U3 POWER PAK'R AIR CUSHION MACHINE

U3 Pak’r Manual

Page

1

Air Cushion Machine

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pak’r Manual Table of Contents 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0

10.0

Page

2

11.0 12.0 13.0

Safety precautions Specifications Basic operating theory Component identification Touch Panel menus: (Settings Screens) Loading Film Operating the system Mounting the Roll Holder Maintenance Items – Adjustments 9.1 Cover removal 9.2 Registration Assembly Adjustments 9.3 Pinch Roller Adjustment Maintenance Items – Replacement Instructions 10.1 Upper Belt replacement 10.2 Lower Belt replacement 10.3 Blade replacement: 10.4 Cone tip replacement: 10.5 Roller Replacement Preventative Maintenance Main PCB layout Addendums: 13.1 13.2 Programming / Updating the firmware using the AVRISP mkII programmer and software 13.3 Exploded Parts view and Bill of Materials

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pak’r Manual 1.0

Safety precautions:

There are no user replaceable parts in this system –refer all maintenance items to a FP International trained technician.

Warning Read and thoroughly understand this manual before operating the machine.

Operation and service of the machine is to be performed by trained personnel.

DO NOT Operate this equipment with the covers open or off.  

The Seal wheel operates at 180 degrees Celsius, and will burn flesh upon contact, extreme caution should be used when working around the seal assembly.

The drive wheels in this system operate at a very high speed, extra care should be taken to insure loose clothing, etc. is not caught in the drive wheels or assemblies.

Warning: This system should only be Installed or moved by FP International trained technician Caution: this unit should only be operated by trained personel Operation of this equipment does not require any special safety equipment by the operator.

Page

3

In an Emergency the equipment can be powered off by turning the Power Switch counter clock wise from the “1” position to the “0” position

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pak’r Manual 2.0

Specifications:

Film Width (Flat): up to 30” (762mm) Cushion Size: Please consult your sales representative for available products.

Production Speed: Variable to 120 linear feet per minute. (36.6 linear meters per minute) Machine weight: System weight 48lbs (21.8 Kg) Electrical supply requirements: US 120VAC +/- 5% 4 amp minimum single phase (480 watts) EU: 230VAC +- 5% single phase / 2amp (460 watts) Options: Accessories include:  Wireless Machine to Machine communications  Sheeter  Pre-tear unit Standard roll weights: 17 lbs. to 35 lbs. (7.7 Kg to 15.9 Kg)

3.0 Basic Operating Theory o o

Page

4

o

How it seals – continuous rotary wheel contacting the film RFID - Each roll of film has an RFID tag imbedded in the roll, the U3 reads the tag and sets the machine up for the type of film loaded on the roll holder.

I-Marks on the film allows enabling of the use of sheeter or pre-tear unit, is only available on u3 specific film. Contact your sales representative for additional information.

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pak’r Manual

Touch Panel

4.0 Component Identification:

Start/Stop/Reset Button Feed Buttons ▲ ▼

Power Switch U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

Page

5

Sheeter Assembly

U3 Pak’r Manual Front View

Film Channel

RFID Port

Pinch Rollers

Accessories Port

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

Page

Rear View

6

AC Power Plug

U3 Pak’r Manual

Film Channel

Roll Holder

Inflator

Left Side View U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

Page

7

On / Off Switch

U3 Pak’r Manual 5.0 Touch Panel Menus: (Settings Screens 1 of 3) WARMING UP

# CUSHIONS = DISPLAY NUMBER OF CUSHIONS CURRENTLY SET, "----" FOR ZERO

PLEASE WAIT <2 MIN -(#CUSHIONS)-

AT/ST = DISPLAY ACTUAL TEMP/SET TEMP CONTINUOUSLY

(AT/ST)

SEAL TEMP

# CUSHIONS

SEAL PRESSURE

MODE

FILL LEVEL

RESTORE

READY -(#CUSHIONS)-

(AT/ST)

SEAL TEMP

# CUSHIONS

SEAL PRESSURE

MODE

FILL LEVEL

RESTORE

SLEEPING

SYSTEM SHOULD GO TO SLEEP (POWER DOWN HEATER) AFTER 90 MINS

PRESS START TO WAKE

SEAL TEMP

# CUSHIONS

SEAL PRESSURE

MODE

FILL LEVEL

RESTORE

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

8

(AT/ST)

Page

-(#CUSHIONS)-

U3 Pakâ&#x20AC;&#x2122;r Manual 5.0 Touch Panel Menus: (Settings Screens 2 of 3) (ACTUAL TEMP/ SET TEMP)

IF SEAL TEMP IS PRESSED

SEAL TEMPERTURE

DISPLAY ACTUAL TEMP / SET TEMP ON TOP AND ALLOW SET TEMP TO BE CHANGED UP AND DOWN

-(#CUSHIONS)-

PRESS START TO ACCEPT CHANGES - TIMEOUT AFTER 10 SECONDS RETURN TO HOME SCREEN

SEAL TEMP

# CUSHIONS

SEAL PRESSURE

MODE

FILL LEVEL

RESTORE

(SEAL PRESSURE)

IF SEAL PRESSURE IS PRESSED

SEAL PRESSURE

DISPLAY SEAL PRESSURE AND ALLOW UP DOWN ADJUSTMENT

(AT/ST)

PRESS START TO ACCEPT CHANGES - TIMEOUT AFTER 10 SECONDS RETURN TO HOME SCREEN

SEAL TEMP

# CUSHIONS

SEAL PRESSURE

MODE

FILL LEVEL

RESTORE

(FILL LEVEL)

IF FILL LEVEL IS PRESSED

FILL LEVEL ADJUSTMENT -(#CUSHIONS)-

DISPLAY FILL LEVEL AND ALL UP DOWN ADJUSTMENT +/- 10%

(AT/ST)

PRESS START TO ACCEPT CHANGES - TIMEOUT AFTER 10 SECONDS RETURN TO HOME SCREEN

# CUSHIONS

SEAL PRESSURE

MODE

FILL LEVEL

RESTORE

Page

SEAL TEMP

9

-(#CUSHIONS)-

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual 5.0 Touch Panel Menus: (Settings Screens 3 of 3) -(# CUSHIONS)-

IF NUMBER OF CUSHIONS IS PRESSED

# CUSHIONS

DISPLAY # CUSHSIONS ON TOP AND ALLOW UP/DOWN CHANGES

(AT/ST)

PRESS START TO ACCEPT CHANGES - TIMEOUT AFTER 10 SECONDS RETURN TO HOME SCREEN

SEAL TEMP

# CUSHIONS

SEAL PRESSURE

MODE

FILL LEVEL

RESTORE

OPERATIONAL MODE

IF MODE IS PRESSED

"OPERATIONAL MODE" -(#CUSHIONS)-

WILL DISPLAY THE CURRENT OPERATIONAL MODE IN CENTER ROW

(AT/ST)

SEAL TEMP

OPTION 1: FOOT PEDAL OPTION 2: AUTO-INDEX

# CUSHIONS

SEAL PRESSURE

MODE

FILL LEVEL

RESTORE

PRESS START TO RESTORE

PRESS ENTER TO ACCEPT CHANGES NOTE: WHEN IN AUTO-INDEX MODE - MACHINE DIPLAY SHOULD CHANGE TO "READY-AUTO" AND 3 CUSHIONS MUST BE 4 OR MORE

IF RESTORE IS PRESSED

FACTORY SETTINGS -(#CUSHIONS)-

USE UP OR DOWN ARROW TO SCROLL BETWEEN MODES

PRESS START TO RESTORE ALL FACTORY SETTINGS - TIMEOUT AFTER 10 SECONDS

(AT/ST)

RETURN TO HOME SCREEN

# CUSHIONS

SEAL PRESSURE

MODE

FILL LEVEL

RESTORE

Page

10

SEAL TEMP

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual

Page

11

6.0 Loading Film

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pak’r Manual 7.0 Operating the U3 Pak’r:         

Power the machine on by turning the red power switch from “0” to the “1” position Open the roll holder cover(Loading film figure 1) Load the film onto the roll holder – (Registration marks on the film in) (Loading film figure 2) Close the film cage Pull the film through the pinch rollers (Loading film figure 3) Pull the film over the top cover Open the air channel in the film and push it over the air fill tube cone (Loading film figure 4) Pull the film down into the air tube Depress the ▼Forward Button and feed the film down the air tube until the feed rollers grab the film.

(Loading film figure 5)

The Machine is now ready to make packaging. 



The RFID technology will read the film installed and set the U3 Pak’r for optimal performance. o The fill level, sealing temperature and sealing pressure can be adjusted for specific applications through the touch screen. (See Section 4.0) The number of pillows can be set through the touch panel (see section 4.0) o o o

Page

12

o o

Holding the foot pedal down (if installed) will override the pillow setting on the equipment.

Tapping the foot pedal will cause the machine to deliver a preset number of pillows.

The machine can be operated from the Start/Stop/Reset button  Setting the # of Pillows (section 4) to “---“ and pressing the Start/Stop/Reset button will cause the machine to run continuously until the Start/Stop/Reset button is pressed again To start the machine Press the Start/Stop/Reset button.

Press the Start/Stop/Reset button again to stop the machine.

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual 8

Mounting the Roll Holder

Mounting the roll Holder

Mounting the Roll Holder to the Inflator

6 holes for mounting the roll holder

The Roll Holder is mounted to the Back of the Inflator with 6 Screws; the screws are mounted through 6 slots in the Roll Holder to allow for left â&#x20AC;&#x201C; right adjustment of the roll holder to the inflator

Page

13

Back View

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual

6 Slots for the roll holder screw attachments

Page

14

Aligning the roll holder to the inflator: (As viewed from the top of the Machine, with the roll holder door opened)

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual

Page

15

Align these two surfaces (should form a straight line on the edges)

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual Mounting the machine to the stand: Bottom View

Mount to stand through the feet

Page

16

The system is mounted to the stand with 4 screws through the feet of the inflator and two screws through the feet of the roll holder.

(Note: The roll holder feet may need to be loosened from the inside of the roll holder to align them to the holes in the stand)

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual 9.0 Maintenance and Repair Procedures Note: There are no user replaceable parts in this system â&#x20AC;&#x201C; please refer all maintenance items to a FP International trained technician.

Safety Warnings: The Seal wheel operates at 180 degrees Celsius, and will burn flesh upon contact, extreme caution should be used when working around the seal assembly.

The drive wheels in this system operate at a very high speed, extra care should be taken to insure loose clothing, and etc. is not caught in the drive wheels or assemblies.

Page

17

Do not operate this equipment with the covers open or removed.

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual 9.1 Cover removal / replacement Prior to opening the system, remove the power cord, unplug the roll holder assembly RFID plug and unplug the accessory port. See figure 1.

Figure 1 Remove the Top left cover first by removing the 4 screws on the cover, and the screw on the top right side, through the right side cover. See figure 2 / 3

Figure 3

Page

Remove the 5 screws holding the lower left Panel in place. Slide the top metal cover to the left and lift it out.

(Figure 4)

18

Figure 2

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual

Figure 4 Remove the four screws holding the lower belt cover in place and lift it out. (Figure 5)

Figure 5

Figure 6

Sheeter Covers: Remove the screws as indicated in figure7, lift the covers out.

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

Page

Figure 7

19

On the right, insert U3 key and open the lower right door. Remove the screws as indicated in Figure 6 and remove the top right cover.

U3 Pakâ&#x20AC;&#x2122;r Manual Remove the pre-tear cover as shown in Figure 8. (Note: it may not be necessary to remove this cover to work on the sheeter.)

Page

20

Figure 8

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pak’r Manual 9.2 Registration Assembly Adjustments Purpose: The Fiber Optic Sensor (Figure 1) and Amplifier (Figure 2) are used to detect the registration marks on the film and correctly position the film perforations for the pre-tear unit. The optical sensor reflects off the air tube and detects changes between the marked and unmarked parts of the film.

Fiber Optic controller P/N: SG2U199054

Fiber Optic Sensor: SG2U199050

Note: This procedure should only be performed if the unit is experiencing attempted perforation tears at the wrong place on the film. There are several potential problems with the U3 machine that could be causing this problem including: 1.

2.

3.

4.

Fiber optic sensor misaligned or out of range: Verify that the head of the sensor is about 5mm away for the fill tube and that the sensor is pointing directly at the center of the fill tube. Loosen the sensor mounting bracket and adjust if required. When the sensor is properly aligned the red light near the 8 will be illuminated on the amplifier (1 to 8 is the range). See Figure 2.

If the fiber cable is nicked, cut or bent. Replacement is necessary. The signal strength will also be 8 as described above.

The operational mode of the sensor must be in High Speed (HS) – Dark Operate (DO) mode. See instructions bellow for changing the operational mode.

The sensor requires tuning to properly and reliably sense the registration mark.

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

Page

TUNING THE SENSOR 1. Remove the top right side cover  This will allow you to accesses the amplifier shown in Figure 1.

2. Adjust the optical sensor to about 5mm above the film  3mm-10mm is the acceptable range.  Make sure the sensor is pointing straight toward the center of the air tube.  Tighten the mounting screw firmly.

3. Load a roll of film onto the machine 4. Feed the film until the black registration mark on the film is directly under the optical sensor.  The red light from the sensor should be shining on the black registration mark. (Figure 1).

5. Press and hold the YELLOW DOWN ARROW BUTTON “-“ for 3 seconds and release when the GREEN POWER ON LED goes out.  If this is done properly the Configuration LED’s DO and LO will begin alternately flashing.

6. Press and release the YELLOW DOWN ARROW BUTTON “-“once.

7. Use the feed buttons on the machine display panel to jog the film forward a few inches.  The registration mark should no longer be under the sensor.

8. Press and release the Static “-“down arrow button again.  If this procedure has been followed correct the LED next to the number 8 on the bar graph display will blink for a couple of seconds they turn solid. The Green power on LED will turn on again.

21

CHANGING THE OPERATIONAL MODE TO HS-DO 1. Remove the right side cover to access the amplifier as shown in Figure 2.

2. Power on the machine.

3. Flip down the protective cap on the amplifier to access the adjustment buttons.

4. Press and hold the + (UP) and – (DOWN) YELLOW BUTTONS at the same time for 3 seconds until the top GREEN POWER ON LED goes out.

5. Use the + (UP) and – (DOWN) YELLOW BUTTONS to change the operational mode. Continue to press and release the button until both HS and DO are illuminated.

6. Press and hold both + (UP) and – (DOWN) YELLOW BUTTONS again for 3 seconds until the GREEN POWER ON LED turns on.

U3 Pakâ&#x20AC;&#x2122;r Manual 9.

The sensor has been tuned. To test the sensor, use the feed buttons on the machine display to feed the film forward continuously. Every time a black registration mark passes under the sensor, the LED on the bar graph display with drop from 8 to 1 momentarily and the Yellow Output LED with flash quickly.

NOTE: If a number of less than 8 is displayed when no registration mark is under the sensor or a number greater than 1 is displayed when the registration mark is under the sensor, the sensor tuning is not optimized and the steps above should be repeated.

The sensor has been calibrated and the unit is now ready for operation.

Note: The RF ID Tag on the roll will tell the system what the distance is to the perforation automatically for the film that has been loaded onto the unit.

Figure 2

Page

22

Figure 1

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual 9.3 Pinch Roller Adjustment Carriage assembly: The film carriage assembly is mounted on the back of the U3 with 6 mounting screws, additionally the carriage attaches to the mounting frame with two bolts that screw in through the feet. The entire assembly can be adjusted by loosening the screws and sliding the carriage left or right to align the carriage with the U3 main unit. Currently the recommended starting location is to align the Carriage about 5mm in from the right edge of the inflator (as viewed from behind), re-tighten the screws when complete. Proper alignment will help prevent the film from popping off the air tube.

Page

23

Pinch Rollers: (Figure 1) The pinch rollers are a wear item and will need to be adjusted or replaced periodically. The Pinch Rollers should be adjusted to allow film loading but prevent backfill from the blower tube that will cause the film to jam and tear.

The adjustments are located on both sides of the rollers.(Figure 1) 1. Loosen the lock nuts on the adjustment spindle on both sides of the roller assembly. (Figure 2) 2. Turn the adjustment bolts counter clockwise on both sides until you observe a gap between the rollers. (Figure 2) 3. Turn the adjustment on the inflator side clockwise until the rollers touch, and then add another Âź turn clockwise.

4. Turn the adjustment bolt on the outside (away from the inflator) clockwise until the right side of the upper roller is about 1/16â&#x20AC;? away from the lower roller, the rollers should spin freely, test the machine for proper operation by starting and stopping the inflator, let the machine rest for 60 to 90 seconds between starts and watch for backfill into the film behind the pinch roller. Adjust as necessary. (note the location of the slide to the tick counters) (Figure 2) 5. Tighten the lock nuts (Figure 2)

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual 10.0 Maintenance Items â&#x20AC;&#x201C; Replacement Instructions Purpose: This procedure provides the directions for replacement of the sealer belts, cone tip and cutting blade.

These parts are wear items.

Safety Warning: Prior to performing this procedure unplug the system from the AC Power outlet.

Caution: The Sealer Roller will be hot to touch â&#x20AC;&#x201C; allow the machine to cool before performing this procedure.

10.1 Upper Belt replacement

Page

24

1. Remove the top cover 2. Remove the bottom cover 3. At the top of the registration amplifier, where the wires connect, open the plastic cover (#1 Figure 5) push the top towards the outside of the machine(#2 Figure 5) , this will allow you to remove the wires without disturbing the placement of the optical sensor (#3 Figure 5). The wires are actually fiber optic and it does not matter which wire is installed in which hole when you re-assemble the belt assembly. (Figure 5) 4. Remove the top belt assembly by removing the front and back retaining screws. (Figure 2) Gently lift the assembly up and out, being careful not to damage the heater roller or the pressure stepper motor assembly.

5. Change the top belts, as necessary loosen the tension rollers by loosening the locking nuts on the side of the unit and then unscrewing the tension position screws (Figure 1) mark the position of the screws to facilitate re-tensioning the new belts. a. Replace the Top Belts as pairs to avoid film jamming. b. Reset the tension adjustments back to their original locations.

6. Re-install the upper belt assembly, it may be necessary to roll the gears back and forth to ensure the teeth properly line up and the assemblies fit together properly.

7. Re-install the registration assembly; perform the registration assembly alignment procedure if you moved the optical sensor on the upper belt assembly during dis-assembly.

8. Re-install the covers, power on the machines and test for proper operation.

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual 10.2 Lower Belt replacement 1. Follow the upper belt replacement procedure steps 1 through 4.

2. Loosen the locking nut and release the tension on the tension roller by turning the wing nut clockwise. a. Watch the spacer on the wing nut and insure it spins freely and loosens as you loosen the wing nut.

3. Pull the belt off, from the front roller first, and inspect it for wear. Replace as necessary. a. When re-installing the belt insure the deep groves in the front and back rollers align properly with the belt. (Figure 3) Pull the belt until the teeth drop into the groves of the lower belt guide assembly and there is some tension on the belt. b. Re-adjust the tension roller back to its original position.

4. Clean the heat wheel, scrape off built up material with your finger nail or very soft scotch bright.

5. Follow steps 6 through 9 in the Upper belt replacement procedure

10.3 Blade replacement: 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Remove the covers Remove the Upper roller assembly Remove the lower belt.

Remove the two screws that hold the inflator tube assembly in place. (Figure3) Remove the inflator tube assembly (it pulls out from the black tube at the base of the assembly) The blade is mounted to the assembly with one .05mm retaining screw, remove the screw and replace the blade. (Figure #4) Caution: The blade is extremely sharp and care should be exercised when handling it.

Re-assemble the inflator tube assembly and reattach it to the lower belt assembly Follow steps 3 through 5 above. (including steps 6 through 9 of the upper belt replacement procedure) Re-attach the registration assembly Perform the registration sensor gap adjustment per the fiber optic sensor PCB adjustment procedure.

10.4 Cone tip replacement: 1. The cone tip is a wear item, inspect and replace as required.

2. The cone tip pops on and off, pull on it to remove and insert new tip.

10.5 Roller Replacement: The sealing roller should be inspected for nicks and melted plastic, the surface can be damaged by sharp instruments that may have been used to clear jams, and will result in inconsistent seals.

The sealing roller is held in place with three screws; remove the upper belt assembly to gain access to the roller.

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

Page

1. Remove the three screws and replace the roller 2. Re-install the upper belt assembly, it may be necessary to roll the gears back and forth to ensure the teeth properly line up and the assemblies fit together properly.

3. Re-install the registration assembly; perform the registration assembly alignment procedure if you moved the optical sensor on the upper belt assembly during dis-assembly.

4. Re-install the covers, power on the machines and test for proper operation.

25

CAUTION: The sealing roller heats to 190°C allow it to cool completely before touching the surface.

U3 Pakâ&#x20AC;&#x2122;r Manual (Note: the optic sensor will be mounted on the top left of the upper belt assembly)

Figure 1

Figure 2

Figure 3

Page

26

Figure 4

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pak’r Manual 11.0 Preventative Maintenance: Weekly (any time a tech sees a machine):  Remove any dust or dirt on the machine.  Check that the pinch (nip) rollers on the back of the film cage are functioning. Verify operation and adjustment per the pinch roller adjustment procedure.  Operate the machine in the normal manner; observe the cutting and sealing properties.

If the cut is uneven and jagged, replace the blade. Follow the blade replacement procedure.  Inspect the belts for wear, replace as needed.  Inspect the drive and pre-tear rollers for wear, replace as needed.

Monthly:  Weekly items.  Remove front cover, inspect wheels and tube, and remove any plastic scraps.  Inspect the sealer and shield, remove any built up plastic.  Clean the main drive wheels with dry cloth to remove build up.  Rotate the Teflon cone tip so it wears evenly.

Page

27

Yearly:  Weekly items, monthly items.  Remove side and back covers, clean out any accumulated dust or plastic scraps.  Check all drive gears for excessive wear, replace as needed.  Replace the blade, if this has not been done in the last year.  Inspect the air filter, replace as needed (greatly depends on operating conditions).  Check main drive wheels, replace as needed (greatly depends on operating conditions).  Check the Seal Wheel mounting screws for tightness – tighten as required.

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service

U3 Pakâ&#x20AC;&#x2122;r Manual

Page

28

12.0 Main PCB Layout

U3 User Manual Manual

Last Update: Preliminary By: J Moviel Location: \\Sol\FS-Tech Docs\Master Escalation\Training Development\U3 Service