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ErgoPack 745X-Li Operating Instructions Manual

Strapping systems
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  • Page 2 Hanns-Martin-Schleyer Str. 21 89415 Lauingen, Germany hereby declare, that the Ergonomic Pallet Strapping Systems type "ErgoPack 700X- Li, 713X-Li, 726X-Li, 745X-Li“, 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 3 89415 Lauingen hereby declare, that the Ergonomic Pallet Strapping Systems type "ErgoPack 700X-Li, 713X-Li, 726X-Li, 745X-Li“, 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 strapping systems we have brought on to the market.

  • Page 4: Table Of Contents

    Table of contents 1.​ Validity of the operating instructions​ 7​ General Moving the strapping system 8​ Parking the strapping system 8​ Work area space requirement 9​ Environmental conditions 9​ Energy supply Li-ion charger/battery 10​ Notes on environmental protection 11​ 2.6.1​ Disposing of the Li-ion battery 11​...
  • Page 5 57-61​ 8.2 Tensioning and sealing of pallets above 70 cm height 62-65​ 8.3 Sealing control Tensioning and sealing pallets below 70 cm height with 67-69​ ErgoPack standard Tool-Lift Risks 70-73 9.1 Emergency information 9.1.1​ First aid measures​ 9.1.2​ Firefighting measures...
  • Page 6 10.​ Service and repair 75​ 10.1 Cleaning the ChainLance 75​ 10.2 Replacing the ChainLance 76-80​ 10.3 Replacing the reversing sledge 81-83​ 10.4 Replacing individual chain links 84​ 10.5 Replacing the length adjusting belt 85-86​ 10.6 Changing the sealing head 87-89​ 10.7 Changing the control box joystick unit 90-94​...

  • Page 7: Validity Of The Operating Instructions

    The operation in these instructions is explained by using the ErgoPack 726X-Li as an example. All points in these instructions referring to the operation of the sealing head are not applicable as far as the “ErgoPack 700X-Li” is concerned. These operating instructions are valid for the following models:...

  • Page 8: General

    General 2.1 Moving the strapping system The strapping system can be pushed in an upright position with the two hand grips (Fig.1). For pushing it you must release the brakes of the two guide rolls on the strap side (Fig.1a). 2.2 Parking the strapping system 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...

  • Page 9: Work Area Space Requirement

    2.3 Work area space requirement For a safe operation while strapping, the system has to be positioned correctly in front of the pallet. Therefore, a free area of ​ ​ a t least 1,10 m width in front of the pallet to be strapped is required. 1,10 m 0,30 m Fig.

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

    2.5 Energy supply Li-ion charger/battery Li-ion charger wide range charger Opertating voltage: 100-240 V 50/60 Hz Rated power consumption: up to approx. 650W Charging current (nominal): up to 10A Li-ion battery Weight: approx. 5,0 kg Charging time: approx. 3,5 hours Voltage (nominal): 36,3 V Capacity (nominal):...

  • Page 11: Notes On Environmental Protection

    2.6 Notes on environmental protection Physical or chemical materials injurious to health have not been used for manufacturing the strapping system. Concerning the waste disposal, valid national rules and regulations have to be considered. Take care about disposing packaging, the product itself and parts accordingly.

  • 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

    2.8 Meaning of warning symbols, presentation conventions 2.8.1 Explanation of symbols General warning sign Warning of explosion and fire caused by short circuit, overheating or other electrical/mechanical misuse​ Warning against laser radiation 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.

  • Page 14: Explanation Of The Safety Representation

    Do not dispose of in household waste Follow instructions 2.8.2 Explanation of the saftey representation Warning! Marks a hazard with moderate risk. If not avoided, it can result in death or serious injury Caution! Marks a hazard with a minor risk. If not avoided, it can result in a minor or moderate injury Attention! Marks a situation to be considered.

  • Page 15: Recommendations For Protective Measures

    Recommendations for protective measures These operating instructions will help you to understand the strapping system and how to use it according to regulations. The operating instructions contain important notes on how to use the strapping system safely, properly and economically. Adhering to the notes helps you to avoid dangers, repairs and down times and also increases the reliability and life span of the strapping system.

  • 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. -16- UK (Li)

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

    Do not use a defective or damaged battery. • Only use batteries that are approved for your systems (original • ErgoPack battery). Persons with reduced physical, sensory or mental capabilities or lack • of experience and knowledge must not use the battery and charger unless they are supervised or instructed to do so by a person responsible for their safety.

  • Page 18: Safety Instructions For Charging

    3.1.3 Safety instructions for charging • Read the instructions for the charger before charging. • Operate the charger only in enclosed spaces that are ventilated, dry and dust-free. Do not cover the unit. • Make sure that the charging current and voltage are suitable for your battery.

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

    3.1.5 Safety instructions for storing the Li-ion battery pack • Remove the battery from the strapping system or disconnect it from the charger when not in use. • Store the battery in a dry, well-ventilated place away from flames and food. •...

  • Page 20: Description

    Description 4.1 Design Fig. 5 Control panel Safety cutter Strap brake Control display Fig. 4 Fig. 7 Sealing head Sliding window with safety switch Operating instructions Tool-Lift Fig. 6 Covering of battery box -20- UK (Li)

  • Page 21: Control Panel Strapping System

    4.2 Control panel strapping system Main switch (power supply 0/1) OFF switch (disconnects the power supply) Joystick (moving the ChainLance in and out with precision speed control) Reset switch (function check while switching on and acknowledging of malfunctions) EMERGENCY STOP switch (stops the strapping system) Fig.

  • Page 22: Control Panel Sealing Head

    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 the error cannot be rectified -> ErgoPack service partner -22- UK (Li)

  • Page 23: Li-Ion Battery

    4.5 Li-ion battery 4.5.1 General view Li-ion battery Fig. 11 1. "Charge and discharge socket" 2. "Sticker" 3. "Anti-twist device" 4. "Charge status LED display with on/off button" -23- UK (Li)

  • Page 24: 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 Meaning LED on ● LED off ◯ LED flashes (50% on, 50% off) ⋆...

  • Page 25: Display And Commissioning Of The Li-Ion Battery Chargingstation/Charger

    4.6 Indication and commissioning of the Li-ion Battery charging Station/Charger 4.6.1 General view of the Li-ion battery charging station Fig. 13 1. Mains switch 2. LED-Green 3. LED-Red 4. Overview charge level indicator 5. Channel for anti-twist Li-ion battery -25- UK (Li)

  • Page 26: General View Li-Ion Battery Charging Station

    4.6.2 General view of Li-ion battery charger Fig. 14 1. Mains switch 2. LED-Green 3. LED-Red 4. Overview charge level indicator -26- UK (Li)

  • Page 27: Commissioning Li-Ion Battery Charging Station/Charger

    4.6.3 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 28: Technical Data

    Dimensions (all types) Length 665 mm Width 770 mm Height 1200 mm Weight (without optional equipment): ErgoPack 700X-Li (incl. Li-ion battery) 95 kg ErgoPack 713X-Li (incl. Li-ion battery) 103 kg ErgoPack 726X-Li/745X-Li (incl. Li-ion battery) 104 kg Maximum chain speeds:...

  • Page 29: Sealing Head

    Plastic strap Strap materials Polypropylene (PP) Polyester (PET) Strap width 713X, adjustable to 9-10 mm / 12-13 mm 726X, adjustable to 12-13 mm / 15-16 mm 745X, adjustable to 15-16 mm / 18-19 mm Strap thickness 713X 0,40-0,80 mm (PET) 0,50-0,80 mm (PP) 726X 0,50-1,00 mm (PET/PP)
  • Page 30 Measured A-graded noise emission level (EN ISO 11202) (EN 60745-1/2:2009) 713X 79 dB (A) 77 dB (A) pAeq 726X 78 dB (A) 82 dB (A) pAeq 745X 79 dB (A) 81 dB (A) pAeq Sound power level, on average (EN 60745 -1/2:2009) 713X 88 dB (A) 726X...

  • Page 31: Li-Ion Battery

    5.3 Li-ion battery Typ: Li-ion batteries Weight: approx. 5,0 kg Dimensions: Length 393 mm 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:...

  • Page 32: Li-Ion Battery - Charging Station/Charger

    5.4 Li-ion battery – charging station/charger Typ: Wide range charger Weight: Charger 1,7 kg (incl. charging station) (8,8 kg) Dimensions: Length 225 mm 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.

  • Page 33: Intended Use

    Intended use The strapping system is designed for strapping pallets (machine assisted hand strapping). It has been designed and built for safe and ergonomic operation during strapping. The strapping system is only suitable for strapping with plastic straps (polypropylene PP and polyester PET). Strapping with steel strapping is not possible with this strapping system.

  • Page 34: 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 704345. 7.2 Charging the Li-ion battery 1.) Connect charger to the main voltage...
  • Page 35 3.) Remove the Li-ion battery from the strapping system by pulling it out. 4a.) When using the Li-ion Charging station, the Li-ion Battery into the Li-ion charging Station to load up to the stop gently into Fig. 16 place. Then close Power switch on the Li-ion Set the charger to "I".
  • Page 36 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 37: Setting Strap Width At The Sealing Head

    7.3 Setting strap width at the sealing head The sealing head can be used with different strap widths: ErgoPack 713X 9-10 mm or 12-13 mm ErgoPack 726X 12-13 mm or 15-16 mm ErgoPack 745X 15-16 mm or 18-19 mm The setting of the strap width is explained using the example of model 726X.

  • Page 38: Switching On The Strapping System

    Turn the main switch (23d) to the right to operating mode “1" and − hold it in this position for approximately 2 seconds. Fig. 23 Fig. 22 Follow the instructions on the display after the “ErgoPack” logo − disappeared (after approx. 45 seconds). -38- UK (Li)

  • Page 39: Setting The Date And Time

    7.5 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. 1. Step: Check the time in the display in the main menu at the top left.
  • Page 40 5. Step: Check the date. Year, month and day can each be set with the "+/-" button. Then confirm the set date with the "Store" button. If the date does not need to be set, you can switch to setting the Fig.

  • Page 41: Setting Strap Tension Range At The Sealing Head

    7.6 Setting strap tension range at the sealing head Two strap tension ranges can be set at the sealing head: NORMAL = Standard tension range for PET strap 713X = 400-1200 N 726X = 900-2500 N 745X = 1300-4500 N SOFT = Soft tension range for PP strap 713X = 150-750 N...

  • Page 42: Setting Strap Tension At The Sealing Head

    7.7 Setting strap tension at the sealing head 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. •...
  • Page 43 713X Standard 1000 1100 1200 lbf* Soft 726X Standard 1100 1300 1500 1700 1900 2100 2300 2500 lbf* Soft 1000 1120 1240 1360 745X Standard 1300 1700 2100 2500 2900 3300 3700 4100 4500 lbf* 1000 Soft 1000 1150 1300 1450 1600 (rounded values)

  • Page 44: Setting Mode Of Operation At The Sealing Head

    7.8 Setting mode of operation at the sealing head Press „Operating mode“ (1) button. • Unused displays disappear. • The currently set operating mode flashes for 5 seconds. • + and – appear. Press button + (2) or – (3) until the required operating mode is displayed. Fig.

  • Page 45: Select Favourite

    Fig. 30 b (3) changes from outlined to bold. All parameters change to the pre- set values of this settings level. * The operating mode favourite is factory blocked! Activation only through your ErgoPack service partner possible. -45- UK (Li)

  • Page 46: Setting Welding Time

    7.10 Setting welding time The set welding time is displayed always by filled dots, when the 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. •...

  • Page 47: Changing Strap Coil

    7.11 Changing strap coil Switch on the strapping system as described in section 7.4 For changing the strap coil press „F2“ button (32a) and follow the instructions appearing on the display. Fig. 32 By pressing „next“ button, 1. Step appears on the display. 1.
  • Page 48 2. Step Open the sliding window (33a). After opening the sliding window, 3. Step appears automatically. Fig. 33 3. Step Fold down the pivot arm with the red circular disk until its final stop. Fig. 34 Place a new strap coil onto the red circular disk, that the strap uncoils in the counter-clockwise direction when looking down on the roll.
  • Page 49 Fold up the arm with the strap coil again in its vertical position as shown on the picture. Fig. 36 Now, remove the tapes or adhesive tapes fixing the strap on the coil. Fig. 37 Attention! Remove adhesive tapes from the strap coil completely. Adhesive residues remaining on the strap coil may stick inside the strapping system and lead to malfunctions.
  • Page 50 Fold up the cover of the white roll for strap infeed, thread the strap through the U-bolt… Fig. 38 …and over the white roll to the Fig. 39 inside. Thereafter fold the cover back down again. Fig. 40 After pressing „Next“ on the touch display you will finish the 3.
  • Page 51 4. Step Press from the left hand side on the metal clamp Fig. 42 lock located in the red chain link… …then slide the strap from the right to the Fig. 43 left through the slot in the clamp lock. Fig.
  • Page 52 5. Step Press the „Positioning ChainLance“ button until the ChainLance stops Fig. 46 automatically and the 6. Step appears. Fig. 47 Warning, risk of injury! Never put your fingers between the chain links. -52- UK (Li)
  • Page 53 6. Step Remove the strap from the clamp lock of the red chain link and hold it straight up as shown (Fig. 50). Thereafter, press the „Retract chain“ button until the ChainLance stops and the 7. Step appears. Fig. 48 Fig.
  • Page 54 7. Step Open the eccentric latch in the red head piece of the ChainLance by pushing it inwards with your finger. (Fig. Fig. 51 Push the strap from the back through the head piece of the ChainLance (as shown). The strap must pass between the two aluminium eccentrics.
  • Page 55 Move the reversing sledge completely backwards by pressing the „Retract ChainLance“ button. Afterwards you will get back to the main menu. Attention! Make sure that the strap remains continuously tensioned while moving back the ChainLance, to avoid the strap being pushed into the strapping system.

  • Page 56: Setting Pallet Width

    10 cm steps (Fig. 57). As soon as you confirm your setting with „OK“, this new pallet width will be saved in the preset pallet widths. Fig. 57 Your ErgoPack is now ready for strapping. -56- UK (Li)

  • Page 57: Operation

    Operation 8.1 Strapping 1. Step Place the ErgoPack at a distance of approx. 30 cm (D) in front of the pallet to be strapped. If your system is equipped with the optional line laser: Align the ErgoPack parallel to the pallet so...
  • Page 58 ... and back up again on the opposite side. Fig. 60 If the setting of the pallet width and the positioning of the strapping system are correct, the distance between the chain and the pallet is about 10 Fig. 61 Attention! Push the joystick until the ChainLance appears on the other side and falls in your direction.
  • Page 59 3. Step Hold the strap with your left hand as shown, directly at the head piece of the ChainLance… Fig. 62 ... move the ChainLance completely back by pushing the joystick in „move in“ direction. Fig. 63 Attention! Always keep the strap slightly under tension when moving the ChainLance backwards, to avoid that loops can be formed at the reversing sledge.
  • Page 60 4. Step The strap lifter comes up automatically when the reversing sledge moves back into the strapping system. Now you have to loose the strap tension of your left hand; otherwise the strap lifter will not be able to come up. Fig.
  • Page 61 If for sealing the strap you have to pull some  additional strap out of the strapping system, do not take the strap directly at the strap lifter… Fig. 65 ...but about 10cm below the strap lifter. Hold the strap with the whole hand and pull it out of the strapping system.

  • Page 62: Tensioning And Sealing Of Pallets Above 70 Cm Height

    8.2 Tensioning and sealing of pallets above 70 cm height 1. Step Strap the pallet as described in section 8.1 2. Step Overlap the straps so that the end of the strap lies underneath. Fig. 68 3. Step Hold then both straps as shown with the right hand.
  • Page 63 4. Step Push the sealing head towards the pallet with the left hand tilt it 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. Fig.
  • Page 64 * This operating mode AUTO = Fully automatic strapping is factory blocked! Activation only through your ErgoPack service partner possible. Warning! Strap tensioning or strapping, danger of jamming and crushing Do not place hands or other body parts between the strap and the packaged goods during the strapping process.
  • Page 65 The tensioning process is finished, once the indicator bar is filled in fully. Fig. 75 The welding process is finished, once the indicator bar (1) is filled fully. The cool down starts (2). After cool down there is a beep and the display lights up green.

  • Page 66: Sealing Control

    8.3 Sealing control Control the sealing regularly. The welding time must be checked in accordance with point 7.10 and changed if necessary when the straps are welded badly. Fig. 79 1 Good welding: The whole sealed surface has been properly welded without any extra material being squeezed out to the side.

  • Page 67: Tensioning And Sealing Pallets Below 70 Cm Height With Ergopack Standard Tool-Lift

    8.4 Tensioning and sealing pallets below 70 cm height with ErgoPack standard Tool-Lift 1.Step Pull out the black knob of the locking bolt. Afterwards, pull the sealing head forward out of the holder and place it on the package to be strapped.
  • Page 68 Now, with your right hand, feed the strap through the guiding of the sealing head, by pulling it towards yourself. Fig. 83 4. Step The tensioning and the sealing of the strap is Fig. 84 different according to the set mode (manual / semi- automatic or automatic mode, see point 7.8).
  • Page 69 5. Step As soon as the signal has sounded and the display lights up green, pull the rocker lever towards the handle and move the sealing head out to the left. Fig. 86 If your strapping system is equipped with the optional Triplex Tool-Lift: Pull out the sealing head horizontally, slew the sealing...

  • Page 70: Risks

    Risks Attention: Laser beam! Direct eye contact with the laser beam or reflecting radiation may result in permanent eye injuries. Never look direct in the laser. Laser category 2 Power: 10 mW DIN EN 60825-1:2015-07 Wavelength:635 nm Warning: Strap tensioning or strapping, danger of jamming and crushing.
  • Page 71 Warning! Following hazards can result in serious injuries: Chain lance, risk of injury When the ChainLance moves upwards on the opposite side of the pallet, its own weight causes it to fall over the pallet towards the operator. If you are not careful, the ChainLance can fall on the operator's head and cause injuries.
  • Page 72 Warning! Following hazards can result in serious injuries: 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 can enter that area. This is due, especially for the limited or bad visible area on the opposite site of the pallet (operators view).

  • Page 73: 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 74: Firefighting Measures

    9.1.2 Fire fighting measures Warning! Inhalation of vapours may cause poisoning.  Place on the side of the fire from which the wind comes  Use respiratory protection if possible. If possible, carefully remove the Li-ion battery from the strapping system.

  • Page 75: 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 76: Replacing The Chainlance

    10.2 Replacing the ChainLance 1. Step Cut off the strap in front of the white roll and fix it with an adhesive tape to the coil. Pull out the rest of the strap remained in the strapping system through the head piece of the ChainLance and dispose it.
  • Page 77 Afterwards, switch off the strapping system by pressing the OFF button and remove the Li- ion battery from 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.
  • Page 78 Now, pull out the reversing sledge by about 1 m and fold up the joint. (Fig. 94) Fig. 93 3. Step Pull the ChainLance out of the strapping system as shown and roll it up. Fig. 94 -78- UK (Li)
  • Page 79 4. Step Push the new ChainLance in again in reversed order of the removal. Fig. 95 By pushing the end piece of the ChainLance into the system, the end pieces preloaded by a spring (Fig.96), has to be aligned straight (Fig.
  • Page 80 … so that the end of the ChainLance can be inserted into the groove of the ChainLance (Fig. 98) in the central part of the strapping Fig. 98 system (Fig. 100). Fig. 99 Also for that, the preloaded Groove of the ChainLance chain links have to be pressed down with your finger (Fig.

  • Page 81: Replacing The Reversing Sledge

    10.3 Replacing the reversing sledge 1. Step Cut off the strap in front of the white roll and fix it with an adhesive strip to the coil. Pull out the rest of the strap remained in the strapping system through the head piece of the ChainLance and dispose it.
  • Page 82 3. Step Push a screwdriver (blade width 5,5 mm) between the wings of two chain links … Fig. 104 … and slew the chain to the side by turning the screwdriver carefully … Fig. 105 … until the two chain links fully separate.
  • Page 83 4. Step Push the ChainLance manually back into the strapping system until the ChainLance has completely moved out of the reversing sledge. Fig. 107 5. Step Place the reversing sledge on its top as illustrated and use a screwdriver to unscrew both screws of the length adjusting belt.

  • Page 84: Replacing Individual Chain Links

    10.4 Replacing individual chain links In case of broken individual chain links, the ChainLance can be opened as described under point 10.2 to replace those defective chain links. It is temporarily also possible to remove a defective chain link without the need to insert a new chain link.

  • Page 85: Replacing The Length Adjusting Belt

    10.5 Replacing the length adjusting belt 1. Step (dismantling) Perform steps 1 to 5 listed in point 10.3 and continue with step 2. 2. Step Open the cover „Li-ion battery compartment“ as described under point 7.2 „charging the Li-ion battery“. Now, unlock the ball lock pin by pressing the release button and pull it out of the storage...
  • Page 86 4. Step (installation) Push the ChainLance all the way back into the strapping system so that you can see the groove of the length adjusting belt. 5. Step Push the new length adjusting belt into the small groove below the groove for the ChainLance.

  • Page 87: Changing The Sealing Head

    10.6 Changing the sealing head Warning! Improper handling of the electronic components can lead to defect or malfunction of the strapping system. To prevent voltage flashover to electronic components during maintenance work, the person carrying out the maintenance must discharge himself (e.g. by touching a water pipe). Observe the assembly and disassembly sequence in order to be able to safely discharge electrostatic charges.
  • Page 88 3. Step Unlock the red locking ring on the plug of the cable of the sealing head by turning it counter clockwise. Now, remove the plug. Fig. 115 4. Step Remove the 4 screws of the red metal cover at the holder of the spiral cable.
  • Page 89 6. Step Pull out the locking bolt for unlocking the sealing head and remove the sealing head. Fig. 118 If your strapping system is equipped with the optional Triplex Tool-Lift: Remove both screws M5 (4mm Allen wrench). These screws are secured with special wedge-lock washers (the wedge- lock washers can be reused).

  • Page 90: Changing The Control Box Joystick Unit

    10.7 Changing the control box joystick unit Warning! Improper handling of the electronic components can lead to defect or malfunction of the strapping system. To prevent voltage flashover to electronic components during maintenance work, the person carrying out the maintenance must discharge himself (e.g.
  • Page 91 3. Step Remove the cover „joystick“ by pulling on the handle holes, provided at the bottom side (the cover is fixed by magnets). Fig. 123 4. Step Fold the pivot arm upwards again. Fig. 124 -91- UK (Li)
  • Page 92 5. Step First disconnect the plugs of the power cable, then the two motor cables on the opposite side and then all other plugs. Attention! Fig. 125 The plugs are secured with a screw socket which has to be unlocked by turning it counter clockwise.
  • Page 93 8. Step Now carefully loosen the plug connections on the back of the control unit. Attention! Disconnect the earth cable (green-yellow) last. Attention! Fig. 128 For disconnecting the plug of the black/red cable, you have to pull the flap of the plug. 9.
  • Page 94 10. Step The installation of the control unit is done in the reversed order of the disassembling. While connecting the cables always take note of the information on the label (130a) located on the front side of the control unit. 130a Fig.

  • Page 95: Changing The Control Box Display Unit

    10.8 Changing the control box display unit Warning! Improper handling of the electronic components can lead to defect or malfunction of the strapping system. To prevent voltage flashover to electronic components during maintenance work, the person carrying out the maintenance must discharge himself (e.g.
  • Page 96 4. Step Unlock the red locking ring on the plug of the cable of the sealing head by turning it counter clockwise. Now, remove the plug. Fig. 133 5. Step Remove the 4 screws on the side of the control unit and… Fig.

  • Page 97: Changing The Motor

    10.9 Changing the motor Warning! Improper handling of the electronic components can lead to defect or malfunction of the strapping system. To prevent voltage flashover to electronic components during maintenance work, the person carrying out the maintenance must discharge himself (e.g. by touching a water pipe). Observe the assembly and disassembly sequence in order to be able to safely discharge electrostatic charges.
  • Page 98 2. Step Fold down the pivot arm. Fig. 137 3. Step Remove the cover „joystick“ by pulling on the handle holes, provided at the bottom side (the cover is fixed by magnets). Fig. 138 4. Step Fold the pivot arm upwards again.
  • Page 99 5. Step Unscrew the two plugs guided to the motor from the right side of the control box „joystick“ unit. Fig. 140 Attention! The plugs are secured with a screw socket which has to be unlocked by turning it counter clockwise.
  • Page 100 … remove now the motor carefully. Take care not to lose the feather key (143a). Fig. 143 143a 7. Step The installation of the motor is done in the reversed order of the disassembling. Attention! The plug-in connection is positioned relative to one another through a plastic nose and groove.

  • Page 101: Cleaning/Replacing The Tension Wheel At The Sealing Head

    10.10 Cleaning/replacing the tension wheel at the sealing head Cleaning the tension wheel without disassembling There is an access hole (144a) in the − protection cover below the motor. The tension wheel and the tooth plate can be cleaned with compressed air through this access hole.

  • Page 102: Cleaning/Replacing The Tooth Plate At The Sealing Head

    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.

  • Page 103: Replacing The Cutter At The Sealing Head

    10.12 Replacing the cutter at the sealing head Release 4 cylinder screws Torx (3), − remove strap guide rear (4) and side cover (2). − Release cylinder screw Torx (5), take care that you do not loose the compression spring (7), remove knife (1) with flanged bushing (6) Fig.

  • Page 104: 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 105: 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. -105- UK (Li)

  • Page 106: 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. 1. Step Remove the cover „joystick“ as described in section 10.7 step 1 to 4 and take off the cover „display“...
  • Page 107 3. Step Press the „F3“ button (1) on the display and click „next“ (2) until page 6 (3) of the menu appears. Unlock the lock (4) with the corresponding access code. Fig. 150 4. Step Firmware chain axis: After unlocking, insert the USB stick with the current firmware into the USB port of the control unit „joystick“...
  • Page 108 6. Step Procedure of the update “display”: HMI Touchpanel After confirmation, the start center appears. Start Center Select now „settings“. Settings Click on the file „Service & Commissioning“. Service & Commissioning Select „Restore“ Restore Search your USB-stick by clicking on „Search“. 1/3 USB (2.0) After your USB-stick was found, scroll down and Search...

  • Page 109: Service Partner

    Service Partner For help and questions regarding maintenance, service and spare parts, you can contact our service partner at the following address: Wessex Packaging 26 Mead Avenue Houndstone Business Park BA22 8RT Yeovil, Somerset Great Britain -109- UK (Li)

  • Page 110: Personal Protective Equipment

    Personal protective equipment Inform yourself! Before usage of the strapping system, the operating instructions have to be read carefully and understood. Service and maintenance on the strapping system have only to be done by trained staff. Wear a safety helmet! When strapping pallets higher than 1,20 m, a safety helmet has to be worn.

  • Page 111: General Safety Warnings For Power Tools

    General safety warnings for power tools Warning ! Read all safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. The term „power tool“ in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
  • Page 112 Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep the cord away from heat, oil, sharp edges or moving parts.
  • Page 113 e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
  • Page 114 g) Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.

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