Sealed Air Fill-Air Rocket User Manual Download Page 1

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Rev. C

© Sealed Air Corporation (US) 2014

Fill-Air Rocket™ Inflatable Packaging System User’s Guide

REA

#1 B

L6T

REA

#1 B

L6T

Standard Tabletop

Version

Optional Stand with

Integrated Bin

Fill-Air

Rocket

™

Inflatable Packaging System

User’s Guide

Original Instructions

Summary of Contents for Fill-Air Rocket

Page 1: ...014 1 Fill Air Rocket Inflatable Packaging System User s Guide RE AD Y 1 BL6 T RE AD Y 1 BL6 T Standard Tabletop Version Optional Stand with Integrated Bin Fill Air Rocket Inflatable Packaging System User s Guide Original Instructions ...

Page 2: ...Rev C Sealed Air Corporation US 2014 2 ...

Page 3: ...o ______________________________________________________________ Accessories ______________________________________________________________ ______________________________________________________________ Please attach the business card of your Sealed Air Representative here Fill Air Rocket Inflatable Packaging System For Toll Free Service Information Call 1 800 243 1102 U S ...

Page 4: ...8 3 3 Electrical Power Requirements 20 3 4 Material 21 3 5 System Components 22 4 0 Set up 4 1 System Set up 28 4 2 Applications 31 5 0 Operation 5 1 Loading the Material Roll 34 5 2 System Controls 36 5 3 Control Panel 38 5 4 Producing Air Filled Bags 40 5 5 Producing Air Filled Bags in Auto Replenish Mode 42 5 6 Producing Air Filled Bags in Batch Mode 44 Table of Contents Table of Contents ...

Page 5: ...art button is pressed the control panel Power LED is ON 53 7 3 2 The material advances and edge seals are present but the bags do not fill with air 54 7 3 3 The material advances the bags fill with air but do not seal or seal fully 55 7 3 4 The inflated bags leak air 57 7 3 5 The inflated bags have an inconsistent air fill amount 59 7 3 6 The system does not stop producing bags when the bin is ful...

Page 6: ...ocations 2 25 Fig 3 5 Component Locations 3 27 4 0 System Set up Fig 4 1 System Set up Table Top Version 29 Fig 4 2 System Set up Stand Version 30 Fig 4 3 Typical Application Remote Inflation 31 Fig 4 4 Typical Application On Line Inflation with Optional Stand with Integrated Bin 32 5 0 Operation Fig 5 1 Loading the Material Roll Steps 1 and 2 34 Fig 5 2 Loading the Material Roll Step 3 35 Fig 5 3...

Page 7: ...List of Tables and Illustrations Table of Contents 5 0 Operation cont Fig 5 6 Producing Air Filled Bags into a Bin in Auto Replenish Mode 43 Fig 5 7 Producing Air Filled Bags in Batch Mode 45 6 0 Maintenance and Repair Tab 6 1 Preventative Maintenance Schedule 47 Fig 6 2 Replacing the Edge Seal 49 ...

Page 8: ...ntion to the need to be aware of components that may be hot This goggles symbol calls attention to the need to wear protective eye wear while performing maintenance procedures This exclamation point symbol calls attention to equipment features that you should be familiar with by reading the enclosed literature This will help prevent operating and maintenance problems This triangle symbol calls att...

Page 9: ... defined as those individuals who have been trained by a Sealed Air representative and are authorized to operate the system and to perform basic maintenance as outlined in this guide Warning Only qualified service personnel who have been trained by a Sealed Air representative are allowed to perform maintenance and repair procedures Qualified Service Personnel is defined as those individuals who ha...

Page 10: ...Rev C Sealed Air Corporation US 2014 10 intentionally blank ...

Page 11: ...m The system is plugged into a properly rated grounded outlet see 3 3 Electrical Power Requirements Warning Failure to properly ground the system could create an electrical shock hazard Warning Do not remove the guards or access covers The guards and access covers should be removed only by an authorized Sealed Air Representative or qualified service personnel that have been trained by a Sealed Air...

Page 12: ...y the Fill Air Rocket system other than the procedures contained in the 4 0 Set up 5 0 Operation or 6 0 Maintenance and Repair sections of this guide All repairs must be done by a Sealed Air Representative or qualified service personnel that have been trained by a Sealed Air representative Warning Use protective eye wear as indicated when performing maintenance and repair procedures Warning Do not...

Page 13: ...mal operation Please check to make sure you comply with your local health and safety requirements 8 Environmental conditions Storage temperature machine and material rolls 32º 110ºF 0º 43ºC Operating temperature machine and material rolls 60º 110ºF 16º 43ºC Note Material rolls if extremely cold or hot must be brought to operating temperature to properly seal Materials stored at temperatures outsid...

Page 14: ...ir Corporation US 2014 14 2 0 Safety 2 1 Important Safety Precautions cont Safety Devices Section View Figure 2 1 Warning Hot Roller and Risk of Entrapment Material Roll ON OFF Switch E Stop Button Edge Seal Assembly ...

Page 15: ...built in safety devices Emergency Stop Button E Stop This red button when pushed disables all system functions It is located above the control panel Warning Hot Roller When material is inflating and sealing the edge seal roller is hot Be aware of the edge seal function and location Warning Risk of Entrapment Keep fingers loose hair clothing and jewelry away from the edge seal roller when material ...

Page 16: ...irective the 2004 108 EC Electromagnetic Compatibility EMC Directive and the 2011 65 EU RoHS Directive EN 60204 1 Safety of Machinery Electrical equipment of machines EN 13849 Safety Controls EN 12100 2010 Safety of Machinery Principles for risk assessment EN ISO 13857 Safety of Machinery Safety distance to prevent danger zones being reached by upper limbs EN 349 Safety of Machinery Minimum gaps t...

Page 17: ...cteristics of ISM equipment EN 55014 Radio interference characteristics of Household equipment EN 61000 6 2 Generic Immunity Industrial Environment EN 61000 4 2 ESD EN 61000 4 3 Radiated immunity EN 61000 4 4 EFT EN 61000 4 5 Surge EN 61000 4 6 Conducted immunity EN 61000 4 11 Voltage dips and interruptions EN 50581 RoHS UL 963 Sealing Wrapping and Marking Equipment CSA C22 2 no 68 Motor operated ...

Page 18: ...n a bin sensor or optional accessory is employed the supply of inflated bags can be continually automatically replenished see 5 5 Producing Air Filled Bags in Auto Replenish Mode Batch Mode Dispense a programmed length of bags see 5 6 Producing Air Filled Bags in Batch Mode 3 2 Sequence of Operation 1 The operator presses the start key and the drive motor is activated drawing the material from the...

Page 19: ...ration US 2014 19 Fill Air Rocket Inflatable Packaging System User s Guide 3 0 Overview Sequence of Operation Figure 3 1 3 2 Sequence of Operation cont Material Roll Material Bar 2 1 Inflation Nozzle 3 Edge Seal Start Key 4 ...

Page 20: ...oblems as well as operator discomfort due to static discharge Electrical Power Requirements Table 3 2 3 3 Electrical Power Requirements 3 0 Overview Fill Air Rocket Receptacle A C Voltage Phase Current Inflatable Packaging System Type 115 VAC Version NEMA 5 15R 100 120 VAC Single Phase 15 Amp Service 50 60 Hz Grounded 2 2 avg 230 VAC Version CEE 7 7 220 240 VAC Single Phase 13 Amp Service 50 60 Hz...

Page 21: ...S For available EU Material types see 8 6 Film EU Material storage temperature range is 32º 110ºF 0º 43ºC Material rolls can be stored in this temperature range but must be brought to within the operating temperature range before being used Materials stored at temperatures outside the specified storage temperature range can be damaged and rendered unusable Material operating temperature range is 6...

Page 22: ...ptacle see 3 3 Electrical Power Requirements 4 Control Panel This panel with LCD display and keys is used to operate program and diagnose the system see 5 3 Control Panel 5 Power Cabinet This cabinet houses the system s mechanical and electrical components Warning Do Not Open This cabinet should not be opened except by qualified service personnel or a Sealed Air representative 6 Material Mandrel T...

Page 23: ...Rev C Sealed Air Corporation US 2014 23 Fill Air Rocket Inflatable Packaging System User s Guide 3 0 Overview Component Locations 1 Figure 3 3 3 5 System Components cont READY 1 BL6T 6 7 3 4 1 2 5 ...

Page 24: ... the Edge Seal Warning Hot roller Warning Risk of entrapment 9 Material Roll This roll contains preformed bags with a perforation line between which are then filled with air and sealed 10 Bin Sensor This sensor when active will monitor the bag supply in a bin located below it see 5 2 System Controls 11 Accessories Port This connection is for optional accessories see 5 2 System Controls ...

Page 25: ...T For technical assistance or for any questions regarding this system call 1 800 505 8861 U S and Canada www sealedair com Serial FAR 10001 Electrical 100 120V 220 240V 2 2A 1 1A Single Phase 50 60Hz Weight 25 lb 11 3kg This equipment is manufactured by Sealed Air Corporation US Patents pending Fill AirRocket Inflatable Packaging System 9 8 11 10 Warning Hot Roller and Risk of Entrapment ...

Page 26: ...12 Stand Optional Accessory This stand provides for an on line overhead or large bin dispense position 13 Integrated Bag Bin Optional Accessory This bin holds the supply of inflated bags 14 User s Guide 3 5 System Components cont 3 0 Overview ...

Page 27: ... Fill Air Rocket Inflatable Packaging System User s Guide 3 0 Overview Component Locations 3 Figure 3 5 3 5 System Components cont RE AD Y 1 BL6 T User s Guid e Origina l Instruc tions Fill Air Roc ket Inflat able Pack aging Syste m 13 14 12 ...

Page 28: ...he installation area should have a sufficient amount of clear dry and level space for your packaging application operation and service of the system Tabletop version 18 0 max x 17 5 x 17 75 46m x 44m x 45m Lx W x H see Figure 4 1 Stand version 32 0 x 42 25 x 60 0 81m x 1 07m x 1 52m L x W x H see Figure 4 2 4 Verify that the required electrical power receptacle is installed at the desired machine ...

Page 29: ... User s Guide 4 0 Set up 4 1 System Set up cont System Set up Table Top Version Figure 4 1 REA DY 1 BL6 T 20 51m Service 24 61m Service 24 61m Operation and Service 24 61m Service 24 61m Operation and Service 17 75 45m Power Cord 10 3 05m 18 0 46m with roll max 24 61m Service 17 5 44m ...

Page 30: ...ion 2 0 61m Operation 24 61m Service 2 0 61m Operation and Service 60 0 1 52m Optional Stand with Integrated Bin 29 5 x 32 0 x 42 0 75m x 81m x 1 07m Power Cord 10 3 05m 42 25 1 07m Service w Bin 29 5 75m Operation 42 25 1 07m Operation w Bin 4 0 Set up 4 1 System Set up cont System Set up Stand Version Figure 4 2 ...

Page 31: ... Inflatable Packaging System User s Guide Typical Application Remote Inflation Figure 4 3 4 0 Set up 4 2 Applications READY 1 BL6T Customer Provided Work Table Customer Provided Work Table Small Accumulation Bin Optional 36 25 x 20 75 x 28 5 92m x 53m x 72m ...

Page 32: ...tion On Line Inflation with Optional Stand with Integrated Bin Figure 4 4 4 2 Applications cont READY 1 BL6T Customer Provided Case Sealer Customer Provided Conveyor Chute Dispensing Arm Optional Optional Stand with Integrated Bin 23 5 x 30 0 x 42 25 60m x 76m x 1 07m ...

Page 33: ...Rev C Sealed Air Corporation US 2014 33 Fill Air Rocket Inflatable Packaging System User s Guide 4 0 Set up intentionally blank ...

Page 34: ...mandrel 2 Feed the material into the system Lower the red handle clamp to open the edge seal By hand thread the material Under the material bar Spread the material layers open and wrap around the inflation nozzle Between the two wheels on the edge seal assembly 5 0 Operation 5 0 Operation Loading the Material Roll Steps 1 and 2 Figure 5 1 1 Fill Air Ro ck et Infl ata ble Pac kag ing Sys tem 2 Mand...

Page 35: ... s Guide 5 0 Operation 5 1 Loading the Material Roll cont Loading the Material Roll Step 3 Figure 5 2 3 Close the clamp While maintaining tension on the material raise the red handle clamp to close the edge seal Proceed to 5 4 Producing Air Filled Bags 3 RE AD Y 1 BL 6T Clamp Handle Closed ...

Page 36: ...h LCD Display and keys is used to operate program and diagnose the system see 5 3 Control Panel 4 Bin Sensor This ultrasonic sensor located inside the power cabinet when activated in the Auto Replenish Mode detects the amount of inflated bags in the bin When the bag supply is low the system automatically resumes to create more air filled bags 5 Service Port For use by qualified service personnel o...

Page 37: ...Rev C Sealed Air Corporation US 2014 37 Fill Air Rocket Inflatable Packaging System User s Guide System Controls Figure 5 3 5 0 Operation 5 2 System Controls cont READY 1 BL6T 6 3 1 5 2 4 ...

Page 38: ...h Mode to set the batch length 4 Start Key This green key when pushed starts air filled bag production 5 Start LED This green light indicates that inflated bag production is selected Note In Auto Replenish Mode when the bin is full and production is paused this light will blink 6 Stop Reset Key This red key when pushed stops air filled bag production or resets the system once a fault is cleared 7 ...

Page 39: ... Corporation US 2014 39 Fill Air Rocket Inflatable Packaging System User s Guide 5 0 Operation 5 3 Control Panel cont Control Panel Figure 5 4 Fill Air Rocket Inflatable Packaging System READY 1 BL6T 1 7 6 9 3 2 4 5 8 ...

Page 40: ...Keep fingers loose hair clothing and jewelry away from the edge seal roller when material is inflating and sealing 1 Press the Start Key to begin air filled bag production Once the system is ON and the Start Key is pressed the Fill Air Rocket system will Start to produce bags 2 Adjust the air fill amount as desired while bags are being produced Using the Up Down Keys adjust the air fill amount onl...

Page 41: ...ll Air Rocket Inflatable Packaging System User s Guide 5 4 Producing Air Filled Bags cont Producing Air Filled Bags Figure 5 5 5 0 Operation Fill Air Rocket Inflatable Packaging System READY 1 BL6T Start Key 1 Stop Key 3 Air Fill Adjust Keys 2 ...

Page 42: ...uilt in sensor or another sensor must be enabled by your Sealed Air representative 1 Press the Start Key to begin air filled bag production Verify that Auto Replenish Mode is selected Once the system is ON and the Start Key is pressed the Fill Air Rocket system will Start to produce bags Automatically pause bag production when the bin is full or a pause signal from an accessory is received Automat...

Page 43: ... Note The bin sensor is adjusted for each packaging application The fill levels can be varied from full to half full The bin sensor automatically senses when the bag supply reaches the preset low level The system automatically starts bag production to refill the bin 5 5 Producing Air Filled Bags in Auto Replenish Mode cont Producing Air Filled Bags into a Bin in Auto Replenish Mode Figure 5 6 5 0 ...

Page 44: ...your Sealed Air representative Note Batch Length Adjust must be enabled by your Sealed Air representative 1 Select Batch Mode Press the Batch Mode Select Key to enter Batch Mode 2 Adjust the batch length Using the Up Down Keys set the batch length in feet 3 Press the Start Key to start the batch Once the system is ON and the Start Key is pressed the Fill Air Rocket system will Start to produce bag...

Page 45: ... System User s Guide 5 6 Producing Air Filled Bags in Batch Mode cont Producing Air Filled Bags in Batch Mode Figure 5 7 5 0 Operation Fill Air Rocket Inflatable Packaging System READY Batch Size 20 1 BL6T BATCH ON Start Key Up Down Keys 2 3 Batch Mode Select Key 1 Stop Key 5 4 ...

Page 46: ...Rev C Sealed Air Corporation US 2014 46 intentionally blank ...

Page 47: ...and repair procedures Warning Use protective eye wear when performing maintenance and repair procedures Preventative Maintenance Schedule Table 6 1 Fill Air Rocket System Maintenance Schedule Activity Procedure Monthly Clean Blow off all dust and debris from the system Avoid inhalation of dust and debris Inspect Check for any unusual wear on components Check for any unusual wear or build up on the...

Page 48: ...e There is a finger slot in the top of the edge seal assembly to ease removal of the wheel 3 Pull the edge seal wheel off of the knurled drive roller 4 Install the new edge seal Align the three 3 connection pins on the new wheel with the three 3 receptacle holes in the seat Note The hole pattern and pins are in a keyed pattern Push the release button in while pushing the wheel fully onto the knurl...

Page 49: ...table Packaging System User s Guide 6 0 Maintenance and Repair Replacing the Edge Seal Figure 6 2 6 2 Replacing the Edge Seal cont Receptacle Holes 3 Release Button Clamp Shown Open Knurled Drive Roller Finger Slot Edge Seal Wheel Edge Seal Wheel Side Seal 1 2 3 ...

Page 50: ...er supply is interrupted 4 Electrical component failure Turn the main power switch to the ON position Verify the main power cord is plugged into a properly rated outlet see 3 3 Electrical Power Requirements Verify facility power supply see 3 3 Electrical Power Requirements Contact your Sealed Air representative 7 1 There is no power to the system and the control panel Power LED is OFF 7 0 Troubles...

Page 51: ...ial web is off the inflation nozzle 2 Bags under filled with air Twist E Stop to release Load new roll see 5 1 Loading the Material Roll Reload roll as required see 5 1 Loading the Material Roll Remove bags from bin as required Clean bin full sensor lens with dry cloth or paper towel Reload roll as required see 5 1 Loading the Material Roll While the system is producing bags press the Up Key to in...

Page 52: ...the edge seal and press Reset Key Check condition of edge seal and verify that it is fully seated Replace as required see 6 2 Replacing the Edge Seal Contact your Sealed Air representative Clamp Open Edge Seal Open 7 2 Displayed Fault Messages cont Note If your displayed message is not listed below contact your Sealed Air representative DISPLAYED MESSAGE Possible cause recommended solution ...

Page 53: ...equired see 5 1 Loading the Material Roll Remove the inflated bags from the bin automatic refill will restart Note The bin sensor is adjusted for each packaging application The full levels can vary from a full bin to a half full bin Refill will begin once the bin is emptied to the low level see 5 5 Producing Air Filled Bags in Auto Replenish Mode Contact your Sealed Air representative 7 3 1 The ma...

Page 54: ...material is facing in towards the inflation nozzle see 5 1 Loading the Material Roll Increase the air fill amount see 5 3 Control Panel Load new material see 5 1 Loading the Material Roll Return material roll contact your Sealed Air representative Contact your Sealed Air representative 7 3 2 The material advances and edge seals are present but the bags do not fill with air PROBLEM Possible cause r...

Page 55: ...l or seal fully Check condition of edge seal on the bag Check condition of edge seal and verify that it is fully seated Replace as required see 6 2 Replacing the Edge Seal Contact your Sealed Air representative While the system is producing bags press the Down Key to reduce the air fill amount see 5 3 Control Panel Load new material see 5 1 Loading the Material Roll Return material roll contact yo...

Page 56: ...l or mechanical failure Verify film setting Change as required Contact your Sealed Air representative Remove re install and calibrate the edge seal see 6 2 Replacing the Edge Seal Contact your Sealed Air representative 7 3 3 The material advances the bags fill with air but do not seal or seal fully cont 7 3 Problems with Making Inflated Bags cont ...

Page 57: ...ition of edge seal on the bag Check condition of edge seal assembly and that it is fully seated Replace as required see 6 2 Replacing the Edge Seal Contact your Sealed Air representative The seals need a few seconds to cool before being used Allow the bin to refill before continuing Contact your Sealed Air representative While the system is producing bags press the Down Key to reduce the air fill ...

Page 58: ...out of adjustment 8 Electrical or mechanical failure Verify film setting Change as required Contact your Sealed Air representative Remove re install and calibrate the edge seal see 6 2 Replacing the Edge Seal Contact your Sealed Air representative Contact your Sealed Air representative 7 3 4 The inflated bags leak air cont 7 3 Problems with Making Inflated Bags cont ...

Page 59: ...o high 4 Incorrect inflation setting 5 Electrical or mechanical failure Reload material roll see 5 1 Loading the Material Roll Load new material roll see 5 1 Loading the Material Roll Return material roll contact your Sealed Air representative While the system is producing bags press the Down Key to reduce the air fill amount see 5 3 Control Panel Contact your Sealed Air representative Contact you...

Page 60: ...ion or has failed 4 Faulty internal bin sensor 5 Electrical or mechanical failure Fill the void and spread the bags out evenly in the bin Verify auto replenish mode is selected see 5 5 Producing Air Filled Bags in Auto Replenish Mode Verify that the connections at the sensor and at the receptacle are fastened and tight Contact your Sealed Air representative Contact your Sealed Air representative C...

Page 61: ...hone consultation call the appropriate number below For Service and Replacement Parts 1 Contact your Sealed Air Account Representative 2 Contact toll free Technical Support 1 800 243 1102 8 30 AM 5 00 PM EST M F with remote service after 5 PM See 8 2 Using Technical Support in the United States For Technical Information and Troubleshooting Assistance 1 Contact toll free Technical Support 1 800 243...

Page 62: ... Company name Company phone number 2 Fill Air Rocket System information System serial number the FAR _ _ _ _ _ number located on the serial number label on the back of the system System application type a description of your system setup 3 A detailed description of the symptoms that the Fill Air Rocket System is exhibiting Any faults the system displays 8 0 Customer Service ...

Page 63: ... Fax 31 0 24 3710101 Customer Service Locations Czech Republic Prague 420 2 20199551 France Joigny 33 0 3 8692 0431 Germany Alsfeld 49 0 6631 96680 Greece Shimatari Viotias 30 2620 32551 Hungary Újhartyán 36 29 573300 Italy Bellusco 39 039 6835446 The Netherlands Nijmegen 31 0 24 3710150 Poland Ozarów Mazowiecki 48 0 22 7217530 South Africa Spartan 27 0 11 9234600 Spain Abrera 34 93 7738325 Sweden...

Page 64: ...0699622 10 x 5 250mm x 130mm 4 200 1 280m 27 FA250NHS 8 100699532 10 x 8 250mm x 200mm 4 200 1 280m 27 FA300NHS 5 100699558 12 x 5 300mm x 130mm 4 200 1 280m 27 FA300NHS 8 100699533 12 x 8 300mm x 200mm 4 200 1 280m 27 Fill Air Extreme Efficiency Film Film SAP Bag Size Roll Length Rolls per Pallet FA200NHE 5 100802290 8 x 5 200mm x 130mm 5 900 1 798m 36 FA200NHE 8 100802552 8 x 8 200mm x 200mm 5 9...

Page 65: ...5 100716032 250mm x 130mm 1 280m 36 FA250NHS 8 100716033 250mm x 200mm 1 280m 36 FA300NHS 5 100715988 300mm x 130mm 1 280m 36 FA300NHS 8 100716031 300mm x 200mm 1 280m 36 Fill Air Extreme Efficiency Film Film SAP Bag Size Roll Length Rolls per Pallet HDE8 5 100813188 200mm x 130mm 1 799m 48 HDE8 8 100813189 200mm x 200mm 1 799m 48 HDE10 5 100813382 250mm x 130mm 1 799m 36 HDE10 8 100813384 250mm x...

Page 66: ...Rev C Sealed Air Corporation US 2014 66 Notes Notes ...

Page 67: ...Rev C Sealed Air Corporation US 2014 67 Fill Air Rocket Inflatable Packaging System User s Guide Notes Notes ...

Page 68: ...led Air Corporation US 2014 68 10 Old Sherman Turnpike Danbury CT 06810 4173 P 800 648 9093 F 203 791 3618 SealedAir com Fill Air Rocket Inflatable Packaging System User s Guide T 339 P N 5010PVR 01 Rev C 03 14 ...

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