PRODUCTS Operating Manual
4.1 Loading the film 4.2 Setting the machine parameters 4.3 Adjusting the operator settings 4.3.1 Adjusting heat seal and blower settings 4.3.2 Adjusting number of cushions 4.4 Restarting after changing the roll
1. Introduction This instruction manual has been produced by Green Light Products Ltd to ensure the safe and efficient use of the Opus Air Cushion Packaging System. It is, therefore, a condition of use that ALL Opus Air machine operators familiarise themselves with the contents of this manual. Furthermore, any person that uses the Opus Air should have completed the appropriate training program for the system. Servicing and maintenance of the Opus Air system may only be carried out by an authorised and suitably qualified service technician or engineer. Green Light Products Ltd Capital Business Park Parkway Cardiff South Wales United kingdom CF3 2PX UK T ) ++ 44 29 2079 0880 F ) ++ 44 29 2079 2470 E ) sales@greenlightproducts.co.uk
2. Opus Air Machine Specifications The Opus Air machine converts rolls of pre perforated and sealed flat tubing into air cushions for use as void fill packaging. For safety reasons the cushions are to be used ONLY as a packaging material and MUST NOT be used as a flotation aid, a toy or other unspecified use. Technical Specification Machine maximum length: Machine maximum width: Machine maximum height: Machine weight: Control Buttons: 35cm/14 30cm/12 27cm/11 8.5kg/19lb Main power switch, start / stop, reset (system), (menu) select, menu control (up and down buttons), emergency stop. Power Supply (Europe): Power Supply (USA): Power Supply (Japan): Film material: 230V / 240V, 50Hz 110V, 60Hz 110V, 60Hz, 1500 watts Medium density polyethylene blend with oxobiodegradable additive. Length of roll: 200m- 500m/ 656ft-1640ft Roll width: 200mm or 400mm/ 8 or 16 Machine Setting/ Film size Film Settings 200mm x 200mm/ 8 x 8 Fast 200mm x 200mm/ 8 x 8 Slow 200mm x 100mm/ 8 x 4 400mm x 120mm/ 16 x 5 400mm x 50mm/ 16 x 2
3. Opus Air Safety Instructions Operators must never use the machine other than in accordance with the instructions set out in this manual or from an authorised trainer. On no account should the machine cover be removed exposing the internal workings of the machine. Under no circumstances should operators expose or modify the electrical components of the machine. Operators must not put their hands into the machine whilst the machine is working. The machine will automatically shut down in the event of a film blockage. To re-start the machine, clear the blockage and press reset. Press the start button to recommence. The machine uses electrical current to heat the sealing mechanism. Do not place flammable materials over the heat sealing section and avoid putting hands inside the cover during operation. In the event of an emergency, press the red emergency stop button. The machine will no longer be live. To restart the machine, rotate the emergency stop button, which will spring out to the normal operating position. PLEASE NOTE: THE EMERGENCY STOP BUTTON IS ONLY TO BE USED FOR EMERGENCIES. For normal start and stop, use start / stop button. At the end of each working day, or if the machine is to remain inactive for longer periods of time, the machine should be switched off using the main power switch. This is located at the right hand side of the machine where the power cable enters the machine.
4.1 Loading the Film 1. Ensure that the film size setting is set for the correct roll size. 2. Simply slide the roll onto the axle (A). Ensure that the side where the heat seals DO NOT MEET the edge of the roll is nearest the vertical chassis plate. 3. Cut open the edge of the film nearest to the vertical chassis plate. 4. Take the film and loop it back over the top roller (B). 5. Open the heat seal mechanism by lifting the silver handle (C). 6. Thread the open end of the film onto the guide bar (D) and pull the film through the open jaws of the side heat seal mechanism and through the rubber drive wheel mechanism (E). Ensure that the perforation is NOT on the drive wheel. 7. The film is now ready to run. 8. Press Start / Stop button (F) on display panel to begin and end operation. Please see below demonstration video:- http://www.youtube.com/watch?v=g7yzabyelsu&feature=youtu.be (DO NOT use red emergency stop button for general stopping) E C D B F A
4.2 This operation would normally be done by the service engineer installing the machine. Under exceptional circumstances the settings may need to be changed. This should only be done by a qualified service engineer or an operator trained in changing the engineering settings. In order to change the Engineering Settings, the password needs to be keyed into the display panel. Please contact your distributor for access to the password. Using the Select button scroll through the parameters on the menu that need to be changed. NOTE: The only parameters that should be changed are Heat Seal, Blower, and Bag Count settings Using the up or down arrows, adjust the value of the parameter as required. To change heat seal settings, it is best to increase or decrease in increments of 10. Should you require changing another parameter, press the select button again to locate the parameter that needs changing and repeat above procedure. Important. Once the required parameters have been set, scroll through the parameters until Exit Engineer Mode is displayed. Press the UP key to exit. 4.3 Adjusting the Operator Settings When the machine is not in Engineering mode the operator can adjust the following parameters to give the exact cushion functionality required: Heat seal setting +/- 10 Blower speed +/- 10 Number of cushions 1 to 10,000
4.3.1 Adjusting the Heat Seal and Blower Settings Under normal circumstances, all heat seal Operator Settings will be set at ZERO during installation. The operator is able to adjust these settings up 10 units and down 10 units using the following procedure: The Blower is always set towards the +10 setting to avoid over inflation. Press Select Continue to press Select to scroll through the menu options until you get to the parameter that is to be changed Press the UP / DOWN buttons to change the value 4.3.2 Adjusting the Number of Cushions Opus Air can be run in manual mode or automatic. In manual, the operator simply presses the Start button to begin producing air cushions and the Stop button to finish the production. Opus Air will default to produce 10,000 cushions unless instructed to do otherwise using the automatic operation mode. To automatically select the number of cushions required, press the Select button and scroll through the menu until you see the Select Number of Bags. Press the UP / DOWN buttons to adjust to the number you require, up to 10,000 cushions. The machine will stop when the count quantity as been reached. To pause the machine during the run press the start / stop button. To restart the machine press start. Machine will resume and continue to required quantity. 4.4 Restarting after the roll of film has run out When the roll has finished, the display on the control panel will reads OUT OF FILM. Re-load a new roll according to the instructions enclosed and press the START button. (DO NOT use red emergency stop button for general stopping)
Film blockage/ Film winding round heat sealing assembly. 1. Remove any film causing blockage. 2. Check belts are in correct position. 5. Opus Air Fault Diagnostics Description Machine does not start. Action 1. Check mains power is on and that the red light by the switch is on. (If it is not on please check 10 amp fuse below socket). 2. Check that the emergency stop button is not depressed. ( Emergency stop message will be on screen if it is depressed). Film not sealing Film heat seals are stretching Film comes off guide bar (Fig 1: D) Display will show Out of film message. 1. Check machine is in correct film type setting for film type. 2. Check belts are in the correct position and not damaged. 3. Check heat setting as this may need an increased adjustment. 1. Reduce the heat in increments of 5 and check to ensure bags are sealing correctly. 2. Reduce the blower setting as over inflation can cause stretching. 3. Check roll of film is not dragging against machine vertical chassis plate. 1. Check the roll has been properly loaded onto the film loading axle bar with the incomplete cross seal closest to the vertical chassis. 2. Check that the machine is in correct film type setting for film type. 3. Check that film is not dragging against machine vertical chassis plate. 4. Check that the film loading axle bar is at the correct angle. See link for instructions. http://www.greenlightproducts.co.uk/filmloading-bar-correct-angle-instructions-3425/
Description Eprom error on display. Action 1. The Eprom may need to be reset. 2. See link for instructions. 3. http://www.greenlightproducts.co.uk/opusair-machine-maintenance-procedures-7858/ EO3 error on display EO1, E02 and EO4 error message. 1. Check heater elements are not damaged or broken. 2. Check screws are secured tightly so there is a good connection. 3. See link for instructions http://www.youtube.com/watch?v=8bxilanvdag &feature=youtu.be 1. If any of these error messages appear on the display please contact your distributor for assistance. Recommended: A daily inspection of belts to prevent the above issues. Please also see the below link for service and maintenance video help:- http://www.greenlightproducts.co.uk/maintenance-videos-0278/