POWER PAK'R USER MANUAL

Purpose of Document

This manual is an integral part of the machine and should be carefully looked after. It contains information that may be useful or required at a later date, for example when carrying out repairs and maintenance. It is recommended that you keep one copy near the machine and that you file the other one, for example with the records of your technical department. The manufacturer may be able to supply you with an additional copy.

INTERNATIONAL®

TM

Free-Flow Packaging International, Inc.

Machine Identification

POWER PAK’R OPERATING MANUAL www.fpintl.com

This user manual details the daily use and maintenance of the POWER PAK’R, an installation that is part mechanical, part electrical. Details of maintenance work to be carried out by the manufacturer’s personnel only are expressly excluded.

Designation: POWER PAK’R air cushion machine Model: U.S.A. - MU301INFLR Europe - MU302INFLR

Inventing the Future of Packaging

REVISION 1.2.9

8/2012

The Manufacturer

Service & Support

The machine is produced by:

U.S.A. 24 Hour Technical Service: 1-866-374-7877 U.S.A. Website: www.fpintl.com Europe: www.fpintl.eu United Kindom: 0044-1-28-070-3161 Germany: 0049 (0) 7324-96490 France: 0033 (0) 1 34 04 18 00 Benelux: +31 (0) 45 566 7400

FP International 1090 Mills Way Redwood City, CA 94063

Table of Contents

Box Contents

Box Contents 4 Technical Data 5 Safety 6-7 POWER PAK’R Machine Parts 8 Unpacking & Initial Setup 9-10 Loading a Film Roll 11-12 Basic Operation 13-14 Machine Modes 15-16 System Options 17-18 Error Codes 19 Warranty 20-21 Model: MU3STRLHLD Contact & Support 22 Standard Roll Holder

As you unpack two boxes, you will find the following: POWER PAK’R® Air Cushion Machine (1) Model #: MU301INFLR Standard Roll Holder (1) Model #: MU3STRLHLD Power Cord (USA or EUR version, depending on country of purchase) User Manual Warranty Registration Card: Please complete this card and return to FP International within 4 weeks of installation.

IMPORTANT: SAVE ALL ORIGINAL BOXES AND PACKING MATERIALS!

USA

OR

USER MANUAL

Model: MU301INFLR Inflator Unit EUROPE

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SYSTEM KEYS (TAPED TO INFLATOR UNIT) For Supervisor Use

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Technical Data & Specifications Machine Identification Plate

The POWER PAK’R Machine creates air cushions on-demand for use as cushioning, protective wrap, and general transport packaging. Strict compliance with the safety instructions are required to ensure personal safety (See Safety Instructions in this manual).

Specifications Film Roll Product Production Rate power Rating Machine Dimensions Recommended Power Fuse Maximum Roll Diameter Width of Roll Machine Weight Roll Weights

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Safety Instructions

Preconfigured air cushion film for POWER PAK’R Machine up to 120 lineal foot/minute 35 meters/minute Model #MU301INFLR - 110V 400W #MU302INFLR - 230V 400W (18”) wide X (22”) long X (16”) tall (45cm) wide X (56cm) X (41cm) tall 5mm X 20mm, Slow-Blow: 5A Fuse

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250mm (10”) Up to 760mm 48 lbs. (22Kg) Up to 35lbs. (16Kg) POWER PAK’R User Manual

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To ensure the personal safety of operating personnel and/or users of this machine, the instructions below must be followed at all times.

1. Avoid all contact with internal electrical components.

2. In case of emergency, turn the red STOP button to the left (US models) or press red STOP button (EU models). The machine will stop. Once a fault has been corrected, the machine can be restarted following the directions below.

3. If the machine is not used for any length of time, the Main Switch must be turned OFF at the rear of the machine.

4. During Installation and Maintenance, the Power Switch must be in the OFF position, with the Power Cord disconnected.

5. All safety and protection measures must be fitted and adequately maintained in accordance with Iocal regulations.

6. Only trained and qualified service personnel may maintain any electrical and or mechanical part of the machine.

7. FP International machines are supplied preset and fully tested. Any loss arising from production downtime and failure of the machine caused by incorrect operation, poor or faulty maintenance, or the use of materials other than those provided by FP International shall void the terms of the warranty.

8. During machine operation, NEVER touch the film at its point of entry into the machine. Do not attempt to guide the film into the machine. Injury may result.

9. Under no circumstances may any installed safety feature be overridden.

10. After loading the Film Roll, the machine will automatically adjust to the right seal temperature for the film. Any contact with the heating element must be avoided (or any part in direct contact with the heating element) since it may remain hot for several minutes after the machine has been switched OFF. 11. Personal Protective Equipment (PPE) is not needed.

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Safety Features:

Safety Instructions

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The machine is fitted with the following safety features: • Door switch on the housing: the machine is disabled when the housing is open (EU models only) • Film feed button: the feed rollers only rotate when the button is pressed in.

Parts 1

European Version

2

U.S.A. Version

• • • • •

Children and animals must be kept away from the machine.

Do not reach in to the machine while it is operating or has been switched on.

Even when the machine is not operating, it may be “on”, meaning it may start to operate automatically.

Safety features may not be removed or disabled.

Keep the workplace clean and free from obstacles.

Ensure adequate lighting.

The safety of the machine may deteriorate with prolonged use. Ensure frequent maintenance.

Do not use the machine if the safety features are in any way damaged or malfunctioning. Make sure the machine is repaired.

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1

Control Panel

2

Standard Film Roll Holder

3

Emergency Stop

4

Inflation Unit

4

Safety Rules: • • •

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POWER PAK’R

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Unpacking & Initial Setup

STEP 1: Unpacking The POWER PAK’R Air Cushion System comes standard with Inflator Unit (Model # MU301INFLR) and Standard Roll Holder (Model #MU3STRLHLD) unless a different Roll Holder was ordered. Shipment will be in TWO separate boxes as pictured below. Please see your FP sales representative for more information on available options your POWER PAK’R Air Cushion System.

Installing Roll Holder

STEP 2: Installing Roll Holder Unless otherwise ordered, each POWER PAK’R Air Cushion System comes standard with Standard Roll Holder (Model #MU3STRLHLD). See the below instructions to attach the Roll Holder to the Inflator Unit.

1 1. Open the POWER PAK’R Inflator Unit box.

2. Remove the protective material by pulling up and out of the box.

3. Lift the POWER PAK’R Inflator Unit out of the box and

place on a stable table for further installation process.

4. IMPORTANT: REPLACE PROTECTIVE MATERIAL BACK IN EMPTY BOX AND SAVE BOTH BOXES 5. Repeat steps 1-4 to unpack the Standard Roll Holder.

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1. On the back of the Inflator Unit, there are 6 screws attached to the unit. Using a 4mm allen wrench remove the screws.

2. Align the Roll Holder to the Inflator Unit and

replace the six screws by using the same 4mm

allen wrench.

4 3. NOTE: This is usually done by FP’s certified

technician

3

1 3

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Loading a Film Roll

•

STEP 1: Connecting Power • Insert provided Power •

Close the roll holder as shown and pull the film over the roll holder casing

Cord into the rear of the machine.

Plug Power Cord into a dedicated, grounded outlet.

Rear of POWER PAK’R Ma-

STEP 2: Loading a Film Roll • Push Film Roll onto Film Roll Holder • (with the film feeding off the top of the roll as shown) until it seats firmly.

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STEP 3: Threading the Film Pull the film through the rollers • Pull to unwind 18 inches (45cm) of film.

Open the Air Channel at the right side of the film roll.

• Slip the Air Channel over the end of the Air Fill Tube.

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• Guide the film through the channel by pressing and holding the Forward button on the Control Panel

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Basic Operation

Control Panel Display Overview

Starting Up 1. Turn the power to “I” on position to turn on the machine 2. Wait for the Start/Stop light to flash green and red 3. Press the button once to initialize and calibrate the machine 4. Display will indicate “WARMING UP - PLEASE WAIT < 2 MIN” 5. Machine is ready when the light is solid green and control panel displays “READY”

1

Start/Stop

2

Feed - Forward

3

Feed - Reverse

SEAL TEMPERATURE • Press SEAL TEMP • Use the UP/DOWN display buttons to adjust the set temperature to +/- 50 around the factory set point SEAL PRESSURE • Press SEAL Pressure • Use the UP/DOWN display buttons to adjust the set pressure +/- 50 around the factory set point • Press the Start/Stop button to accept the changes FILL LEVEL • Press FILL LEVEL • Use the UP/DOWN display buttons to adjust the set pressure +/- 20 around the factory set point • Press the Start/Stop button to accept the changes

3 2

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Note: Adjustments should only be made by trained personnel.

RESTORE • Press RESTORE and Start/Stop button to restore factor default settings • Press RESTORE then UP/DOWN display arrow to choose “Screen Locked” or “Screen Unlocked”. Once screen is locked, no adjustments

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Machine Modes

POWER PAK’R Machine Mode & Operation The POWER PAK’R Machine automatically chooses the correct air and temperature settings for the Film Roll you have loaded.

While the system is in Manual Mode, it will produce inflated air cushions until the Start/ Stop button is pressed.

Manual Mode - Foot Pedal (Optional) 2. When “#” is displayed on the control panel for number of cushions: • Tapping and releasing foot pedal will start the machine • Machine will stop automatically when cushion count is reached • Pressing and holding the foot pedal will run the machine until the foot pedal is released.

In Automatic Mode (machine equipped with optional Pre-Tear), you can determine the number of cushions per string and the system will generate the same number of air cushions once the once first set is removed from the system.

Auto-Indexing Mode (if equipped with Pre-Tear)

Manual Mode

1. Press “MODE” on the control panel display, “AUTOMATIC” appears on screen 2. The number of cushions defaults to “5”. Adjust this value as needed. Note, countinous “--” cannot be selected in this mode.

3. Press the Start/Stop button or tap the foot pedal to start 4. Pull the inflated cushions from the machine, the machine will automatically replenish the cushios.

5. After 90 seconds of inactivity, the AUTOMATIC mode will time out and the user will need to press the Start/Stop button to resume operations.

1. When “--” is displayed on the control panel for number of cushions: • Pressing Start/Stop will start the machine • Pressing Start/Stop again will stop the machine 2. When “#” is selected for number of Cushions • Pressing Start/Stop will start the machine • Machine will stop automatically when cushion count is reached

Note: Foot Pedal and Start/Stop button will operate the same in Auto-Indexing and Manual Mode

Manual Mode - Foot Pedal (Optional)

1. When “--” is displayed on the control panel for number of cushions: • Tapping and releasing the foot pedal will start the machine • Tapping and releasing the foot pedal again will stop the machine • Pressing and holding the foot pedal will run the machine until released

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System Options

POWER PAK’R Normal Operating Setup

Replacing Film Rolls Using Swivel Mount Stand

The POWER PAK’R Air Cushion System is one of the fastest on the market today, and also customizable for any operation. The POWER PAK’R was designed to work either as table-top packing system or over a conveyor. The below illustrates the POWER PAK’R Universal Wide Base Stand (Model #MUN00CSTBS), Swivel Mount Standand

1. Locate the Swivel Mount Stand knob and pull

down to swivel right only so the left side of the roll holder faces the operator.

2. Once the roll holder is positioned in front of you at an comfortable angle, open the roll holder case and remove the empty roll.

3. Insert the replacement film roll as shown to the right.

4. Simply follow steps 2-3 on page 11 and 12 of this

Swivel Mount Stand - If equipped, allows operators to replace film rolls over the conveyor for ease of use. Can rotate left or right.

Pneumatic Kit (US model) - Adjust the height of the stand over pack lines by a using a simple lever. 80 psi compressed air required.

The Universal Wide Base Stand (US model) - for over the conveyor usage or pack lines. Adjustable height and system can be mobile.

The Pneumatic Kit is installed to allow easy adjustment of the height of Universal Stand to replace film roll and to return to normal height while oeprating. This is installed by a certified FP technician.

1. Once installed, pushing the red lever down will lower the stand and Inflator Unit.

2. Pulling the red lever back up to it’s normal position will return the stand to it’s normal height.

Side View

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Operating Pneumatic Kit

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Display Error Codes Display Code E1 E2 E2 E3 E4

Error Codes If the Display shows an Error Code, and the red LED flashes, consult the chart below to determine the cause. Clear the problem as described below then press the START/STOP Button to resume normal operation. If error persists, contact First Priority Service Group at 1-866-FPI-SUPP(ORT)

POWER PAK’R™ Air Cushion Machine, Accessories, and Customer Kits Limited Warranty

Warranty Notice

FP International (“FPI”) warrants the POWER PAK’R Air Cushion Machine, accessories, and customer kits against defects in material and workmanship for a period of one year from the date you purchased that product, as stated on your sales or delivery receipt. This warranty applies only if you are the original end-user purchaser and is not transferable.

You will be asked to provide proof of purchase as a condition of receiving warranty service.

For POWER PAK’R Machines, accessories, and customer kits under this warranty, FPI will, at its sole option, repair or replace any defective part or product with a functionally equivalent new or factory-reconditioned part or product. Replacement parts and products are warranted to be free from defects in material and workmanship for 90 days or for the remainder of the applicable warranty period for the parts or products they are replacing or in which they are installed, whichever is longer. FPI will have no obligation to repair or replace any parts or products until you return the defective product to FPI. You will be responsible for all transportation risks and costs in connection with this warranty service.

Error Termperature Too High Seal Temp Rising Temperature Not Rising Sheeter Jam End of Roll or Film Jam Cover Open

Exclusions This Limited Warranty does not apply to (1) expendable or consumable parts, including injector blades and Teflon seal belts and tape; (2) normal wear from regular use of the POWER PAK’R Machine; (3) any product with the serial number removed; (4) any POWER PAK’R Machine that has been operated with non-FPI film; or (5) any product if damaged or defective due to (a) accident, misuse, abuse, contamination, improper or inadequate maintenance or calibration or other external causes; (b) software, interfacing, parts

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or supplies not supplied by FPI; (c) loss or damage in transit; or (d) modification or service by other than FPI or an FPIauthorized service provider.

Non-Warranty Repairs For service that FPI performs that is not covered under this Limited Warranty, FPI will charge its standard time and materials rates. Customer will be responsible for all transportation risks and costs in in connection with this service.

Limitations of Warranty/Local Laws EXCEPT AS EXPRESSLY SET FORTH IN THIS LIMITED WARRANTY, FPI MAKES NO OTHER WARRANTIES OR CONDITIONS, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. FPI EXPRESSLY DISCLAIMS ALL WARRANTIES AND CONDITIONS NOT STATED IN THIS LIMITED WARRANTY. ANY IMPLIED WARRANTIES THAT MAY BE IMPOSED BY LAW ARE LIMITED IN DURATION TO THE APPLICABLE WARRANTY PERIOD. Some states or countries do not allow a limitation on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages for consumer products, or of a consumer’s statutory rights. In such states or countries, some exclusions or limitations of this Limited Warranty may not apply to you. This Limited Warranty is applicable in all countries and may be enforced in any country where FPI or its authorized service providers offer warranty service.

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Contact and Ordering Info

For Sales and Service United States and Canada: 888 - FPI-SUPP (888-646-4757) or visit us at www.fpintl.com International: 00800-FREEFLOW (00800-37333569) or visit us at www.fpintl.eu

Available Accessories - Contact Your Local FP Representative for More Information Item Code

Description

MU3EXRLHLD

Extended Length Roll Holder

MU300SHT60

POWER PAK’R Wide Width PILLLOW PAK’R Sheeter

MU300PTEAR

Pre Tear Unit

MUN00STAND

Universal Stand Adjustable Height

MUN00CSTBS

Universal Wide Base Stand with Casters

MUN00PNSTK

Pneumatic Kit

MU300SWVMT

Swivel Mount Stand

MUN00WINDER

POWER PAK’R Winder

MUN00PHSRR

Photo Sensor

MUN00FTPDL

Foot Pedal

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Declaration of Conformity Copyright © 2011 Free-Flow Packaging International, Inc. (FP International) All rights reserved.

Without the expressed written permission of FP International, neither the POWER PAK’R Air Cushion Machines and software, nor this User’s Manual, may in any way (including electronically) be reproduced, copied or translated.

INTERNATIONAL®

TM

Free-Flow Packaging International, Inc.

POWER PAK’R, NOVUS and CELL-O are trademarks of FP International. The POWER PAK’R machine is protected by U.S. patents 7,526,904; RE40288; and 7,325,377. Other patents pending. NOVUS film is protected by one or more of the following patents: RE 42,240; 7,361,397; 7,090,912; 6,565,946; 6,410,119; D513,182; D512,311; D480,971; D480,646. CELL-O film is protected by one or more of the following patents: 7,361,397 and D480,646.

Important notice: All safety instructions described in this manual must be carefully followed at all times when operating the POWER PAK’R machine to avoid personal injury or danger to operators, and to avoid damage to any materials. Only FP International’s NOVUS or CELL-O films may be used with the POWER PAK’R Machine.

Concerning the Machinery Directive.

We

FP International BV Nijverheidsweg 4 6422 PD HEERLEN The Netherlands Tel: +31 (0) 45 566 7400 Fax: +31 (0) 45 566 7401

state, entirely for our own responsibility: 1-

We are the manufacturers of the machine:

Make: Model: Serial no.:

FP International BV MU302INFLT U3-2XXXXX

that is the subject of this Declaration.

2- The machine has been designed and constructed in accordance with the requirements laid down in Machinery Directive 98/37/EC (as most recently amended).

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3- The machine also complies with the requirements of the following EC Directives: Low Voltage Directive 73/23/EEG (as most recently amended).

4- The machine has been designed and constructed to the following (European) standards or normative documents: NEN-EN 1037:1996 Prevention of unexpected start-up NEN-EN 1050:1997 Principles for risk assessment.

NEN-EN 1088:1996 Interlocking devices associated with guards NEN-EN 294:1994 Safety distances NEN-EN 418:1994 Emergency stop equipment NEN 5509:1998 User manuals NEN-EN-IEC 60204-1: 2001 Electrical equipment of machinery NEN-EN 60447:1996 Man-machine interface (MMI) #NEN-EN 953:1999 Guards#.

NEN-EN 954-1:1997 Safety-related parts of control systems Place Date: Signature: Position:

HEERLEN

Managing Director