airwave AirWave2 User manual

OPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS
1
Contents
Contents 1
Safety guidelines 2
Air cushion types –FILLER 3
Air cushion types –WRAPPER 4
Machine overview 5
Technical data 5
Recommended settings 6
Accessories and spare parts 9
Initial operation 10
Operating instruction 12
Preset function –quick selection 14
Lock function 15
Change the knife 16
Change the Teflon belt 19
Change the transport belt 22
Film guide pins 24
Error codes 25
Options and expandability 26
Advanced settings 28
To change advanced settings touch at start screen. 28
Enter code “1-3-5”, continue with and choose desired submenu. 28
Maintenance & Cleaning 29
Warranty 30
Declaration of Conformity 30
Support and Service 31
Document version 01.10.2019

OPERATING INSTRUCTIONS
2
Safety guidelines
Please read the safety guidelines and operating instruction closely before using the
machine.
- Turn off the machine and disconnect power before opening the machine or performing
any repair or maintenance work on the machine.
- Switch off the machine if it will not be used for an extended period of time.
- Do not insert any objects into the machine when it is connected to power.
- To prevent the risk of electric shock, ensure that the machine does not come into contact
with liquids.
- Do not operate the machine without the covers for the machine components.
- Keep hair and loose clothing away from the film feed mechanism.
- Place the machine only on surfaces that are adequately large, stable, flat, and horizontal.
This machine is designed for safe operation in compliance with the use, instructions, and
guidelines specified in these operating instruction.
All persons who use this machine must be familiar with the content of
these operating instructions and must carefully follow the safety
guidelines.
AirWave Packaging shall not be responsible for damage resulting from improper use of the
machine or non-observance of the safety guidelines.

OPERATING INSTRUCTIONS
3
Air cushion types –FILLER
Our standard version –Polyethylene 20 µm (0.8 mil)
7.1-7.3 with 700 m (23000 ft.); 7.4-7.5 with 600 m (1970 ft.)
Type 7.1 AirWave air cushion filler 100 x 210 mm (3.9 x 8.3 in)
Ideal for filling small voids and for use as an intermediate layer
Type 7.2 AirWave air cushion filler 150 x 210 mm (5.9 x 8.3 in)
Ideal for filling medium-sized voids and for use as an air cushion ring
Type 7.3 AirWave air cushion filler 200 x 210 mm (7.9 x 8.3 in)
Ideal for filling large voids
Type 7.4 AirWave air cushion filler 130 x 300 mm (5.1 x 11.8 in)
Ideal for filling large voids
Type 7.5 AirWave air cushion filler 240 x 300 mm (9.4 x 11.8 in)
Ideal for filling large voids
All type 7.x are also available as Jumbo rolls with more running meters per roll,
and also in 15µm (0.6 mil) or 12µm (0.5 mil), in pink antistatic version, in our „Heavy Duty“ version
made of laminated material, or as 100% biodegradable material.
Get in touch with us.

OPERATING INSTRUCTIONS
4
Air cushion types –WRAPPER
Our standard version –Polyethylene 20µm (0.8 mil)
8.1-8.6 with 450 m (1480 ft.); 8.3 600 with 300 m (980 ft.)
Type 8.1 AirWave wrapper 420mm (16.5 in) 2 large chambers
2 large chambers for large volumes and for use as a top layer
Type 8.2 AirWave wrapper 420mm (16.5 in) 2 small chambers
2 chambers for moulded components, edge protection, and
wrapping
Type 8.3 AirWave wrapper 420mm (16.5 in) 4 chambers
4 chambers for use as an intermediate layer, wrapping, and
envelope
Type 8.4 AirWave wrapper 420mm (16.5 in) 8 chambers
8 chambers for use as an envelope and intermediate layer
Type 8.5 AirWave wrapper 420mm (16.5 in) 7 wavy chambers
7 chambers for use as an envelope and intermediate layer
Type 8.6 AirWave wrapper 420mm (16.5 in) cloud type chambers
4 chambers for use as an envelope and intermediate layer
Type 8.3-600 AirWave wrapper 600mm (23.5 in) 6 chambers
6 chambers for use as an envelope and intermediate layer
All type 8.x are also available as Jumbo rolls with more running meters per roll,
and also in 15µm (0.6 mil) or 12µm (0.5 mil), in pink antistatic version, in our „Heavy Duty“ version
made of laminated material, or as 100% biodegradable material.
Get in touch with us.

OPERATING INSTRUCTIONS
5
Machine overview
Technical data
Power supply: 115-240 V; 50-60 Hz
Power consumption: 200 W
Production speed: 20 m / min (66 ft. / min)
12 m / min (39 ft. / min)
Weight: 6.25 kg
Color: Standard: anthracite / blue (individual on request)
AirWave2 dimensions (l / w / h): 413 / 316 / 232 mm (16.3 / 12.5 / 9.2 in)
extendible base 150 mm (6 in)
Control panel
Filling pipe for
air supply
Sensor end of film
Film channel
Film roll shaft
Power cord, power switch
Interface for external
control (optional)
Extendable base
Connection jumbo roll
holder (optional)
Spare part
compartment

OPERATING INSTRUCTIONS
6
Recommended settings
*Recommended speed: 12m/min ** Guiding pins recommended *** Recommended speed: 8m/min
Cushio
n Type
Temperature
Air Volume
Blowing Time
8m/min
(26ft/min)
12m/min
(39ft/min)
20m/min
(66ft/min)
8m/min
(26ft/min)
12m/min
(39ft/min)
20m/min
(66ft/min)
8m/min
(26ft/min)
12m/min
(39ft/min)
20m/min
(66ft/min)
°C
°F
°C
°F
°C
°F
PE 20 µm (0.8 mil):
7.1
180
356
235
455
250
482
25
35
40
0
0
0
7.2
180
356
235
455
250
482
27
37
42
0
0
0
7.3
180
356
235
455
250
482
30
40
44
+0,5
+0,3
+0,1
7.4
180
356
235
455
250
482
30
40
44
+0,5
+0,3
+0,1
7.5
180
356
235
455
250
482
45
50
54
+0,5
+0,3
+0,1
*8.1
180
356
235
455
-
-
50
70
-
0
0
-
*8.2
180
356
235
455
-
-
50
70
-
0
0
-
**8.3
180
356
235
455
250
482
65
80
85
0
0
-0,1
**8.4
180
356
235
455
250
482
65
80
85
0
-0,3
-0,1
8.5
180
356
235
455
250
482
65
85
90
0
-0,3
-0,1
8.6
180
356
235
455
250
482
65
85
90
0
-0,3
-0,3
8.3 XL
***
180
356
235
455
-
-
95
95
-
-0,3
-0,3
-
8.4 XL
***
180
356
-
-
-
-
95
-
-
-0,3
-
-
8.3 XXL
***
180
356
-
-
-
-
100
-
-
-0,3
-
-
8.4 XXL
***
180
356
-
-
-
-
100
-
-
-0,3
-
-
ECO 15 µm (0.6 mil):
7.1
170
338
210
410
230
446
25
35
40
0
0
0
7.2
170
338
210
410
230
446
27
37
42
0
0
0
7.3
170
338
210
410
230
446
30
40
44
+0,5
+0,3
+0,1
7.4
170
338
210
410
230
446
30
40
44
+0,5
+0,3
+0,1
7.5
170
338
210
410
230
446
45
50
54
+0,5
+0,3
+0,1
*8.1
170
338
210
410
-
-
50
70
-
0
0
-
*8.2
170
338
210
410
-
-
50
70
-
0
0
-
**8.3
170
338
210
410
230
446
65
80
85
0
0
-0,1
**8.4
170
338
210
410
230
446
65
80
85
0
-0,3
-0,1
8.5
170
338
210
410
230
446
65
85
90
0
-0,3
-0,1
8.6
170
338
210
410
230
446
65
85
90
0
-0,3
-0,3
8.3 XL
***
170
338
210
410
230
446
95
95
-
-0,3
-0,3
-
SuperECO 12 µm (0.5 mil):
7.1
165
329
200
392
220
428
25
35
40
0
0
0
7.2
165
329
200
392
220
428
27
37
42
0
0
0
7.3
165
329
200
392
220
428
30
40
44
+0,5
+0,1
+0,3
7.4
165
329
200
392
220
428
30
40
44
+0,5
+0,1
+0,3
7.5
165
329
200
392
220
428
45
50
54
+0,5
+0,1
+0,3

OPERATING INSTRUCTIONS
7
*Recommended speed: 12m/min ** Guiding pins recommended *** Recommended speed: 8m/min
Cushi
on
Type
Temperature
Air Volume
Blowing Time
8m/min
(26ft/min)
12m/min
(39ft/min)
20m/min
(66ft/min)
8m/min
(26ft/min)
12m/min
(39ft/min)
20m/min
(66ft/min)
8m/min
(26ft/min)
12m/min
(39ft/min)
20m/min
(66ft/min)
°C
°F
°C
°F
°C
°F
SuperECO 12 µm (0.5 mil):
*8.1
165
329
200
392
-
-
50
70
-
0
0
-
*8.2
165
329
200
392
-
-
50
70
-
0
0
-
**8.3
165
329
200
392
220
428
65
80
85
0
-0,1
0
**8.4
165
329
200
392
220
428
65
80
85
0
-0,1
-0,3
8.5
165
329
200
392
220
428
65
85
90
0
-0,1
-0,3
8.6
165
329
200
392
220
428
65
85
90
0
-0,3
-0,3
8.3 XL
***
165
329
200
392
-
-
95
95
-
-0,3
-0,3
-
Heavy Duty 26 µm (1.0 mil):
7.1
190
374
235
455
250
482
-
35
40
0
0
0
7.2
190
374
235
455
250
482
-
37
42
0
0
0
7.3
190
374
235
455
250
482
-
40
44
+0,5
+0,3
+0,1
7.4
190
374
235
455
250
482
-
40
44
+0,5
+0,3
+0,1
7.5
190
374
235
455
250
482
-
50
54
+0,5
+0,3
+0,1
*8.1
190
374
235
455
-
-
-
70
-
0
0
-
*8.2
190
374
235
455
-
-
-
70
-
0
0
-
**8.3
190
374
235
455
250
482
-
80
85
0
0
-0,1
**8.4
190
374
235
455
250
482
-
80
85
0
-0,3
-0,1
8.5
190
374
235
455
250
482
-
85
90
0
-0,3
-0,1
8.6
190
374
235
455
250
482
-
85
90
0
-0,3
-0,3
8.3 XL
***
190
374
235
455
-
-
95
95
-
-0,3
-0,3
-
8.4 XL
***
190
374
235
455
250
482
95
95
100
-0,3
-0,3
-0,3
8.3 XXL
***
190
374
-
-
-
-
100
-
-
-0,3
-
-
8.4 XXL
***
190
374
-
-
-
-
100
-
-
-0,3
-
-
Flex 20 µm (0.8 mil):
7.1
135
275
170
338
180
356
25
35
40
0
0
0
7.2
135
275
170
338
180
356
27
37
42
0
0
0
7.3
135
275
170
338
180
356
30
40
44
+0,5
+0,3
+0,1
7.4
135
275
170
338
180
356
30
40
44
+0,5
+0,3
+0,1
7.5
135
275
170
338
180
356
45
50
54
+0,5
+0,3
+0,1
*8.1
135
275
170
338
-
-
50
70
-
0
0
-
*8.2
135
275
170
338
-
-
50
70
-
0
0
-
**8.3
135
275
170
338
-
-
65
80
-
0
0
-0,1
**8.4
135
275
170
338
-
-
65
80
-
0
-0,3
-0,1
8.5
135
275
170
338
-
-
65
85
-
0
-0,3
-0,1
8.6
135
275
170
338
-
-
65
85
-
0
-0,3
-0,3
8.3 XL
***
135
275
170
338
-
-
95
95
-
-0,3
-0,3
-

OPERATING INSTRUCTIONS
8
*Recommended speed: 12m/min ** Guiding pins recommended *** Recommended speed: 8m/min
Listed values are recommendations to warrant durability of machine at good results. These values
should not be exceeded. But temperature and air volume can slightly vary dependent on ambient
conditions or application.
Cushi
on
Type
Temperature
Air Volume
Blowing Time
8m/min
(26ft/min)
12m/min
(39ft/min)
20m/min
(66ft/min)
8m/min
(26ft/min)
12m/min
(39ft/min)
20m/min
(66ft/min)
8m/min
(26ft/min)
12m/min
(39ft/min)
20m/min
(66ft/min)
°C
°F
°C
°F
°C
°F
Bio 20 µm (0.8 mil):
7.1
135
275
170
338
180
356
25
35
40
0
0
0
7.2
135
275
170
338
180
356
27
37
42
0
0
0
7.3
135
275
170
338
180
356
30
40
44
+0,5
+0,3
+0,1
7.4
135
275
170
338
180
356
30
40
44
+0,5
+0,3
+0,1
7.5
135
275
170
338
180
356
45
50
54
+0,5
+0,3
+0,1
*8.1
135
275
170
338
-
-
50
70
-
0
0
-
*8.2
135
275
170
338
-
-
50
70
-
0
0
-
**8.3
135
275
170
338
180
356
65
80
85
0
0
-0,1
**8.4
135
275
170
338
180
356
65
80
85
0
-0,3
-0,1
8.5
135
275
170
338
180
356
65
85
90
0
-0,3
-0,1
8.6
135
275
170
338
180
356
65
85
90
0
-0,3
-0,3
8.3 XL
***
135
275
170
338
-
-
95
95
-
-0,3
-0,3
-
Flex ClimaFilm 30 µm (1.2 mil):
7.1
165
329
200
392
-
-
25
35
-
0
0
-
7.2
165
329
200
392
-
-
27
37
-
0
0
-
7.3
165
329
200
392
-
-
30
40
-
+0,5
+0,3
-
7.4
165
329
200
392
-
-
30
40
-
+0,5
+0,3
-
7.5
165
329
200
392
-
-
45
50
-
+0,5
+0,3
-
*8.1
165
329
200
392
-
-
50
70
-
0
0
-
*8.2
165
329
200
392
-
-
50
70
-
0
0
-
**8.3
165
329
200
392
-
-
65
80
-
0
0
-
**8.4
165
329
200
392
-
-
65
80
-
0
-0,3
-
8.5
165
329
200
392
-
-
65
85
-
0
-0,3
-
8.6
165
329
200
392
-
-
65
85
-
0
-0,3
-
8.3 XL
***
165
329
200
392
-
-
95
95
-
-0,3
-0,3
-
PaperWave-Bio:
***7.1
200
392
230
446
270
518
25
35
40
0
0
0
***7.2
200
392
230
446
270
518
27
37
42
0
0
0
***7.3
200
392
230
446
270
518
30
40
44
+0,5
+0,3
+0,1

OPERATING INSTRUCTIONS
9
Accessories and spare parts
Power cord (1 pcs)
Hex key (3 pcs)
Teflon belts (1 pcs)
Knife (1 pcs)
Fuse (1 pcs)
Film guide pins (2 pcs)

OPERATING INSTRUCTIONS
10
Initial operation
Switch on machine
Connect power to the machine and switch on the
machine.
The start screen will appear automatically after
approximately 3 seconds on the display.

OPERATING INSTRUCTIONS
11
Insert film roll
Please rotate the spindle anti-clockwise
(about 1/2 turn) to unlock the core holder.
To load and also to unload a film roll.
Turn clockwise to lock.
Please note that the roll sits all the way on
the spindle.
Load the roll of film onto the unlock film roll
shaft.
Please note the side of air fill channel of the film.
The channel must be on the side closest to the
machine.
Guide the air fill channel of the film onto the air
nozzle. Slide the film on the air nozzle a few more
cm forward in direction of sealing unit.
That will simplify the next step.
Pull the film above the air nozzle and through the
film channel and press the “IN/OUT button”
while pulling the film all the way through.
The corner of the film can be cut at an angle to
make it easier to fit the film over the air nozzle.

OPERATING INSTRUCTIONS
12
Operating instruction
Use the touch display to set the sealing temperature, film length, and air volume.
Start, Stop function
Once machine is powered on the sealing unit starts heating
up. When set target temperature is achieved „Start panel“
change color.
and machine is ready to use.
When a roll of film is loaded and all settings are correct,
touch to start the production of air cushions.
During production of air cushions display show Stop panel.
Touch to stop production of air cushions
Adjust air volume
Adjust air volume of the air cushions between 0 and 100, by touching
or at touch display.
The air volume can be adjusted before production of air cushions at start screen and also
during air cushion production at stop screen.
Please see recommended settings for adequate air volume for the different cushion types.

OPERATING INSTRUCTIONS
13
Adjust seal temperature
Adjust seal temperature by touching temperature panel
Touch or to adjust target temperature.
Then touch to close setting page and return to start
screen. The machine starts heating or cool down until set
temperature.
Please have a little patience. Air cushion production can
only start when target temperature is achieved.
If you touch during heating up or cooling down
process the machine will get in waiting position and will
start air cushion production by itself once target
temperature is achieved.
Please see “recommended settings”for the different cushion types.
To change displayed unit, please see “advanced settings”.
Preset film length
The length of the air cushion film you want to produce can be preset in meters, as needed.
This value is set to 0 by default, which tells the machine to produce air cushions
continuously.
To set requested length of air cushion strand, touch at start screen.
Enter the requested length
Touch to confirm and return to start screen
Touch to discontinue and return to start screen
without changed setting.
Please note that preset length will be kept until delete or
new adjustment.
To change displayed unit, please see “advanced settings”.

OPERATING INSTRUCTIONS
14
Preset function –quick selection
Five presets with temperature, air volume, running speed and Blowing time are possible
for a quick selection. Programming can be done at programming level.
Touch at start screen to get to the screen for selecting program
For quick selection of a preset touch assigned number (1, 2,
3, 4, or 5) and keep in touch until return to start screen.
Settings will automatically be transferred in start screen
Factory-adjusted: M1 for type 7.1 PE-Film 20µm; M2 for
type 8.3 PE-Film 20µm
To program or change a preset enter “4-5-6” and touch
Select one program by touching M1, M2, M3, M4 or M5 to
get to the corresponding programming level.
Touch to return to start screen with without any
changes.
To change displayed unit, please see “advanced settings”.
At programming level touch or to adjust
temperature, air volum, running speed or blowing time.
When all settings are done, touch to continue
changes and get back to program quick selection page.
Touch to return to program quick selection page
without any changes.

OPERATING INSTRUCTIONS
15
Lock function
Control panel can be locked, to prevent setting changes by unauthorized person.
Touch at start screen to get to the screen for entering code.
Enter code “1-2-3”, touch to confirm and return to
start screen
Touch to return to start screen without lock
function.
A little padlock symbol show that touch display is locked.
If so, it is only possible to
feed film , start , or stop air cushion
production.
Temperature, air volume or production length is not
possible to change. Therefore display needs to be unlocked.
Touch “SET” enter code and touch “ENT” to confirm and
return to start screen.

OPERATING INSTRUCTIONS
16
Change the knife
You can easily change the knife for AirWave2 yourself.
Step 1: Switch off the machine and disconnect power
Always switch off the machine before opening it.
Disconnect power to the machine by removing
the power cord completely from the machine.
Allow the machine to cool down!
You must follow this step. It is for your safety.
Step 2: Remove cover
Undo both screws of upper cover with appropriate
hex key and remove cover

OPERATING INSTRUCTIONS
17
Step 3: Remove the knife
Undo the locating screw with the provided hex key.
Remove the blade bracket.
Caution!!
Even used blades are extremely sharp!
Step 4: Change blade
Undo the little screw which fixes the blade with
the provided hex key.
Turn around the blade one time 180° or
apply a new one if both sides were already
used.
Fix the blade with the corresponding screw.

OPERATING INSTRUCTIONS
18
Step 5: Insert the knife
Insert the knife into the slot at the machine
and fix it with the screw.
Remount the upper cover and fix it with the
screws with provided hex key.

OPERATING INSTRUCTIONS
19
Change the Teflon belt
You can easily change the Teflon belts at AirWave2 yourself.
Step 1: Switch off the machine and disconnect power
Always switch off the machine before opening it.
Disconnect power to the machine by removing
the power cord completely from the machine.
Allow the machine to cool down!
You must follow this step. It is for your safety.
Step 2: Remove covers
Undo both screws of upper cover with appropriate
hex key and unscrew lower cover with provided
hex key and remove it.