes all Operatorscreens, as well as the following additionalMACHINE SETUP parameter screens:

Language SelectionTemperature Scale (ºF/ºC)Distance Selection (Metric/English)Belt Odometer

For all MACHINE SETUP parameter screens, thearrow cursor ( ) designates the active Actual valueline. Use the Plus/Minus (+/-) buttons to changethe line value. Press the Up/Down arrow ( )buttons to accept the new value and move to anoth-er parameter screen.

From the Seal Temperature screen, pressing theUp arrow ( ) button brings you to the LanguageSelection screen, if the Management level accesspassword has been entered.

NOTE: At any access level, on any screen,pressing the Reset (/ /) button returnsyou to the Ready to Run screen. Referto the Operator Controls instruction.

MACHINE SETUP Screens

Language SelectionAllows the screens to display output in any one offive language choices. The default language choiceis English. Select a numeral that corresponds toone of the five available languages. See Figure 1.

0 French1 German2 Italian3 Spanish4 English

MANAGEMENT INTERFACE SCREENSPREGIS AIRSPEED 5000AIR CUSHION MACHINE

MANAGEMENT INTERFACE SCREENS - P5000

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Temperature ScaleAllows the screens to display temperature in eitherthe ºF or ºC scale. The default choice is ºF. SeeFigure 2.

0 ºF (Fahrenheit)1 ºC (Centigrade)

Distance SelectionAllows the screens to display distance in eitherEnglish feet-per-minute (fpm) or Metric meters-per-minute (mpm). The default choice is fpm. SeeFigure 3.

0 English (fpm)1 Metric (mpm)

Belt OdometerUsed to view the current run distance, in kilometers(km), since the last time the belts were rotated. TheActual value designates the current run distance.

When the Actual value reaches the preset value, setat the technician level, the Main screen “Ready toRun” message is replaced by a “Change Belts”message. The machine will continue to operate.

After the belts are rotated, press and hold the Minus(-) button to reduce the Actual value to zero (0).Reducing the Actual value to zero resets theodometer in the PLC, returning the Main screenmessage to “Ready to Run”.

Figure 1Language Selection screen

Figure 2Temperature Scale screen

Figure 3Distance Selection screen

Figure 4Belt Odometer screen

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Start-Up

1. Slide the roll of film, with the unsealed airtube slot to the inside, over the shaft. Theinside of the core is gripped by the shaftplungers.

2. Route the film web around the bottom of thefilm roller. See Figure 1.

3. Slide the unsealed edge slot of the film overthe air injection tube, up to the infeed nip(first) rubber rollers.

4. If not already closed, turn both nip Open/Closelevers to close the tape drive nips.

NOTE: Jogging the film will not initiate infla-tion.

5. Press the JOG button until the end of the filmis fed through the sealing section, slitter, out-feed end nip and belt rollers.

The film has a tendency to bunch up on theslitter blade. The film must be pulled throughthe machine by hand while pressing the JOGbutton.

NOTE: Refer to the Operator Controls instruc-tion for touchscreen operation.

OPERATING PROCEDUREPREGIS AIRSPEED 5000AIR CUSHION MACHINE

Electric shock hazard. DO NOT opencover. Do not touch moving components.Failure to heed may result in injury.

Figure 1Film Web Thread-Up

OPERATING PROCEDURE - P5000

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6. Press the up ( ) arrow button to move thetouchscreen cursor to the top line. Then,press the plus (+) or minus (-) buttons to setthe desired operating mode:

Normal Operation starts and runs film con-tinuously until a stop is pressed.Automatic Stop after x ft runs an amount offilm, set by the operator, and then stops.Keep Basket Full uses optional sensors in abasket or bin to start/stop as required to keepthe bin full.

7. If the Automatic Stop mode is selected, pressthe down ( ) arrow button to go to the lengthselection line. Then, press the plus (+) orminus (-) buttons to set the desired film length.

8. Press the START button to create air cushions.

9. Set the air pressure (psi), with the gauged reg-ulator, for the size of air cushion being run.Refer to the label on the machine. See Figure2.

NOTE: Settings on the air pressure label areintended as guides only. Actual settingswill vary depending upon circum-stances and conditions.

NOTE: To test for proper inflation of cushions,gently squeeze cushion with both handswhile viewing it from the perf edge.There should be a 0.75"-1.0" gapbetween the forefinger and thumb onboth hands.

10. Press the STOP button to stop the machine.

Figure 3Sealing Belt Thread-UpFigure 2

Cushion Inflation Pressure

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Introduction

Expected sealing belt life is approximately 100-200hours (9,000-18,000 meters). The upper belt willwear faster than the lower belt due to sealing wirecontact. To extend belt life by up to 20%, each beltmay be flipped around as explained in the follow-ing description.

After both edges of the upper belt are completelyworn through, transfer the lower belt to upper beltposition. Discard the worn out upper belt. Installa new lower belt. The belt transferred to the upperposition is again put through the same cycle of use.

Belt Replacement

To replace the sealing belt(s):

1. Set the air cushion machine power to OFFwith the switch. See Figure 1.

SEALING BELT REPLACEMENTPREGIS AIRSPEED 5000AIR CUSHION MACHINE

Figure 1Infeed End (Backside View)

Figure 2Outfeed End (Front/Side View)

On/Off Switch

Infeed NipOpen/Close

Lever

Outfeed NipOpen/Close

Lever

DO NOTOperate

With GuardsRemoved!

Electrical shock or unexpected machinemovement can cause injury. DO NOToperate machine with guards removed orcovers open.

For your safety, follow your company’slockout/tagout policy as required for eachtask.

InfeedNip

Rollers

Outfeed Nip Rollers

SeeFigure 3

SEALING BELT REPLACEMENT - P5000

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2. Turn both nip Open/Close levers up to openthe belt drive nips. See Figures 1 and 2.

3. Remove the front upper and lower guard cov-ers by sliding them off the guide pins.

4. Lift the upper guard/clamp and seal wireassembly off the lower clamp block and plat-en, while turning the cam shaft. Turn the shaftuntil the high side of the cam is at the top,holding the guard/clamp and seal wire assem-bly up. See Figure 3.

5. For both the upper and lower belt, push thetensioner roll to create the slack required toremove the sealing belt. See Figures 2 and 4.

6. Remove the belts from between both sets ofnip wheels and the infeed side belt diverterrollers. See Figure 4.

7. Remove the sealing belts.

8. Install the belts between the infeed and outfeednip wheels and the infeed side belt diverterrollers. Use belt thread-up diagram if needed.

9. For each sealing belt, push the associated ten-sioner roller inward, collapsing its spring, toallow the sealing belt to be fitted around allrollers. See Figures 2 and 4.

10. Lift the upper guard/clamp and seal wireassembly while turning the cam shaft. Turnthe shaft until the low side of the cam is at thetop, allowing the guard/clamp and seal wireassembly to drop down onto the lower clampblock and platen. See Figure 3.

11. Turn both nip Open/Close levers down toclose the tape drive nips. See Figures 1 and 2.

12. Install the front upper and lower guard coversby sliding them over the guide pins until themagnets secure the guards.

13. Set the air cushion machine power to ON withthe switch. See Figure 1.

Figure 3Upper Guard/Clamp and Seal Wire Lift Cam

Shaft

Cam

SEALING BELT REPLACEMENT - P5000

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Figure 4Sealing Belt Routing

UpperSealing Belt

Lower Sealing Belt

Air InjectionSlot

InfeedNip

Rollers

GuideRoller



DiverterRollers

OutfeedNip Rollers

Outfeed GuideRollers

Guide Roller

InfeedGuideRollers

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Daily Maintenance

1. Check the condition of the sealing belts, trans-port rollers, and nip rollers. Flip or replacebelts if worn 75% through, or if the splice ispeeling or pulling apart more than 0.03" (0.76mm).

Weekly Maintenance

1. Clean the sealing belts, guide rollers, niprollers, seal wire, lower platen, slitter blade,and counter wheel of any contaminationand/or debris.

2. Ensure that all parts turn freely, including allbelt rollers, the film dancer roller and pivotshaft, and the unwind shaft (with brake off).

3. Ensure the unwind shaft brake mechanismworks properly. The brake must be able to gofrom totally free to a tight grip on the shaft.

Monthly Maintenance

1. Check all components for excessive wear,including the nip plastic drive gears, rubbernip rollers, and the slitter blade.

2. Check fasteners for looseness.

3. Clean the compressor air inlet screen of anydebris.

4. Check the alignment of the seal wire with theplaten and the upper guard/clamp with thelower block.

5. Inspect the sealing surface (green) of the lowerplaten for wear and replace if necessary.

Semi-Annual Maintenance

1. Apply axle grease (Exxon Ronex MP™ orequivalent) to the face of nip actuation cams.Also apply grease to the mating surfaceswhere the cams contact and actuate the upperrollers of the infeed and outfeed nips.

NOTE: Refer to the Introduction instruction forthe lubrication location.

MAINTENANCE SCHEDULEPREGIS AIRSPEED 5000AIR CUSHION MACHINE

Electrical shock or unexpected machinemovement can cause serious injury ordeath. For your safety, follow your compa-ny’s lockout/tagout policy as required foreach task.

1. Problem: Machine will not start.

Cause: Machine not set-up properly.

Solution: Turn power ON.

Press RESET button.

Press START button.

Read message at top of screen.Text will read Ready to Run, Paused, or Running.

Thread up film so encoder wheel turns. Machine will not run more than a few seconds if the counter wheel does not turn.

2. Problem: Cushion does not inflate.

Cause: Machine not ready.

Solution: Jogging machine will not start inflation, use START button.

Turn air pressure regulator knob clockwise until the gauge reads 1-4 psi, as required for cushion size being run.

Cause: Insufficient injection air.

Solution: Check if air injector tube is pluggedor disconnected.

Check if air compressor is operating properly.

Cause: Poor quality seal or no seals.

Solution: Refer to Problem 5 Solutions.

Cause: Too much air in cushion blows seals open.

Solution: Reduce the inflation air pressure with the gauged regulator.

NOTE: To test for proper inflation of cushions,gently squeeze cushion with both handswhile viewing it from the perf edge.There should be a 0.75"-1.0" gapbetween the forefinger and thumb onboth hands.

3. Problem: Film jams.

Cause: Cushion release slit not being cut properly.

Solution: Clean or replace the slitter blade.

Cause: The operator is not pulling the film through the machine while pressing the JOG button for web thread-up.

Solution: During film thread-up, pull the film past the slitter while pressing the JOG button.

Cause: Film burn through.

Solution: Turn down the sealing temperature.

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TROUBLESHOOTINGPREGIS AIRSPEED 5000AIR CUSHION MACHINE

Electrical shock or unexpected machinemovement can cause serious injury ordeath. For your safety, follow your compa-ny’s lockout/tagout policy as required foreach task.

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3. Problem: Film jams. (Cont’d.)

Cause: Film not being pulled evenly.

Solution: Ensure both the infeed and outfeed nips are closed.

Cause: Film slipping.

Solution: Check nip wheels and sealing belts for contamination and clean as necessary.

Check that the unwind shaft brake system releases and the parent roll turns freely.

Cause: Gap in film is too small for air injector tube.

Solution: Replace the roll of film if the gap is smaller than 0.56"

Cause: Film waste clogging slitter.

Solution: Remove melted film and waste from knife area.

4. Problem: No film movement.

Cause: Film is not properly positioned in machine.

Solution: Thread the film as per the thread-up diagram label on the side of the machine. Lightly pull the leading edge of the film through the machine, past the slitter and outfeed nip, while jogging. The film must be taut before pressing START.

Cause: Film or belts not being pulled.

Solution: Ensure both the infeed and outfeed nips are closed completely. The rubber nip rollers should compress together resulting in a 0.38" flat spot between them.Ensure all seal belt idlers turn freely.

Cause: Film slipping.

Solution: Check nip wheels and sealing belts for contamination and clean as necessary.

Cause: Gap in film is too small for air injector tube.

Solution: Replace roll of film.

Cause: Counter wheel not operating.

Solution: Check if counter wheel is against air injection tube.

Check if wheel traction o-ring is worn or missing.

Check if flat spring is holding wheel firmly against air injection tube.

Check if air injection tube is bent, not allowing counter wheel to make proper contact.

Check if the proximity sensor is close enough to the wheel to switch on and off as the wheel turns.

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5. Problem: Poor quality seal or no seals.

Cause: Sealing wire broken.

Solution: Replace the sealing wire.

NOTE: Allow the seals to cool for approxi-mately one minute before testing.

Cause: Sealing wire not hot enough.

Solution: Adjust the sealing temperature.

Cause: Air pressure blowing out seals.

Solution: Decrease the inflation air pressure to prevent overinflating.

Check that the upper guard/clamp is seated properly on lower block, iso-lating the seal from inflation.

Check that the lower platen is pivoting properly.

Check that the lower platen stiff, outer plastic (Durit™) sealing sur-face is securely mounted to the lower layer of soft silicone.

Ensure both nips are fully closed. It is critical that the outfeed nip is pro-viding the proper nip pressure on the seal.

Check that both outfeed cooling fans are working properly.

Cause: Film not held tight together between sealing belts.

Solution: Check to ensure the upper guard/clamp is lowered/closed.

Cause: Sealing belts are worn.

Solution: Replace sealing belts as necessary.

6. Problem: Main screen “Ready To Run” mes-sage replaced with “Change Belts” message.

Cause: Belt Odometer screen has reached the preset belt change interval value.

Solution: Replace the sealing belt(s) and have Management reset the Actual value on the Belt Odometer screen to zero (0) meters.

NOTE: Refer to the Sealing Belt Replacementinstruction for more information.

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