Sealed Air Fill-Air Rocket User manual

Rev. C © Sealed Air Corporation (US) 2014
1
Fill-Air Rocket ™ Inatable Packaging System User’s Guide
!
READY
#1 BL6T
!
READY
#1 BL6T
Standard Tabletop
Version
Optional Stand with
Integrated Bin
Fill-Air Rocket™ Inflatable Packaging System
User’s Guide
Original Instructions

Rev. C
© Sealed Air Corporation (US) 2014 2

Rev. C © Sealed Air Corporation (US) 2014
3
Fill-Air Rocket ™ Inatable Packaging System User’s Guide
Model: _____________________________________________________________
SerialNo: _____________________________________________________________
Accessories: _____________________________________________________________ 
 _____________________________________________________________ 
Please attach the business card
of your SealedAir® Representative here
Fill-AirRocket™InatablePackagingSystem
For Toll Free Service Information Call 1-800-243-1102 (U.S.)

Rev. C
© Sealed Air Corporation (US) 2014 4
1.0 AboutThisGuide .............................................................................................................................. 8
2.0 Safety
2.1 Important Safety Precautions ....................................................................................................... 11
2.2 Compliance .................................................................................................................................. 16
3.0 Overview
3.1 System Description ...................................................................................................................... 18
3.2 Sequence of Operation ................................................................................................................. 18
3.3 Electrical Power Requirements .................................................................................................... 20
3.4 Material ........................................................................................................................................ 21
3.5 System Components ................................................................................................................... 22
4.0 Set-up
4.1 System Set-up .............................................................................................................................. 28
4.2 Applications ................................................................................................................................. 31
5.0 Operation
5.1 Loading the Material Roll ............................................................................................................ 34
5.2 System Controls ........................................................................................................................... 36
5.3 Control Panel ............................................................................................................................... 38
5.4 Producing Air-Filled Bags ........................................................................................................... 40
5.5 Producing Air-Filled Bags in Auto Replenish Mode ................................................................... 42
5.6 Producing Air-Filled Bags in Batch Mode ................................................................................... 44
Table of Contents
Table of Contents

Rev. C © Sealed Air Corporation (US) 2014
5
Fill-Air Rocket ™ Inatable Packaging System User’s Guide
Table of Contents
Table of Contents (cont.)
6.0 MaintenanceandRepair
6.1 Preventative Maintenance .............................................................................................................47
6.2 Replacing the Edge Seal ..............................................................................................................48
7.0 Troubleshooting
7.1 There is no power to the system and the control panel Power LED is OFF .................................50
7.2 Displayed Fault Messages .............................................................................................................51
7.3 Problems with Making Inated Bags ............................................................................................53
7.3.1 The material will not advance when the start button is pressed -
the control panel Power LED is ON. ..................................................................................53
7.3.2 The material advances and edge seals are present but the bags do not ll with air ...........54
7.3.3 The material advances, the bags ll with air, but do not seal or seal fully .........................55
7.3.4 The inated bags leak air ...................................................................................................57
7.3.5 The inated bags have an inconsistent air-ll amount .......................................................59
7.3.6 The system does not stop producing bags when the bin is full - creating a pile-up
or a material jam .................................................................................................................60
8.0 CustomerService
8.1 Who to Contact in the United States .............................................................................................61
8.2 Using Technical Support in the United States ..............................................................................62
8.3 Who to Contact in Europe .............................................................................................................63
8.4 Spare Parts ....................................................................................................................................64
8.5 Film - US.......................................................................................................................................64
8.6 Film - EU ......................................................................................................................................65
 Notesx ............................................................................................................................................66

Rev. C
© Sealed Air Corporation (US) 2014 6
List of Tables and Illustrations
Table of Contents
2.0 Safety
Fig. 2-1 Safety Devices - Section View ...........................................................................................14
3.0 Overview
Fig. 3-1 Sequence of Operation .......................................................................................................19
Tab. 3-2 Electrical Power Requirements ..........................................................................................20
Fig. 3-3 Component Locations - 1 ...................................................................................................23
Fig. 3-4 Component Locations - 2 ...................................................................................................25
Fig. 3-5 Component Locations - 3 ...................................................................................................27
4.0 SystemSet-up
Fig. 4-1 System Set-up - Table Top Version ....................................................................................29
Fig. 4-2 System Set-up - Stand Version ...........................................................................................30
Fig. 4-3 Typical Application - Remote Ination ..............................................................................31
Fig. 4-4 Typical Application - On-Line Ination with Optional Stand with Integrated Bin ............32
5.0 Operation
Fig. 5-1 Loading the Material Roll - Steps 1 and 2 .........................................................................34
Fig. 5-2 Loading the Material Roll - Step 3 .....................................................................................35
Fig. 5-3 System Controls .................................................................................................................37
Fig. 5-4 Control Panel ......................................................................................................................39
Fig. 5-5 Producing Air-Filled Bags ..................................................................................................41

Rev. C © Sealed Air Corporation (US) 2014
7
Fill-Air Rocket ™ Inatable Packaging System User’s Guide
List of Tables and Illustrations
Table of Contents
5.0 Operation(cont.)
Fig. 5-6 Producing Air-Filled Bags into a Bin in Auto Replenish Mode .........................................43
Fig. 5-7 Producing Air-Filled Bags in Batch Mode .........................................................................45
6.0 MaintenanceandRepair
Tab. 6-1 Preventative Maintenance Schedule ...................................................................................47
Fig. 6-2 Replacing the Edge Seal ....................................................................................................49

Rev. C
© Sealed Air Corporation (US) 2014 8
The Fill-Air Rocket™ Inatable Packaging System User’s Guide is written and illustrated to easily
familiarize the operator with system component locations, system operation, and basic troubleshooting
procedures.
This guide covers the Fill-Air Rocket™Inatable Packaging System.
U.S. and other patents pending.
Informationsymbolsusedthroughoutthisguide:
This “bolt of lightning” symbol indicates that there is non-insulated material within your unit that may cause an
electrical shock.
This “hot” symbol calls attention to the need to be aware of components that may be hot.
This “goggles” symbol calls attention to the need to wear protective eye wear while performing maintenance procedures.
This “exclamation point” symbol calls attention to equipment features that you should be familiar with by reading the
enclosed literature. This will help prevent operating and maintenance problems.
This “triangle”symbol calls attention to special notes that will enhance operating and maintenance and repair
procedures.
This “float”symbol indicates that the bag must not be used as a otation device.
This “toy”symbol indicates that the bag must not be used as a toy.
This “pillow”symbol indicates that the bag must not be used as a pillow.
1.0 About This Guide
1.0 About This Guide

Rev. C © Sealed Air Corporation (US) 2014
9
Fill-Air Rocket ™ Inatable Packaging System User’s Guide
1.0 About This Guide (cont.)
1.0 About This Guide
NOTICE
© Copyright 2014 by SealedAirCorporation(US). All rights reserved.
This document is copyrighted. The material contained herein is protected under the US Copyright Act of 1976. This document, in whole or in part, may not be copied,
photocopied, reproduced, translated or reduced to any electronic or machine-readable form without the prior written permission of SealedAirCorporation(US).
Denitionsusedthroughoutthisguide:
•
An Operator is dened as those individuals who have been trained by a Sealed Air® representative and
are
authorized to: operate the system and to perform basic maintenance as outlined in this guide.
 Warning!Only qualied service personnel who have been trained by a Sealed Air® representative
are allowed to perform maintenance and repair procedures.
• Qualied Service Personnel is dened as those individuals who have been trained by a Sealed Air®
representative and are authorized to: operate the system and to perform most maintenance and repair
procedures.
• A Sealed Air® representative is dened as those individuals who are authorized to install and
decommission the system, operate the system, train Operators, train Qualied Service Personnel, and
to perform all maintenance and repair procedures.

Rev. C
© Sealed Air Corporation (US) 2014 10
(intentionally blank)

Rev. C © Sealed Air Corporation (US) 2014
11
Fill-Air Rocket ™ Inatable Packaging System User’s Guide
2.0 Safety
2.0 Safety
2.1 Important Safety Precautions
1. Readandthoroughlyunderstandthisguide.
2. BeforeoperatingtheFill-AirRocket™System,besureofthefollowing:
• The operator has received full training by an authorized Sealed Air® Representative.
• The operator has read and understood all safety instruction labels attached to the system.
• The system is plugged into a properly rated, grounded outlet - see 3.3 Electrical Power
Requirements.
 Warning! Failure to properly ground the system could create an electrical shock hazard.
 Warning! Do not remove the guards or access covers. The guards and access covers should
be removed only by an authorized Sealed Air® Representative or qualied service personnel
that have been trained by a Sealed Air® representative.
 Warning!RiskofEntrapment - Keep ngers, loose hair, clothing and jewelry away from
the edge seal roller when material is feeding, inating, and sealing.
  Warning!HotSurface- Be aware of the edge seal roller function and location.

Rev. C
© Sealed Air Corporation (US) 2014 12
3. TheFill-AirRocket™Systempackagingisintendedtobeusedonlyaspackagingmaterial.
Warning! Do not use the bags as a otation device.
  Warning! Do not use the bags as a toy.
  Warning! Do not use the bags as a pillow.
4. Beforeperformingmaintenanceandrepairprocedures,besureofthefollowing:
• Turn the main power switch to the OFF position, unplug the power cord, and follow proper
Lockout/Tagout procedures when instructed.
  Warning! Do not attempt to repair or modify the Fill-Air Rocket™ system other than the
procedures contained in the 4.0 Set-up, 5.0 Operation, or 6.0 Maintenance and Repair sections
of this guide. All repairs must be done by a Sealed Air® Representative or qualied service
personnel that have been trained by a Sealed Air® representative.
 Warning! Use protective eye wear as indicated when performing maintenance and repair
procedures.
 Warning! Do not open the covers except where instructed in the 5.0 Operation or the
6.0 Maintenance and Repair sections of this guide.
5. Lockout/Tagout(LOTO):
 • All maintenance and repair procedures should be performed in the approved manner using
Lockout/Tagout recommendations.
2.0 Safety
2.1 Important Safety Precautions (cont.)

Rev. C © Sealed Air Corporation (US) 2014
13
Fill-Air Rocket ™ Inatable Packaging System User’s Guide
2.1 Important Safety Precautions (cont.)
2.0 Safety
6. Inspectatregularintervalstoensurethat:
• Component cables are not cut, broken, or damaged.
• All controls and indicators function properly.
  Warning! If operation of the system differs from the descriptions in this guide, turn the
system OFF and disconnect and lock-out the main power until the unit can be inspected by a
Sealed Air® representative.
7. AirborneNoiseEmission:
• This machine does not exceed 75 dB(A) during normal operation. Please check to make sure
you comply with your local health and safety requirements.
8. Environmentalconditions:
• Storage temperature: machine and material rolls 32º-110ºF / 0º-43ºC
• Operating temperature: machine and material rolls 60º-110ºF / 16º-43ºC
  Note:Material rolls, if extremely cold or hot, must be brought to operating temperature to
properly seal. Materials stored at temperatures outside the specied storage temperature range
can be damaged and rendered unusable.
9. ResidualRisk:
Safety guarding is incorporated into the Fill-Air Rocket™ system, however minimal access is present
at the edge seal assembly. Care and avoidance need to be taken to prevent possible contact with
or entrapment by the hot roller.
(see the following pages for 10. Safety Devices)

Rev. C
© Sealed Air Corporation (US) 2014 14
2.0 Safety
2.1 Important Safety Precautions (cont.)
Safety Devices - Section View
Figure 2-1
!
Warning! Hot Roller
and Risk of Entrapment
Material Roll
ON/OFF
Switch
E-Stop
Button
Edge Seal
Assembly

Rev. C © Sealed Air Corporation (US) 2014
15
Fill-Air Rocket ™ Inatable Packaging System User’s Guide
2.0 Safety
2.1 Important Safety Precautions (cont.)
10. SafetyDevices-seeFigure 2-1:
  Warning! Do not remove or tamper with the following built-in safety devices.
 • EmergencyStopButton(E-Stop)- This red button, when pushed, disables all system
functions. It is located above the control panel.
 Warning!HotRoller - When material is inating and sealing, the edge seal roller is hot.
Be aware of the edge seal function and location.
 Warning!RiskofEntrapment - Keep ngers, loose hair, clothing and jewelry away from
the edge seal roller when material is feeding, inating, and sealing.

Rev. C
© Sealed Air Corporation (US) 2014 16
2.0 Safety
2.2 Compliance
The Fill-Air Rocket™ System is eligible to bear the CSA mark shown with adjacent indicators ‘C’ and ‘US’,
the PSE mark, and the CE mark.
The Fill-Air Rocket™ system has been designed and constructed to fulll all the relevant provisions of the
2006/42/EC Machinery Directive, 2006/95/EC Low Voltage Directive, the 2004/108/EC
Electromagnetic Compatibility (EMC) Directive, and the 2011/65/EU RoHS Directive.
EN 60204-1: Safety of Machinery – Electrical equipment of machines
EN 13849: Safety Controls
EN 12100: 2010: Safety of Machinery – Principles for risk assessment
EN ISO 13857: Safety of Machinery – Safety distance to prevent danger zones being reached by upper
limbs
EN 349: Safety of Machinery – Minimum gaps to avoid crushing of parts of the human body
EN 953-1: Safety of Machinery – General requirements for the design and the construction of xed and
removable guards

Rev. C © Sealed Air Corporation (US) 2014
17
Fill-Air Rocket ™ Inatable Packaging System User’s Guide
2.0 Safety
2.2 Compliance (cont.)
EN 61000-6-4: Generic Emissions, Industrial Environment
EN 55011: Radio interference characteristics of ISM equipment
EN 55014: Radio interference characteristics of Household equipment
EN 61000-6-2: Generic Immunity, Industrial Environment
EN 61000-4-2: ESD
EN 61000-4-3: Radiated immunity
EN 61000-4-4: EFT
EN 61000-4-5: Surge
EN 61000-4-6: Conducted immunity
EN 61000-4-11: Voltage dips and interruptions
EN 50581: RoHS
UL 963: Sealing, Wrapping, and Marking Equipment
CSA C22.2 no 68 Motor operated appliance
Verify

Rev. C
© Sealed Air Corporation (US) 2014 18
3.1 System Description
The Fill-Air Rocket™ Inatable Packaging System creates on-demand air-lled packaging from a
compact/uninated pre-formed roll of bags. The
inated bag chain is perforated between bags and
can easily be separated by the operator as needed.
There are three (3) modes of producing air-lled bags:
• Manual Mode
Press the Start Key to begin producing bags and the Stop Key to end production - see 5.4
Producing Air-Filled Bags.
• Auto Replenish Mode
When a bin sensor or optional accessory is employed, the supply of inated bags can be
continually/ automatically replenished - see 5.5 Producing Air-Filled Bags in Auto Replenish
Mode.
• Batch Mode
Dispense a programmed length of bags - see 5.6 Producing Air-Filled Bags in Batch Mode.
3.2 Sequence of Operation
1. The operator presses the start key and the drive motor is activated, drawing the material from
the material roll and over the xed material bar.
2. The material is drawn over the ination nozzle where the two webs are separated and lled with air.
3. The material is drawn through the edge seal where a heat seal traps the air inside the bag.
4. The air-lled bags exit the system.
3.0 Overview
3.0 Overview

Rev. C © Sealed Air Corporation (US) 2014
19
Fill-Air Rocket ™ Inatable Packaging System User’s Guide
3.0 Overview
Sequence of Operation
Figure 3-1
3.2 Sequence of Operation (cont.)
Material
Roll
Material Bar
2
1
Inflation Nozzle
3
Edge Seal
Start Key
4

Rev. C
© Sealed Air Corporation (US) 2014 20
Warning! Failure to properly ground the system could create an electrical shock hazard.
  Warning!Use of an extension cord will increase the levels of static, resulting in operational
problems as well as operator discomfort due to static discharge.
Electrical Power Requirements
Table 3-2
3.3 Electrical Power Requirements
3.0 Overview
Fill-Air Rocket ™ Receptacle A/C Voltage Phase Current
Inflatable Packaging System Type
115 VAC Version NEMA 5-15R 100 - 120 VAC Single Phase 15 Amp Service
50/60 Hz Grounded (2.2 avg.)
230 VAC Version CEE 7/7 220 - 240 VAC Single Phase 13 Amp Service
50/60 Hz Grounded (1.1 amps avg.)