Pregis packmaster pro 383 User manual

Easypack®
Model 383
Operating Manual (EN)
38-OM225-1
English

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Safety Information
Description and Purpose of Machine
Specification and Installation
Machine Controls
Pre-start Checks
Loading Paper
Instructions for Use
Clearing Paper Jams
Troubleshooting
Declaration of Conformity
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4
5
6
7
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10
18
21
22
Contents

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Always switch off the machine from the mains supply before
freeing paper jams or lifting the top cover.
THIS MACHINE MUST BE EARTHED
The wires in the mains cable are coloured as such:
GREEN/YELLOW
BLUE
BROWN
EARTH
NEUTRAL
LIVE
It is important that this machine is installed, maintained and used correctly to
avoid the risk of injury.
This machine contains dangerous voltages and rotating mechanical parts.
Safety Information
• Use the machine only for the purposes described in the Operating Manual.
•This machine is to be used only by trained personnel.
•Do not operate without the guards properly in place.
•The machine will not start with the flap in the open position.
•The machine will not run with the top cover or the paper off-cuts door
open.
•The machine is to be serviced or repaired only by Pregis.
•The machine uses a 230V(±10%), 50Hz, single-phase AC supply.
•To protect against electrical shock, do not immerse the plug or mains cable
in water or spray with liquids.
•Unplug from the electrical supply when not in use.
•Do not operate this machine with a damaged mains cable or plug.
•To disconnect from electrical supply, grip the plug - do not pull on the
mains cable.
The machine is fitted with motor driven cut-off blades which operate automatically
at the end of each cycle. Serious operator injury could result if hands are inserted
through the outfeed flap. Care must also be taken to keep hands away from the
paper entry slot to avoid paper cuts or friction burns to the hand.
The machine can be stopped at any time via the rocker switch. This cuts off
the electrical supply to the control panel and motors.

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Description and Purpose of Machine
The purpose of the Pregis Packmaster-pro machine is to produce tough, resilient cushions
of recyclable packaging material.
The machine is loaded with either a single ply or a two ply roll of paper. As the material
passes through the machine it is formed and shaped to produce a continuous cushion
which is cut off to the selected length.
The cushion material has excellent bulk properties which make it ideal for void filling
throughout the packaging operation.
The cushion is multi-cellular to resist impact forces and is readily molded to cocoon even
the most awkwardly shaped objects and protect them from damage in transit.
The machine is of rugged design and construction and its stainless steel finish is quickly
wiped over for cleaning purposes. The sub frame is mounted on castors to facilitate move-
ment to a new area.
Control Panel
Outfeed Channel with
Outfeed Flap Inside
Paper Roll Holder
Optional Remote Control Panel
The machine is designed to meet EC safety standards and requires connection only to a
suitable electrical supply. Noise levels not to exceed 70dB(A).
Top Cover
Mains power
rocker switch

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Specification
Installation
Specification and Installation
The machine should be positioned in the packing area allowing ample
space for loading the rolls of paper.
Do not allow the mains cable or footswitch cable to become damaged.
Ensure the mains supply cable is routed safely to prevent trip hazards.
Do not attempt to wheel the machine over uneven surfaces or at a speed
greater than a slow walk.
Dimensions (machine) 1170mm (L) x 775 (W) x 545 (H)
Dimensions (frame) 950mm (L) x 840 (W) x 885 (H)
Weight (machine) 124kg
Weight (frame) 24kg
Voltage 230V (±10%), 50Hz
Max Power 400W
Machine Fuse 6.3A
The machine is top heavy when mounted on the frame.
Temperature Min 5°C.
Humidity 10 to 90% RH.
Vibration Do not install the Machine in an area where it is likely to be
subject to constant vibration.
Shock Do not drop the Machine or expose it to sudden shock.
Atmospheric
pollution
Do not install the Machine in an area that is subject to water
hazards, condensation, excessive dust or other atmospheric
contaminants.
Location It is important that the supporting floor is flat and level.
Lifting/Transporting Instructions
The machine must be securely strapped to a pallet for transporting safely.
The machine and frame weigh 148kg.
Connections
The machine must be connected to a 230V, 50Hz, 1-phase electrical supply.
THE MACHINE MUST BE EARTHED.
No other services are required. Maximum power consumption is 400W.

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Machine Controls
‘Off’
Button ‘Home’
Button
Quantity
Knob ‘Length’
Knob
‘On’
Button
Preset
Buttons
‘Run’
Button
‘Off’ Button
Preset Buttons
‘Home’ Button
Length Knob
Quantity Knob
*Fault Indication*
‘Run’ Button
‘On’ Button Press the green ‘On’ button to switch the machine on.
The display will illuminate.
Press the red ‘off’ button to stop the machine in a controlled manner and switch
the machine off.
The display will show 5 ‘dots’.
Stops the machine producing packs if running more than one, cancels ‘A1’ or
‘A2’ semi automatic operation, or restores the last set of values for quantity and
length.
The three buttons can be programmed by the operator with commonly used
quantity and length combinations.
This is used to select the quantity of packs required from ‘A1’, ‘A2’ and 01 to 99
or continuous.
The pack length can be adjusted from 25cm to 999cm long on standard ma-
chines.
This button is pressed to initiate the cycle for single pack, semi-automatic and
continuous operation.
If the machine stops unexpectedly and F1, F2, F3 or F4 are displayed,
this indicates a fault (see troubleshooting, page 21).

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Pre-start Checks
1. The machine is connected to the
mains supply, switched on and
the neon indicator is illuminated.
2. The footswitch tube is connected
to the machine.
4. Switch the machine on by pressing
the green ‘I’ button. The display will
illuminate. If the display shows
flashing ‘dashes’ the machine needs
to be loaded with a roll of paper.
3. The paper cushion can discharge
from the outfeed channel without
any restriction.

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Loading Paper
1. Noting the unwind direction, slide a
new roll of paper onto the paper
arm until the sprung retaining latch
springs up.
Single ply Two ply
4. Press and release the blue feed button
- the paper will load automatically.
The quantity display will flash ‘Ld’ whilst
the paper is loading. Once loading is
complete the display will revert to the
previous settings.
3. Rotate the wheels by hand for about
half a turn to feed-in and grip the pa-
per.
For single ply paper,
feed the sheet be-
tween the roller and
inner guide rods as
shown.
For two ply paper, feed
the inner sheet be-
tween the roller and
guide rods and the
outer sheet between
the inner and outer
guide rods as shown.
2. Pull approximately 70cm of paper from
the roll.
Feed the sheet(s) of paper into the entry
slot.
NOTE: If the machine runs out of paper in auto batch mode, the machine will automatically
continue to produce the remaining quantity of packs as soon as the paper has been loaded.
Paper Rolls

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Loading Paper
1. Using a pallet pump truck, lift the
pallet of paper and align with the
frame. 2. Pull approximately 70cm of paper.
NOTE: If the machine runs out of paper in auto batch mode, the machine will automatically
continue to produce the remaining quantity of packs as soon as the paper has been loaded.
Fanfold pallet
3. Feed the sheet between the
guide panel and inner guide rods
as shown.
4. Feed the sheet of paper into the
entry slot.
5. Rotate the wheels by hand for about
half a turn to feed-in and grip the
paper.
6. Press and release the blue feed button
- the paper will load automatically.
The quantity display will flash ‘Ld’
whilst the paper is loading. Once load-
ing is complete the display will revert
to the previous settings.
NOTE: This requires a different frame and some adjustments.

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Instructions for Use
2. Depress and hold down the footswitch.
The length display will increment up as
the pack is produced and the quantity
display will change to a cycling symbol.
Release the footswitch when the re-
quired length of cushion is produced.
Remove the cushion from the machine.
1. Remove any material from the
outfeed channel and ensure the
outfeed flap is closed.
Do not insert hands through the
outfeed flap inside the outfeed
channel - risk of serious injury
from motor driven cut-off
blades.
A paper cushion is generated continuously by holding down the foot operated
switch. Releasing the footswitch stops the feed and causes the cushion to be
cut off. When using the footswitch the length setting is overridden.
Footswitch Operation

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1. Rotate the quantity knob anti-
clockwise to ‘A1’. 2. Rotate the length knob to the
required pack length.
Instructions for Use
3. Remove any material from the
outfeed channel.
Press the black ‘Run’ button to
initiate the cycle.
Every time a length of paper cushion is removed from the outfeed channel the machine
produces another cushion. The length is set by the length knob.
The footswitch can be used in this mode to override the length setting and produce a
longer length. When the machine starts to produce a paper cushion, press the
footswitch to create the required length.
To stop the machine from producing further packs, press the white ‘Home’ button.
Semi-automatic Operation
4. Remove the material from the out-
feed channel and the machine will
generate another pack.
Whilst not feeding a pack ‘A1’ will
flash to show semi-automatic op-
eration is active - pressing the
‘Home’ button cancels this.
NOTE: If the quantity is set to ‘A2’ two packs are produced, one after the other.

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1. Rotate the quantity knob to ‘01’. 2. Rotate the length knob to the required
length.
Instructions for Use
3. Press the black ‘Run’ button to
initiate the cycle.
Single packs are produced on demand to the set length.
Single Pack Operation
4. The machine will produce one
pack to the set length.

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1. Rotate the quantity knob to the
number of packs required (02-99). 2. Rotate the length knob to the re-
quired pack length.
Instructions for Use
3. Remove any material from the
outfeed channel.
Check there is ample space for
the packs to discharge from
the outfeed channel.
Press the black ‘Start’ button to
initiate the cycle.
Packs are produced continuously to the set quantity and length.
To stop the machine whilst running a set quantity, press the white ‘Home’ button.
To restart press the black ‘Run’ button.
Automatic Operation
4. The machine will produce one
pack to the set length.
NOTE: If the quantity is set above 99, the display will
show paper runs out, or the machine is stopped. and will run continuously until the

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1. Press one of the preset buttons (a,
b or c) - the display will change to
the preset value.
2. Press the black ‘Run’ button to
initiate the cycle.
Instructions for Use
3. Remove any material from the outfeed
channel.
Check there is ample space for
the packs to discharge from the
outfeed channel.
Press the black ‘Start’ button to initiate
the cycle.
A preset quantity and length of pack are produced (three preset buttons available).
Preset Button Operation
NOTE: If the quantity is set above 99, the display will
show paper runs out, or the machine is stopped. and will run continuously until the

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1. Press one of the preset buttons (a, b
or c) - the display will change to the
preset value.
2. Rotate the quantity knob to the
desired number from 01 to 99
(whilst the display is flashing).
Instructions for Use
3. Rotate the length knob to the de-
sired length (whilst the display is
flashing).
The three preset buttons can be programmed simply by the operator.
Programming the Preset Buttons
4. Release the preset button to save
the values - the display will flash
twice before remaining on.

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1. Press and hold all three of the pre-
set buttons (a, b & c).
2. After 5 seconds a ’dot’ will appear
below the right hand digit of the
length display.
Instructions for Use
The three preset buttons can be set to produce the programmed values instantly when
the preset button is pressed and released by the operator.
Programming the Preset Buttons for ‘Instant’ Operation
When one of the preset buttons is pressed and released the programmed quantity and
length of packs will be produced instantly (without pressing the ‘Run’ button).
To change the preset button operation to require the ‘Run’ button to be pressed, press
and hold all three preset buttons for 5 seconds until the ‘dot’ disappears.

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2. The machine will not switch on, or run
with the paper off-cuts door open. 3. The machine will not switch on, or
run with the top cover lifted up.
Instructions for Use
5. Release the preset button to save
the values - the display will flash
twice before remaining on.
1. The machine will only operate when the display is illuminated.
The machine will stop when the paper runs out. The display will change to flashing
‘dashes’ and the tail end of the paper will be automatically run out of the machine.
4. The machine will not switch on or
start if the outfeed flap is open.

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Clearing Paper Jams
4. Lift the top cover, press the release
plunger in and lower the top cover.
Swing the black ‘T’ handles up and
clamp down.
3. Cut the paper across the rods with
a knife, at the infeed guide rods.
Lift the front end of the inner paper
former and remove all paper.
Check that no paper pieces remain
in the folding area, the crimping
area and the outfeed channel.
Paper Feed Jam
Indicated by ‘F2’
For safety, switch off the mains supply to the machine
before clearing paper jams.
Keep fingers away from the edges of the cut-off blades.
2. Lift up the top cover until it locks in
position.
1. Unscrew the two black ‘T’ handles
each side of the top cover until
they swing down.

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Clearing Paper Jams
4. Locate the blade reset tool (supplied)
on the crank nut.
Rotate the crank clockwise to the
position shown; this releases the
paper jammed in the blades.
3. Lift the door forwards over the
knobs to remove.
Paper Feed Jam
Indicated by ‘F3’
For safety, switch off the mains supply to the machine
before clearing paper jams.
Keep fingers away from the edges of the cut-off blades.
2. Slide the door to the right to release
the key tongue from the safety switch.
1. Slacken the two black knobs securing
the paper off-cuts door under the
outfeed channel.

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Clearing Paper Jams
4. Replace the paper off-cuts door taking
care to align the safety switch key.
Tighten the two black knobs.
3. Remove any paper off-cuts from
around the blade mechanism.
Removing Paper Snippets
For safety, switch off the mains supply to the machine
before clearing paper jams.
Keep fingers away from the edges of the cut-off blades.
2. Slide the door to the right to release
the key tongue from the safety switch.
1. Slacken the two black knobs securing
the paper off-cuts door under the
outfeed channel.