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ErgoPack Air 713-580, Original Operating Instructions, Page: 9 / 63

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ErgoPack Air 713-580 Original Operating Instructions Download Page 9

-9- 

2.

 General 

These operating instructions shall help get to know the system and to work 
with it according to its intended use. The operating instructions contain 
important notes on how to use the system safely, properly and economically. 
 
Adhering to the notes helps to avoid dangers, repairs and down times and  
also increases the reliability and life span of the system. 
 

The operating instructions must be available at the place where the system 
is used. It has to be read, understood and used by everybody working with 
the system. 

 These works include operation, maintenance and repair.

 

 
In addition to the operating instructions and the regulations in the country 
and place of  use related to the prevention of accidents, the recognized 
special rules for working safety and according to proper and professional 
standards also have to be respected. 

Summary of Contents for Air 713-580

Page 1: ...Original Operating Instructions For ErgoPack Air 713 580 726 580 745 580 Serial No ______________________ EN V4 ...

Page 2: ...validity if a change is made to the system without our permission Respective EU directives EU Machine directive 2006 42 EG EU Low voltage directive 2006 95 EG EU Guideline on electromagnetic compatibility 2004 108 EG Applied standards EN ISO 12100 2010 EN ISO 13849 1 2007 EN 60204 1 2007 A1 2009 EN 61000 6 2 2005 EN 55011 2009 A1 2010 Marginal class B EN 415 8 2011 Since strapping system 0319XXXX ...

Page 3: ...system with electrical drive electronically controlled via joystick with sealing head for strap widths of 12 16 mm and a maximum tension of 2500N electronically adjustable for heights from 2 5 57cm ErgoPack Air 745 580 Strapping system with electrical drive electronically controlled via joystick with sealing head for strap widths of 15 19 mm and a maximum tension of 4500N electronically adjustable...

Page 4: ... band switches 21 5 Installation 22 5 1 Lifting and unloading of the machine 22 5 2 Battery charger 23 5 3 Charging the battery pack 23 5 4 Fuses of the battery pack 25 6 Operation 26 6 1 Setting of strap width at the sealing head 26 6 2 Switching on the control unit 27 6 3 Choosing the correct tension force range 28 6 4 Setting the tension force at the sealing head 29 6 5 Setting mode of operatio...

Page 5: ... parking 63 9 Spare part lists 63 5 Weight ready for use incl battery without strap without lifting device 280 kg Dimensions without control panel including control panel removable Length 1340 mm 1360 mm Width 1120 mm 1240 mm Height min height adjustment at lowest point 1600 mm Height max height adjustment at highest point 1930 mm Maximum speeds of chain Moving out horizontally 40 m min Moving out...

Page 6: ...m S Air 745 580 Sealing Friction welding Measured A graded noise emission level EN ISO 11202 EN 60745 1 2 2009 Air 713 580 L pa 79 dB A L paeq 77 dB A Air 726 580 L pa 78 dB A L paeq 82 dB A Air 745 580 L pa 79 dB A L paeq 81 dB A Sound power level on average EN 60745 1 2 2009 Air 713 580 L waeq 88 dB A Air 726 580 L waeq 93 dB A Air 745 580 L waeq 92 dB A Measurement inaccuracy K Air 713 580 3 0 ...

Page 7: ... 5 ms 2 Air 726 580 1 5 ms 2 Air 745 580 1 5 ms 2 Plastic strap Strap materials Polypropylene PP Polyester PET Strap width Air 713 580 adjustable to 9 10 mm 12 13 mm Air 726 580 adjustable to 12 13 mm 15 16 mm Air 745 580 adjustable to 15 16 mm 18 19 mm Strap thickness Air 713 580 0 40 0 80 mm Air 726 580 0 50 1 00 mm Air 745 580 0 80 1 30 mm 7 ...

Page 8: ...225 mm Height 220 mm Charging time approx 8 hours Temperature range 5 C 40 C Number of strappings 150 to 500 per charge depending on size of pallet tension welding time frequency of height adjustments and battery pack temperature Life span approx 500 charges Battery change trolley Weight 13 kg Width 550 mm Length 720 mm Height 1035 mm 1 3 Charger battery battery change trolley ...

Page 9: ...eases the reliability and life span of the system The operating instructions must be available at the place where the system is used It has to be read understood and used by everybody working with the system These works include operation maintenance and repair In addition to the operating instructions and the regulations in the country and place of use related to the prevention of accidents the re...

Page 10: ...ng to proper environmental protection Do not open the battery pack Do not throw the used battery pack into the domestic waste fire or water 2 1 Notes on environmental protection Attention Marks a situation to be considered If not considered it can lead to material damage or poor operating results Meaning of warning symbols usage conventions 10 Warning Marks a hazard with moderate risk If not avoid...

Page 11: ...d maintained by trained personnel Wear protective helmet Wear protective helmet when strapping pallets exceeding a height of 1 20 m The obligation to wear a helmet can be avoided if the operator was taught about the risk of injury by the plastic chain falling down This instruction has to be recorded in written Protect yourself Wear eye and hand protection cut proof gloves and also safety boots whe...

Page 12: ...ease tension before welding open the rocker lever After welding cut the strap with a suitable tool strap cutter Attention Risk of squeezing There is a risk of squeezing in the entire surroundings of the ChainLance but especially between the metal chain pieces of the supporting ChainLance also in the area of the reversing sledge the tensioning wheel the guiding wheel and between the lifting unit an...

Page 13: ...t your fingers into the area of the tension wheel of the sealing head and into the ChainLance Reversing sledge risk of crushing Especially around the entire surroundings of the reversing sledge there is a risk of squeezing Hazardous area risk of crushing and risk of injury Make sure before each strapping cycle that there is no person in the hazardous area especially of the ChainLance and nobody ca...

Page 14: ...ere is a risk of squeezing in the entire surroundings of the ChainLance but especially between the metal chain pieces of the supporting ChainLance see Fig 1a and 1b Lifting unit and chassis risk of squeezing There is a risk of squeezing in the surroundings between the lifting unit and the chassis see Fig 2a and 2b 14 ...

Page 15: ...goods Changing battery pack risk of injury While changing the battery pack it has to be held by 2 persons Alternatively the battery pack can be changed by one single person by using the battery change trolley which is available as an accessory Caution Following hazards can result in minor or moderate injuries Strap coil risk of injury While changing the strap coil 2 persons need to transport and l...

Page 16: ... damage has to be done Use only original ErgoPack spare parts Warranty and liability become invalid if other then ErgoPack spare parts are used Covers Do not operate the strapping system if any parts especially covers are disassembled This also applies to all other parts irrespective whether the operator considers them for security irrelevant and or unimportant for the function of the system and f...

Page 17: ...considered any risk due to damaging of dangerous products or their package The machine is not designed for lifting loads or and persons Check the plug and the cable before each use and have them replaced by a specialist if they are damaged Do not use any batteries of other manufacturers use original spare parts only Keep the connection plug to the battery pack away from non related objects and dir...

Page 18: ...rcular disk for strap Supporting ChainLance with guiding ChainLance inside Compartment for battery with chassis protection Lifting device Sealing head Control panel with joystick and colour display Sliding window with safety switch Triplex Tool Lift Guide rollers with parking brake and overrun protection ...

Page 19: ...em 4 3 Control panel sealing head 1 Favourite 2 Welding time 3 Operating mode 4 Plus Keylock 5 Tension force 6 Minus Soft tension a Information symbols b Status indicator bar Tensioning Welding c Display Messages Display activated Welding process is finished tool can be removed Application error Temporary system error can be rectified by the operator Tool fault static system error rectify error If...

Page 20: ...at 100 LED continuous green battery pack fully charged charger switches to conservation charge LED flashing green no battery pack connected charger ready for use Note The battery pack only is fully charged if both LED indication lights are continuously green not flashing If only one LED is continuously green and the second LED is not green even if the first LED has been continuously green for alre...

Page 21: ...ng inside by covers or secured by safety band switches Safety band switches Fig 9 Fig 10 21 Attention The system may not be used if any parts especially covers are dismounted This applies also to all other parts independent if the operator considers them as not safety relevant and or unimportant for the function and operation of the machine ...

Page 22: ...ure the brakes of both guide rollers are blocked pedals are in upright position Fig 11a Fig 11b Fig 12a Fig 12b Fig 13a Fig 13b lock guide rollers lock guide rollers 22 Warning Only the lifting device delivered with the system may be used for lifting the system Any other lifting method means danger for man and system For using the lifting device the pre set strapping height must not exceed 10 cm s...

Page 23: ...Turn the red ring 3 of the plug 4 on the battery pack 2 to the left Fig 14b 4 Disconnect the plug 4 from the battery pack 2 Fig 14b 1 3 4 2 Fig 14a Fig 14b Fig 15 23 Warning Charge the battery only with the ErgoPack Dual 3 step charger through the blue socket Always charge the battery pack completely until both control lights are continuously green Lifting of the charger only by two persons or by ...

Page 24: ...omatically switching to conservation charge when the battery pack is full Any overcharging is impossible 6 5 Fig 16 Fig 17 Fig 18 24 The battery pack can be charged inside the system but you also can take it out Charging the battery pack while operating the system is not possible Note 5 Put the blue plug 5 of the charger into the blue charging socket of the battery pack as shown in Fig 16 by holdi...

Page 25: ... start operation with the control panel in spite of full battery pack either the key switch is turned to position off to the left or the fuse 40 A of circuit 1 of the battery pack is not working All three fuses are standard automotive fuses Circuit 1 24V output to strapping system The battery pack has three circuits Each circuit is protected by a separate fuse The fuses are placed behind the red c...

Page 26: ...e side cover 5 Release counter sunk screw Torx 2 and remove strap guide front 13 mm 1 Release counter sunk screw Torx 4 and remove strap guide front 13 mm 3 Release cylinder screw Torx 10 and remove strap guide rear 13 mm 9 Fit side cover 5 secure cylinder screw with screw locking varnish medium tight Install strap guide rear 16 mm 8 b Change strap width from 15 16mm to 12 13 mm Release three cyli...

Page 27: ...ning clockwise right Press button I 11 Once the Logo ErgoPack has disappeared follow the instructions on the display 4 2 3 11 9 8 2 step The control unit is in the teaching mode Now move the joystick 8 completely to the move out or in the move in direction and keep it pushed until the display shows main menu The control unit is now ready for operation The 7 segment indicator lights up on the displ...

Page 28: ...n Always use the SOFT tension mode when working with PP strap By using the Soft mode the tension wheel accelerates more slowly and avoids excessive strap waste when sealing with PP strap a b c d Press Soft button a The soft mode is deactivated when the SOFT display b changes position and is shown outlined Press Soft button a The soft mode is activated when the SOFT display c changes position and i...

Page 29: ...e tool is operational Setting soft tension The set tension force is displayed continuously when the tool is ready for operation Press tension force button 2 The set tension force flashes for 5 seconds The buttons 1 and 3 appear Unused displays disappear Press 1 or 3 button until the required tension force is displayed The status indicator bar 4 shows the set tension force in relation to the possib...

Page 30: ... 1240 1360 lbf 90 115 145 170 200 225 250 280 305 745 Standard N 1300 1700 2100 2500 2900 3300 3700 4100 4500 lbf 290 380 470 560 650 740 830 920 1000 Soft N 400 550 700 850 1000 1150 1300 1450 1600 lbf 90 120 160 190 225 260 290 325 360 30 rounded values N Newton lbf pound force per square inch Warning Adjusted tension force must relate to the packaged goods to be strapped Possible hazards caused...

Page 31: ...ton must then be briefly pressed so that the straps are welded and the upper strap is cut off SEMI Semi automatic strapping standard factory setting The tensioning button must be pulled and held until the set tension force has been reached The straps are then automatically welded and the upper strap is cut off It can be welded manually at any time by pressing the welding button MAN SEMI AUTO By pr...

Page 32: ...ot place hands or other body parts between the strap and the packaged goods during the strapping process Ensure that there are no other persons in the hazard zone For an emergency stop in the case of danger trapped person To release the strap tension before welding pull the rocker lever In operating mode AUTO also the tensioning or welding button can be pressed again After welding cut the strap us...

Page 33: ...e system is ready for operation Press welding time button 2 Unused displays disappear The filled dots of the current set welding time flash for 5 seconds and appear Press button 1 or 3 until the required welding time appears Save Press welding time button 2 or wait for 5 seconds 3 2 1 Fig 28 c ...

Page 34: ...emoved as described under point 5 1 The electronic height adjustment can only be performed without the lifting device Otherwise it can lead to damages and injuries Step 1 Keep load button pressed until upper switch off position is reached load button next step clear button back to Main Menu Important Each next step will be shown by pressing the load button By pressing the clear button the load mod...

Page 35: ...Upper switch off position reached Step 2 Put on a new strap roll load button next step clear button back to Main Menu Step 3 Open sliding window and push the strap through the yellow slot load button next step clear button back to Main Menu ...

Page 36: ...Fig 34 Fig 35 Fig 36 36 Step 4 Slide the strap through the clamp lock located in the red chain link and close the sliding window again load button next step clear button back to Main Menu ...

Page 37: ...e displayed The system goes fully down to reset height measurement thereafter up again by approx 10 cm load button next step clear button back to Main Menu Step 6 Keep load button pressed until chain feed stops load button next step clear button back to Main Menu ...

Page 38: ...Step 7 Take the strap out of the clamp lock and keep the strap tensioned in you left hand With your right hand simultaneously press load button until chain feed stops load button next step clear button back to Main Menu ...

Page 39: ...ack in order to avoid the strap being pushed back into the system by the ChainLance Step 8 Feed strap through the eccentric lock located at the top of the ChainLance and keep the strap slightly tensioned with your left hand Simultaneously press load button until ChainLance is fully retracted and load Mode is finished ...

Page 40: ...place the overlapping strap through the slot for strap fixture Your ErgoPack Air is now almost ready for strapping only adjust pallet width and strapping height and you are ready to go The next pages will show you how easily and quickly this is done ...

Page 41: ...inium chain supporting ChainLance As soon as the reversing unit at the front end of the supporting ChainLance has passed completely underneath the pallet the supporting ChainLance will be locked by a magnet locking bar As the guiding ChainLance continues to move out the reversing unit turns to a vertical position and the ChainLance finally brings the strap up at the back side of the pallet and ove...

Page 42: ... switch between manual setting and automatic detection of pallet width The selection is shown on the display in the main menu The manual mode shows the set pallet width e g 1 6 m the automatic mode shows auto detect Important If the pallet width is 2 0 m or wider a support point for the supporting ChainLance between 1 0 m and 1 8 m is necessary best wooden for low wear out like pallet board Button...

Page 43: ...s soon as the reversing unit and the sensors located at its side have passed the pallet underneath and appear at the opposite side the magnet locking bar will get the signal to lock the support ChainLance if there is no object left in the reflection cone The magnet locking bar will not lock the supporting ChainLance before it moved out 0 80 m to make sure the reversing unit is not folding up betwe...

Page 44: ...despite the fact that the reversing unit already passed the pallet completely The ultrasonic sensors cannot differ between a pallet and an object person Reflection cone of the ultrasonic sensors As soon as the safety band at the front end of the supporting ChainLance is touching an obstacle the system stops immediately To start it again the reset button has to be pressed The corresponding informat...

Page 45: ... to get into the reflecting cone of the ultrasonic sensors The strap is within the area of the reflecting cone of the ultrasonic sensors and realized as an obstacle Therefore the magnet locking bar cannot lock the supporting ChainLance despite the fact that the reversing unit already passed the pallet Strap outside the reflecting cone of the ultrasonic sensors Hold the strap to the left WRONG stra...

Page 46: ... 10 0 cm 2 Choose required memory L1 L5 Selected height position L 0 3 Press set button to store Back to Main Menu Press clear To set and save the strapping height follow the three steps in the set mode described in the display The double ChainLance has to be fully moved back into the system before setting the pallet height If the setting of the strapping height in the set mode is activated by one...

Page 47: ...6 11 Strapping Fig 55 47 1 step Place the ErgoPack Air parallel to the pallet according to the line laser For a correct distance the laser line should run right below the lower edge of the pallet ...

Page 48: ...g wheel keeps the system parallel to the pallet If a pallet needs to be strapped several times the system will always remain in the same parallel position as it can only be moved for and backwards By pressing the button once more the guiding wheel moves up and the system can be manoeuvred again freely ...

Page 49: ...he move out direction The ChainLance pulls the strap through under the pallet and up again on the opposite side When working in the manual width setting mode the pallet width should be set in a way that the distance between the pallet and the rising ChainLance is about 10 20 cm ...

Page 50: ...nLance appears on the other side and falls towards you Catch the ChainLance at the front edge as shown Do not let it drop onto the package As soon as you have caught the ChainLance let go of the joystick so it moves back to the middle position and the ChainLance stops moving out further 4 step Hold the strap with the left hand by the head piece as shown ...

Page 51: ...on when moving back the ChainLance This avoids the strap forming a loop at the backside of the ChainLance which could jam in the reversing unit and lead to malfunctions and move the Chain Lance completely back wards by pushing the joystick in the move in direction ...

Page 52: ...the strap loosely in your hand For safety reasons the system will switch off automatically if you keep the strap under tension in your hand while the strap lifter rises The strap lifter will rise again each time you push the joystick in the move in direction 5 step The strap lifter rises automatically after the reversing sledge has moved back into the system Now relax the strap in your left hand o...

Page 53: ...an pull out additional strap from the system Do not pull directly at the strap lifter but about 10 cm below it Hold the strap with the whole hand and pull it out of the system Simultaneously you have to relax the strap in your other hand ...

Page 54: ... strap lies underneath Fig 66 Fig 67 3 Step Strap the pallet as described in section 6 11 6 12 Tensioning and sealing 54 3 Step Hold then both straps as shown with the right hand The end of the strap should lie in your hand and not project beyond it ...

Page 55: ...forward at the same time so that the sealing head is parallel to the package Pull the rocker lever to open the clamp of the sealing head With your right hand you can now feed the strap from the top to the bottom through the slot in the sealing head similar to a credit card Now let go of the rocker lever ...

Page 56: ...n 6 3 Thereafter press the round welding button Fig 72 to weld both straps and to cut off the upper one 5 2 SEMI Semi automatic tensioning and sealing Pull the tensioning button Fig 71 until the pre set tension force is reached Afterwards both straps will be automatically welded and the upper strap will be cut off You can also weld the straps manually at any time by pressing the welding button eve...

Page 57: ...a lot of strap waste Especially the tension wheel and the tooth plate have to be checked for damages and kept clean Please refer to section 7 2 Attention If after pressing the welding button the welding process does not start but the sealing head beeps the tension button was not pressed first The welding process is finished once the indicator bar 1 is filled fully The cool down starts 2 After cool...

Page 58: ...ace has been properly welded without any extra material being squeezed out to the side 2 Bad welding The surface has been unevenly welded the selected welding time is too short 3 Bad welding Surplus material has been squeezed out to the side the selected welding time is too long Warning Improper welded straps cannot secure the loads and can therefore cause injuries Never transport or move goods wi...

Page 59: ...stant plastics and is basically maintenance free Clean the outside of the ErgoPack Air with a damp cloth if it is extremely dirty For all servicing and repair work the battery pack has to be unplugged and the emergency stop has to be pressed Clean the guiding ChainLance with acetone or cleaning solvent if it has become greasy or oily The support ChainLance does not need any cleaning For better pro...

Page 60: ...h the wire brush 6 supplied Check tension wheel for worn teeth If a few teeth are broken replace tension wheel observe direction see arrow 7 2 Cleaning replacing the tension wheel at the sealing head Fig 79 Fig 78 78 a 60 Cleaning the tension wheel without disassembling There is an access hole 78a in the protection cover below the motor The tension wheel and the tooth plate can be cleaned with com...

Page 61: ...ion is done in the reversed order of the disassembling Secure pan head screw 1 with screw locking varnish medium tight Installation is done in the reversed order of the disassembling Grease interior gear teeth of the tension wheel lightly with Klüber grease GBU Y 131 Microlube Attention The tension wheel is extremely sensitive when it comes into contact with hard especially metallic objects A hard...

Page 62: ... installing the knife 1 check that the compression spring 7 on top of the knife is still mounted Secure the pan head screw 5 with screw locking varnish medium tight 7 5 Cleaning the ultrasonic sensors If the pallet width is not recognized correctly anymore while the automatic pallet width mode is used possibly one or both ultrasonic sensors are dirty or covered by an object e g piece of wood cardb...

Page 63: ...ot the position number of the part on the exploded drawing 9 Spare parts lists Moving the system The system can be moved with the two ergonomically optimized handles Before moving the system the brakes at both guide rolls have to be released Parking the system After the system was parked the brakes at the two guide rolls of the system have to be locked in order to avoid any accidental movement Fur...

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