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ErgoPack RE Operating Instructions Manual

Ergonomic pallet strapping system
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  • Page 2 Hanns-Martin-Schleyer Str. 21 89415 Lauingen hereby declare, that the Ergonomic Pallet Strapping Systems type "ErgoPack RE", to which this declaration refers, complies with the respective relevant and basic health and safety requirements of the EU directives because of their concept, type of construction and the model we have brought on to the market.
  • Page 3 Hanns-Martin-Schleyer Str. 21 89415 Lauingen, Germany hereby declare, that the Ergonomic Pallet Strapping Systems type "ErgoPack RE“, to which this declaration refers, comply with the respective relevant and basic health and safety requirements of the United Kingdom directives because of their concept, type of construction and the strapping systems we have brought on to the market.

  • Page 4: Table Of Contents

    3.1.5​ Safety instructions for the storage of the Li-ion battery​ 3.1.6​ Safety instructions for implant carriers​ Description Design Control panel strapping system Touch display strapping system Li-ion battery 4.4.1 General view Li-ion battery 4.4.2 LED display Li-ion battery EN (RE)
  • Page 5 Setting the date and time 36-37 Setting pallet width Operation Strapping with Velcro tape 39-43​ Wind up Velcro tape 44-45 Strapping with tension belt 46-48 Wind up tension belt 49-50 Risks 51-54 Emergency information​ 9.1.1 First aid measures​ 9.1.2 Firefighting measures​ EN (RE)
  • Page 6 10.10 Changing the control box display unit 73-74 10.11 Changing the motor 75-77 10.12 Li-ion Battery Error Messages and cleaning 10.13 Li-ion Charging Station/Charger Error messages and cleaning 11. Software Updates 80-82 12. Personal protective equipment 13. General safety warnings for power tools 84-87 EN (RE)

  • Page 7: Validity Of The Operating Instructions

    Validity of the operating instructions These operating instructions are valid for the following models: ErgoPack RE Strapping system with electrical drive, electronically controlled via joystick, with winding device for reusable straps. EN (RE)

  • Page 8: General

    After having parked the strapping system you have to lock up the brakes of the two guide rolls (Fig.1a) on the strap side to avoid that the system is rolling away accidentally. Handles Operating instructions Fig. 1a Fig. 1 Caster wheel with parking brake EN (RE)

  • Page 9: Work Area Space Requirement

    The strapping system is only to be used in a covered dry area, otherwise the risk of an electric shock can not be ruled out. The ambient temperature during operation must not exceed 50°C and not fall below 0°C. For the strapping system, an electrically conductive floor is recommended. EN (RE)

  • Page 10: Energy Supply Li-Ion Charger/Battery

    Up to 1200 strappings with standard strapping* Service life: approx 80% residual capacity after approx 1000 charging cycles standard strapping: Band: 5m Velcro tape (orange) Pallet: pallet width 0,8 m, pallet height 1,15 m Strapping speed: fast Room temperature: 20°C EN (RE) -10-...

  • Page 11: Notes On Environmental Protection

    If the rechargeable battery is not disposed of properly, it may cause a fire and leakage of substances that are hazardous to health and the environment. Fig. 3 EN (RE) -11-...

  • Page 12: Notes On Transport

    2.7.1 Shipping the Li-ion battery pack The Li-ion battery is considered dangerous goods and may only be packed and shipped by trained persons. Please contact your ErgoPack service partner in this regard. 2.7.2 Transporting the Li-ion battery on the road Private users may transport the battery on the road without any restrictions.

  • Page 13: Meaning Of Warning Symbols, Presentation Conventions

    Warning of crushing hazards No open flame or high heat. Danger of explosion and fire.​ Do not operate for persons with pacemakers or implanted defibrillators. Compliant with the relevant European directives​ Symbol for lithium-ion batteries​ (contains recyclable material)​ EN (RE) -13-...

  • Page 14: Explanation Of The Safety Representation

    If not avoided, it can result in a minor or moderate injury. Attention! Marks a situation to be considered. If not considered, it can lead to material damage or poor operating results. Note! Marks useful, additional information. EN (RE) -14-...

  • Page 15: Recommendations For Protective Measures

    In order to protect the strapping system against unauthorized access, it is recommended to remove the key from the main switch and remove the Li-ion battery from the strapping system. The key should be kept safe from unauthorized access. EN (RE) -15-...

  • Page 16: Safety Regulations For Battery And Charger

    +60°C and must not fall below -20°C. • Damaged batteries may not be reused and must be disposed of properly. Note! • Keep the connection plug of the charger and the ErgoPack system away from non-related objects and dirt. EN (RE) -16-...

  • Page 17: General Safety Instructions For Li-Ion Batteries

    Do not use the charger if it is damaged. • Only connect the charger to suitable mains sockets. • Do not open the charger, reach inside the charger with tools or insert anything into the charger. EN (RE) -17-...

  • Page 18: Safety Instructions For Charging

    Do not clean the battery with a water jet, high-pressure cleaner or steam cleaner. • Keep the charger clean and dry. Disconnect all plugs before cleaning the charger. Clean the charger with a dry or at most damp cloth. EN (RE) -18-...

  • Page 19: Safety Instructions For The Storage Of The Li-Ion Battery

    However, there is still a risk that they will be discharged via the user, which poses a risk to implant wearers. EN (RE) -19-...

  • Page 20: Description

    Description 4.1 Design Fig. 5 Control panel Control display Easy-Move-Assistant Fig. 4 Fig. 7 Winding device Operating instructions Covering of battery box Fig. 6 EN (RE) -20-...

  • Page 21: Control Panel Strapping System

    EMERGENCY STOP switch (stops the strapping system) Fig. 8 4.3 Touch display strapping system Fig. 9 Touch display for setting all Function key F1 – F4: parameters at the strapping system, • F3 Menu such as pallet width. EN (RE) -21-...

  • Page 22: Li-Ion Battery

    4.4 Li-ion battery 4.4.1 General view Li-ion battery Fig. 10 1. "Charge and discharge socket" 2. "Sticker" 3. "Anti-twist device" 4. "Charge status LED display with on/off button" EN (RE) -22-...

  • Page 23: Led Display Li-Ion Battery

    ◯◯◯◯ 15…0% ⋆ ◯◯◯◯ Recharge after two days at the latest to avoid permanent damage Battery defective. Please contact your ⋆⋆⋆⋆⋆ ErgoPack service partner Explanation of symbols LED display Symbol Bedeutung LED on ● LED off ◯ LED flashes (50% on, 50% off) ⋆...

  • Page 24: Display And Commissioning Of The Li-Ion Battery Chargingstation/Charger

    4.5 Indication and commissioning of the Li-ion Battery charging Station/Charger 4.5.1 General view of the Li-ion battery charging station Fig. 12 1. Mains switch 2. LED-Green 3. LED-Red 4. Overview charge level indicator 5. Channel for anti-twist Li-ion battery EN (RE) -24-...

  • Page 25: General View Li-Ion Battery Charger

    4.5.2 General view of Li-ion battery charger Fig. 13 1. Mains switch 2. LED-Green 3. LED-Red 4. Overview charge level indicator EN (RE) -25-...

  • Page 26: Commissioning Li-Ion Battery Charging Station/Charger

    4.5.3 Commissioning the Li-ion Battery Charging Station/Charger The ErgoPack Li-ion charging station/charger is used to charge the ErgoPack Li-ion battery is charged. The green or red LED display on the Li-ion charger shows various operating states of the charger and the charge status of the Li-ion battery.

  • Page 27: Technical Data 287

    5.1 Strapping system Dimensions (all types) Length 665 mm Width 770 mm Height 1200 mm Weight (without optional equipment): ErgoPack RE (incl. Li-ion battery) approx. 90 kg Maximum chain speeds: Slow, strapping Moving out horizontally: 27 m/min Moving out vertically:...
  • Page 28 Measured A-graded noise emission level (EN ISO 11202) (EN 60745-1/2:2009) 79 dB (A) 77 dB (A) pAeq Sound power level, on average (EN 60745 -1/2:2009) 88 dB (A) Measurement inaccuracy K 3,0 dB (A) EN (RE) -28-...

  • Page 29: Li-Ion Battery

    Width 153 mm Height 82 mm Cell interconnection: 10S7P Voltage (nominal): 36,3 V Capacity (nominal): 24,15 Ah Energy: 877 Wh Discharge current (nominal): ≤ 35 A Charging current (max.): 14 A Charging end voltage: 42 V Operating temperature: 0…40°C EN (RE) -29-...

  • Page 30: Li-Ion Battery - Charging Station/Charger

    Width 156 mm Height 69 mm Operating voltage: 100…240V 50/60 Hz Rated power consumption: up to approx 650 W Charging current (nominal): up to approx 10 A Final charging voltage: ≤58,8 V Protecting class: IP20 Operating temperature: 0…40°C EN (RE) -30-...

  • Page 31: Intended Use

    45% and by a conductive or electrostatically dissipative floor (dissipation resistance less than 109 Ω). The strapping system is not suitable for operation by persons with implants such as pacemakers or defibrillators. EN (RE) -31-...

  • Page 32: Commissioning

    7.1 Li-ion battery-charging station/charger The main voltage must comply with the details on the type plate. The Li-ion battery charging station / charger is only suitable for charging the supplied original ErgoPack Li-ion battery, article number EP103110. 7.2 Charging the Li-ion battery 1.) Connect charger to the main voltage...
  • Page 33 Li-ion battery into the battery compartment as far as the into Fig. 17 the battery compartment as far as it will go. Attention! When inserting the Li-ion battery into the strapping system, the anti- twist device must point upwards! Fig. 18 EN (RE) -33-...
  • Page 34 Damaged Li-ion batteries can burn or explode.  Never use dropped or damaged Li-ion batteries.  Store dropped Li-ion batteries in a non-flammable container.  Send dropped Li-ion batteries to your ErgoPack service partner. For shipping, see chapter 2.7. Attention! The charging time is approx.

  • Page 35: Switching On The Strapping System

    Turn the main switch (20d) to the right to operating mode “1" and − hold it in this position for approximately 2 seconds. Fig. 19 Fig. 20 Follow the instructions on the display after the “ErgoPack” logo − disappeared (after approx. 45 seconds). EN (RE) -35-...

  • Page 36: Setting The Date And Time

    7.4 Setting the date and time Attention! The date and time may only be set by trained, instructed personnel. You can obtain the required access code from your ErgoPack service partner. Step 1 Check the time in the display in the main menu at the top left.
  • Page 37 Then confirm the time with the "Store" button. If the time does not need to be Fig. 24 set, the date/time setting can be saved by pressing the "Store" button. Press the "24h/12h" button to switch between 24-hour or 12-hour format. EN (RE) -37-...

  • Page 38: Setting Pallet Width

    10 cm steps (Fig. 27). As soon as you confirm your setting with „OK“, this new pallet width will be saved in the preset pallet widths. Fig. 27 Your ErgoPack is now ready for strapping. EN (RE) -38-...

  • Page 39: Operation

    Strapping and winding is possible with different, reusable straps/belts. Two variants are shown as examples in points 8.1 to 8.4. 8.1 Strapping with Velcro tape Step 1 Place the ErgoPack at a distance of approx. 40 cm (D) in front of the pallet to be strapped.
  • Page 40 Release the joystick, so that it returns to the neutral position (central position) and stops the ChainLance moving out further. Catch the ChainLance as shown at the red head piece. Do not let the ChainLance drop onto the package! EN (RE) -40-...
  • Page 41 (Fig. 33a). Fig. 32 Fig. 33 Fig. 33a Attention: The tongue must be outside the winding device. Step 4 Close the winding device again. Step 5 Fig. 34 Insert the tongue into the headpiece. Fig. 35 Fig. 35a EN (RE) -41-...
  • Page 42 "Retract" direction until the ChainLance stops again between the ErgoPack and the packaged goods at the height of the winding device and moves back Fig. 36 minimally to relieve the strain on the strapping.
  • Page 43 Fig. 39 Fig. 39a Fig. 39b Step 10 Move the ChainLance all the way back by pressing the joystick in the "Retract" direction until the ChainLance and the reversing sledge are back in the strapping system. Fig. 40 EN (RE) -43-...

  • Page 44: Wind Up Velcro Tape

    Insert the end of the tape into the winding device with the metal eyelet first and insert the piece of tape into the fork just after the eyelet. Attention: The fluffy side of the Velcro tape must face upwards. Fig. 43 EN (RE) -44-...
  • Page 45 Fig. 44a Step 5 Open the winding device (Fig. 41) and remove the wound-up Velcro tape from the winding device. Fig. 45 EN (RE) -45-...

  • Page 46: Strapping With Tension Belt

    Fig. 46 Step 3 Close the winding device again. Step 4 Fig. 47 Insert the start of the strap into the head piece until it is visible in the slot. Fig. 48 Fig. 48a EN (RE) -46-...
  • Page 47 Move the ChainLance all the way back by pressing the joystick in the "Retract" direction until the ChainLance stops again between the ErgoPack and the packaged goods at the height of the winding device and moves back minimally to relieve the strain on the strapping.
  • Page 48 (Fig. 51a). Fig. 51 Fig. 51a Step 9 Move the ChainLance all the way back by pressing the joystick in the "Retract" direction until the ChainLance and the reversing sledge are back in the strapping system. Fig. 52 EN (RE) -48-...

  • Page 49: Wind Up Tension Belt

    (Fig. 59 and Fig. 59a as examples). Step 3 Press the actuator down and place the clamp lock in the holder. Release the actuator so that the clamp lock clamps into Fig. 54 the holder. Fig. 59 Fig. 59a EN (RE) -49-...
  • Page 50 Fig. 56 properly. Fig. 57a Fig. 57 Step 5 Open the winding device (Fig. 53) and remove the wound tension belt from the winding device. Fig. 58 EN (RE) -50-...

  • Page 51: Risks

    Damaged batteries can burn or explode. Never use dropped or damaged batteries. Electric shock Strapping creates electrostatic charges. These can discharge via the user. The strapping system is therefore not suitable for operation by persons with implants such as pacemakers or defibrillators. EN (RE) -51-...
  • Page 52 Do not put 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. EN (RE) -52-...
  • Page 53 Strapping pallets should, whenever possible, take place in areas with an even surface. When using the strapping system on inclined surfaces, after positioning and before strapping, the brakes of the castor wheels on the strap side have to be locked. EN (RE) -53-...

  • Page 54: Emergency Information

    Before using the strapping system for the first time, a visual inspection for external damage has to be done. Use only original ErgoPack spare parts! Warranty and liability become invalid if other then ErgoPack spare parts are used. 9.1 Emergency information 9.1.1 First aid measures...

  • Page 55: Firefighting Measures

    Evacuate all persons from the immediate fire area. Use plenty of water or fire extinguishers of fire class D to fight the fire. Alert the fire brigade if the fire cannot be fought by yourself or gets out of control. EN (RE) -55-...

  • Page 56: Service And Repair

    Your ErgoPack is made out of galvanized steel, powder coated steel, stainless steel and highly wear resistant plastic and is basically maintenance free. Clean the outside of the ErgoPack with a damp cloth if it is extremely dirty. Warning! During all maintenance and service/repair works, the strapping system has to be switched off by pressing the „OFF“...

  • Page 57: Replacing The Chainlance

    OFF button and remove the Li-ion battery from Fig. 60 the strapping system. For this purpose, the cover of the Li-ion battery compartment has to be opened (by pulling at the wheel covers). (Fig. 60) EN (RE) -57-...
  • Page 58 Now, pull out the reversing sledge by about 1 m and fold up the joint. (Fig. 63) Fig. 62 Step 2 Pull the ChainLance out of the strapping system as shown and roll it up. Fig. 63 EN (RE) -58-...
  • Page 59 ChainLance into the system, the end pieces preloaded by a spring Fig. 65 (Fig.65), has to be aligned straight (Fig. 66). Press the chain links down with your finger and push them into the strapping system … Fig. 66 EN (RE) -59-...
  • Page 60 Groove of the ChainLance Fig. 68 Also for that, the preloaded chain links have to be pressed down with your finger (Fig. 69). Fig. 69 Step 4 Put the strapping system into operation in accordance with section 7. EN (RE) -60-...

  • Page 61: Replace Stiffened Chain Section (2M) Incl. Head Piece

    ChainLance ... Fig. 70 … and place the first 2 metres of chain on the strapping system. Then switch off the strapping system with the OFF button and remove the Li-ion battery from the strapping system. Fig. 71 EN (RE) -61-...
  • Page 62 … and slew the chain to the side by turning the screwdriver carefully … Fig. 73 … until the two chain links fully separate. Step 3 The chain, which is reinforced with glass fibre rods, is installed in reverse order of removal. Fig. 74 EN (RE) -62-...

  • Page 63: Replacing The Reversing Sledge

    Step 4 Fig. 76 The fitting of the reversing sledge is done in the reversed order of the dismantling. Achtung! Die beiden Schrauben des Längenbegrenzungsbandes müssen mit „Schraubensicherung mittelfest“ gesichert werden! EN (RE) -63-...

  • Page 64: Replacing Individual Chain Links

    This can cause a malfunction. Therefore, missing chain links should be replaced as soon as possible. Note! No individual chain link can be replaced in the first 2 metres. The entire chain section (2m) must be replaced in accordance with point 10.3. EN (RE) -64-...

  • Page 65: Replacing The Length Adjusting Belt

    „rocker“ of the locking unit which is connected with the magnet lock through the folding spring bolt. At the same time the other person pulls the length adjusting belt out of the strapping system. Fig. 78 EN (RE) -65-...
  • Page 66 Make sure that the length adjusting belt is inserted into the lower groove and that it does not slide into the upper groove of the ChainLance. Step 6 The further installation is done in the reversed order of the dismantling. EN (RE) -66-...

  • Page 67: Replace The Fork Of The Winding Device

    Open the cover of the winding device. Fig. 80 Step 2 Move the fork upwards and loosen the 3 screws Fig. 81 Step 3 Remove the tape holder. Fig. 82 Step 4 The tape holder is installed in reverse order of removal. EN (RE) -67-...

  • Page 68: Replace The Clamping Lock Of The Winding Device

    Open the cover of the winding device. Fig. 83 Step 2 Loosen the 3 screws. Fig. 84 Step 3 Remove the clamp lock holder. Fig. 85 Step 4 The clamp lock holder is installed in reverse order of removal. EN (RE) -68-...

  • Page 69: Changing The Control Box Joystick Unit

    Observe the assembly and disassembly sequence in order to be able to safely discharge electrostatic charges. Step 1 Remove the cover „joystick“ by pulling on the handle holes, provided at the bottom side (the cover is fixed by magnets). Fig. 86 Fig. 87 EN (RE) -69-...
  • Page 70 Remove the plugs afterwards only. Step 3 Unclip the power cable from its holder on the underside of the control unit. Fig. 89 Step 4 Remove the 4 screws on the side of the control unit. Fig. 90 EN (RE) -70-...
  • Page 71 For disconnecting the plug of the black/red cable, you have to pull the flap of the plug. Step 6 Remove the nut on the ground bolt/threaded stud and then pull off the ground cable and ground strap. Fig. 92 EN (RE) -71-...
  • Page 72 When having the correct position, connect the plug and secure it by the screw socket. This screw socket has to be closed by turning it clockwise. Only then, the function of the plug-in connection is ensured. EN (RE) -72-...

  • Page 73: Changing The Control Box Display Unit

    Fold the Easy-Move-Assistant upwards and open the cover of the winding device. Fig. 94 Step 3 Remove the cover „display“ by pulling on the provided handle holes diagonally downwards. (The cover is fixed by magnets). Fig. 95 EN (RE) -73-...
  • Page 74 Fig. 97 … remove the control box and thereby pull the cable carefully through the cable duct. Fig. 98 Step 5 The installation of the control unit is done in the reversed order of the disassembling. EN (RE) -74-...

  • Page 75: Changing The Motor

    Observe the assembly and disassembly sequence in order to be able to safely discharge electrostatic charges. Step 1 Remove the cover „joystick“ by pulling on the handle holes, provided at the bottom side (the cover is fixed by magnets). Fig. 99 Fig. 100 EN (RE) -75-...
  • Page 76 Remove the plugs only afterwards. Fig. 102 Step 3 First remove the 3 screws (103a) on the motor support plate , then remove the screw with the earth strap (103b) and ... Fig. 103 103a 103b EN (RE) -76-...
  • Page 77 This screw socket has to be closed by turning it clockwise. Only then, the function of the plug-in connection is ensured. The feather key at the motor output has to be positioned exactly to the groove in the shaft. EN (RE) -77-...

  • Page 78: Li-Ion Battery Error Messages And Cleaning

    Keep the battery and contacts clean and dry. Clean dirty contacts with a dry cloth. Note! Send the defective Li-ion battery to the ErgoPack service partner. When shipping lithium-ion batteries, observe the interpretation and enforcement of the relevant regulations of the federal state authorities, see chapter 2.7.

  • Page 79: Li-Ion Charging Station/Charger Error Messages And Cleaning

    Cleaning: Disconnect the charger from the mains and then clean it with a dry or at most damp cloth. Keep the charger clean and dry. Send the defective Li-ion charger to your ErgoPack service partner. EN (RE) -79-...

  • Page 80: Software Updates

    Updates on the control units „Joystick“ and „Display“ only through trained and properly instructed staff. The necessary access code will be provided by your ErgoPack service partner. Step 1 Remove the cover „joystick“ as described in section 10.9 step 1 and take off the cover „display“...
  • Page 81 Firmware display: After unlocking, insert the USB stick with the current firmware into the USB port of the control unit „display“ and start the update by confirming with „OK“. Proceed further as described on page 82. Fig. 109 EN (RE) -81-...
  • Page 82 3/3 Accept, starts automatically and the installation begins. Start Upload As soon as the message „EMERGENCY STOP pressed“ appears, remove the USB-stick. After Fig. 115 unlocking the „EMERGENCY STOP“, press „RESET”. Now you are in the main menu. EN (RE) -82-...

  • Page 83: Personal Protective Equipment

    This instructions have to be recorded in writing. Protect yourself! Wear eye and hand protection (cut proof gloves) and also safety shoes. EN (RE) -83-...

  • Page 84: General Safety Warnings For Power Tools

    Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. EN (RE) -84-...
  • Page 85 Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury. EN (RE) -85-...
  • Page 86 Many accidents are caused by poorly maintained power tools. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. EN (RE) -86-...
  • Page 87 Liquid ejected from the battery may cause irritation or burns. Service a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained. EN (RE) -87-...

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