ErgoPack 700X, 713X, 745X, 726X Original Operating Instructions

EN

For ErgoPack 700X/713X/726X/745X

serial no.___________________

Original Operating Instructions

V9

Declaration of conformity

EU declaration of conformity

(for the purposes of the EU machine directive 2006/42/EG)

We, ErgoPack Deutschland GmbH
Hanns-Martin-Schleyer Str. 21
89415 Lauingen

hereby declare, that the Ergonomic Pallet Strapping Systems type "ErgoPack 700X, 713X, 726X, 745X“,

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 model we
have brought on to the market.
This declaration loses its validity if a change is made to the system without our permission.

Respective
EU directives: EU Machine directive (2006/42/EG)
EU Guideline on electromagnetic compatibility
(2014/30/EU)

Applied standards EN 12100: 2010

EN 415-8: 2016
EN 61000-6-2:2005
EN 55011: 2018-05

EN 60 204-1: 2006

Since strapping system: 0319GTQLR/10050
Since year of manufacture: 2019

Lauingen, 14th of June, 2018

______________________
Andreas Kimmerle
CEO

Authorised representative for publishing technical documentation:
ErgoPack Deutschland GmbH
Hanns-Martin-Schleyer-Str. 21
89415 Lauingen

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Table of contents

1. Validity of the operating instructions 5

2. General 6

2.1 Moving the strapping system 6

2.2 Parking the strapping system 6

2.3 Work area space requirements 7

2.4 Environmental conditions 7

2.5 Energy supply charger/battery 8

2.6 Notes on environmental protection 9

2.7 Meaning of warning symbols, usage conventions 10

3. Recommendations for protective measures 11

3.1 Safety regulations for battery and charger 12

4. Description 13

4.1 Construction 13

4.2 Operating panel strapping unit 14

4.3 Touch display strapping unit 14

4.4 Touch display sealing head 15

4.5 Indication and commissioning of the 36V charger 16-17

5. Technical data 18

5.1 Strapping unit 18-19

5.2 Sealing head 19-20

6. Intended use 21

7. Commissioning 22

7.1 Battery charger 22

7.2 Charging the battery 22-25

7.3 Setting strap width at the sealing head 26

7.4 Switching on the strapping system 27

7.5 Setting strap tension range at the sealing head 28

7.6 Setting tension force at the sealing head 29-30

7.7 Setting mode of operation at the sealing head 31-32

7.8 Select favorite 32

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7. 9 Setting welding time 33

7.10 Changing strap coil 34-42

7.11 Setting pallet width 43

8. Operation 44

8.1 Strapping 44-48

8.2 Tensioning and sealing of pallets above 70cm height 49-52

8.3 Sealing control 53

8.4 Tensioning and sealing of pallets below 70cm height 54-56

9. Risks 57-59

10. Service and repair 60

10.1 Cleaning the ChainLance 60

10.2 Replacing the ChainLance 61-65

10.3 Replacing the reversing sledge ´ 66-68

10.4 Replacing individual chain links 69

10.5 Replacing the length adjusting belt 70-71

10.6 Changing the sealing head 72-73

10.7 Changing the control box joystick unit 74-76

10.8 Changing the control box display unit 77-78

10.9 Changing the motor 79-81

10.10 Cleaning/replacing the tension wheel at the sealing head 82-83

10.11 Cleaning/replacing the tooth plate at the sealing head 83

10.12 Replacing the cutter at the sealing head 84

11. Software updates 85-87

12. Spare parts list 88

13. Personal protective equipment 89

14. General safety warnings for power tools 90-93

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1. Validity of the operating instructions

The operation in these instructions is explained by using the
ErgoPack 726X 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” is

concerned.

These operating instructions are valid for the following models:

ErgoPack 700X

Strapping system with electrical drive, electronically controlled via
joystick, without sealing head

ErgoPack 713X

Strapping system with electrical drive, electronically controlled via
joystick, with a sealing head for strap width of
9-13mm and a maximum tension force of 1200N

ErgoPack 726X

Strapping system with electrical drive, electronically controlled via
joystick, with a sealing head for strap width of
12-16mm and a maximum tension force of 2500N

ErgoPack 745X

Strapping system with electrical drive, electronically controlled via
joystick, with a sealing head for strap width of
15-19mm and a maximum tension force of 4500N

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2. 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 system is rolling
away accidentally.

Handles

Operating instructions

Fig. 1

Fig. 1a

Guide roll with
parking brake

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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 at least 1,10 m width in front of

the pallet to be strapped is required.

1,10 m

0,30 m

Fig. 2

2.4 Environmental conditions

The strapping system is only to be used in a covered dry area, otherwise the
risk of an electric shock can not be ruled out.
The ambient temperature during operation must not exceed 50°C and not fall
below 0°C.
For the strapping system, an electrically conductive floor is recommended.

-7-

2.5 Energy supply charger/battery

Charger 3 stage charger
Prim.: 198-264 VAC 50/60 Hz max. 2,0A
Sec.: 44,5V DC/4,5A
Max. power 200W

Battery pack 3 x 12V AGM battery
Weight: 19,5 kg

Charging time: approx. 10 hours

Operating temperature range: 5°C - 40°C

Number of strappings : Up to 650 standard strappings* per charge

Life span: approx. 300 - 500 charges

*standard strapping:
Battery pack: 100 charging and discharging cycles

Tape: 13mm PET (full strap coil)
Sealing head: 726X, tension force 900N without setting the SOFT tension
mode, welding time 2nd range
Pallet: pallet width 0,8 m, pallet height 1,15 m
Strapping speed: fast
Room temperature: 20°C

-8-

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.

The specialist dealer offers disposal according to proper environmental
protection.

- Do not open the battery

- Do not throw the used battery into the domestic waste bin, into fire or
into water.

Fig. 3

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2.7 Meaning of warning symbols, usage
conventions

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.
If not considered, it can lead to material damage or poor
operating results.

Note!

Marks useful, additional information.

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3. 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.

Note!

The operating instructions must be available at the place where the strapping
system is used (below the sliding window, see Fig. 1).
Before using the strapping system for the first time, the operating instructions
have to be read, understood and used by everybody who works with the
system. These works include operation, maintenance and repair!
See chapter 13 and chapter 14.

In addition to the operating instructions and the rules in the country and
place of use for the prevention of accidents, the recognized special rules for
working safely and according to proper and professional standards also have
to be respected.

In order to protect the strapping system against unauthorized access, it is

recommended to remove the key from the main switch and disconnect the

power supply from the battery pack.

The key should be kept safe from unauthorized access.

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3.1 Safety regulations for battery and charger

• Check the plug and the cable before each use and have them replaced by

a specialist if they are damaged.

• The charger is intended only for the batteries supplied with the strapping

system. Do not charge any batteries from other manufacturers, use
original spare parts only.

• Protect the charger and battery against moisture; operate them in dry

rooms only.

• Do not open the battery and protect it from shock, heat and fire. Danger

of explosion!

• Store batteries in a dry frost-proof place. The ambient temperature must

not exceed 50°C and must not fall below -5°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.

• Plug and socket of battery, charger and power cable have a magnetic
connection. There is a risk that metallic particles, such as e.g. filing or
drilling chips or similar, adhere and may lead to damage of the contacts.

• Plug and socket should therefore be kept away from metallic particles and
regularly checked for the adhesion of such particles. For cleaning, it is best
to use compressed air in conjunction with a brush with synthetic bristles.

-12-

4.1 Design

4. Description

Fig. 5

Control panel
Safety cutter

Fig. 4

Strap brake

Control display

Fig. 7

Sealing head
Sliding window with safety switch
Operating instructions

Fig. 6

Tool-Lift
Covering of battery box

-13-

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. 8

4.3 Touch display strapping system

Fig. 9

Touch display for setting all parameters
at the strapping system, such as pallet
width.

Function key F1 – F4:

• F2 Strap coil changing mode

• F3 Menu

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4.4 Control panel sealing head

1 „Favourite“

2 „Welding time“

3 „Operating mode“

4 „Plus & Keylock“

5 „Tension force“

6 „Minus & Soft tension“

a „Information symbols“

Fig. 10

b Status indicator bar „Tensioning/Welding“

c Display „Messages“

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

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4.5 Indication and commissioning of the
36V charger

Inside the red battery housing there are 3 x 12V AGM batteries installed and
connected in series. The ErgoPack 36V charger charges these batteries.

The green or yellow shining LED indication light on the 36V charger indicates
different operating states of the charger as well as the charging status of the
battery pack.

1.) Once the charger is plugged into the main power supply, the charging
process starts immediately, which will be indicated by a yellow shining LED
indication light, regardless of whether a battery pack is connected or not.

2.) You can now connect the battery pack to the charger. The charging process
starts again, thereby the yellow LED indication light remains yellow. The
batteries will be charged.

3.) As soon the LED indication light shines green, the charging process is
finished, the batteries are fully charged and the charger switches into
preserving mode. An overcharging of the batteries is not possible.

4.) By disconnecting the battery pack from the charger, the LED indication
light remains green and indicates then the operational readiness of the
charger.

5.) A new charging process starts when the battery pack will be connected
again, the LED indication light shines yellow again until the batteries are fully
charged and switches afterwards to green as well.

6.) As long as the charger remains plugged in the main power supply, the
steps described in point 5.) are performed. If the charger will be removed
from the main power supply and plugged in again, firstly the steps described
in point 1.) and afterwards the next steps will follow.

Do not remove the battery pack from the charger during the charging

process!

-16-

Attention!

The charging time is approx. 10 hours. The battery pack is only fully charged
when the LED indication light on the charger is permanently shining green!

LED indication

light

Automotive flat fuse

10A/32V

Fig. 11

-17-

5. Technical data

5.1 Strapping system

Dimensions (all types)
Length 665 mm
Width 770 mm
Height 1200 mm
Weight (without optional equipment):
ErgoPack 700X (incl. battery) 106 kg
ErgoPack 713X (incl. battery) 114 kg
ErgoPack 726X/745X (incl. battery) 115 kg

Maximum chain speeds:

Slow, strapping

Moving out horizontally: 27 m/min
Moving out vertically: 53 m/min
Moving in vertically: 52 m/min

Moving in horizontally: 39 m/min

Medium, strapping
Moving out horizontally: 29 m/min
Moving out vertically: 58 m/min
Moving in vertically: 57 m/min
Moving in horizontally: 45 m/min

Fast, strapping
Moving out horizontally: 66 m/min
Moving out vertically: 78 m/min

Moving in vertically: 76 m/min

Moving in horizontally: 65 m/min

Strap changing: setting up/threading in strap
Moving out: 10 m/min
Moving in: 8 m/min

Max. Chain thrust: 310 N

-18-

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)
745X 0,80-1,30 mm (PET/PP)

5.2 Sealing head

Weight: 3,8 – 4,3 kg
(incl. spiral cable)

Dimensions length 335 mm
(incl. spiral cable) width 140 mm
height 180 mm

Tension

713X 150-1200 N

726X 400-2500 N
745X 400-4500 N

Tensioning speed 290 mm/s (713X)
220 mm/s (726X)

120 mm/s (745X)

Sealing friction-weld sealing

-19-

Measured A-graded
noise emission level
(EN ISO 11202) (EN 60745-1/2:2009)

713X LpA 79 dB (A) L

726X LpA 78 dB (A) L
745X LpA 79 dB (A) L

Sound power level, on average
(EN 60745 -1/2:2009)
713X LW
726X LW
745X LW

Aeq

88 dB (A)

Aeq

93 dB (A)

Aeq

92 dB (A)

Measurement inaccuracy K

713X 3,0 dB (A)
726X 3,0 dB (A)
745X 3,0 dB (A)

pAeq

77 dB (A)

pAeq

82 dB (A)

pAeq

81 dB (A)

Hand arm vibrations without using a Tool-lift
(EN 60745-1/2:2009)
713X a 2,4 ms
726X a 2,4 ms
745X a 2,3 ms

-2

-2

-2

Measurement inaccuracy K

713X 1,5 ms
726X 1,5 ms

745X 1,5 ms

-2

-2

-2

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6. Intended use

This strapping system has been developed and constructed for an ergonomic
and safe strapping of pallets with plastic straps.

The strapping system is only to be used for strapping with plastic straps
(polypropylene and polyester). Strapping with steel strap is not possible with
this strapping system.

The strapping system is not designed to strap open and unpacked aliments.

The set tension force must correspond to the packaged goods to be strapped.
Constructing the strapping system there was not considered any risk due to
damaging of dangerous products or their package.

-21-

7. Commissioning

Attention!

Before using the strapping system for the first time, a visual inspection for
exterior damages has to be done.

7.1 Battery charger

The main voltage must comply with the details on the type plate.
The charger is only suitable for charging the delivered 36V battery pack.

7.2 Charging the battery pack

1.) Connect charger to the main voltage

2.) Open cover of battery case (by pulling at the outer corners

as shown below).

Fig. 12

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3.) Disconnect the plug (13a) from the battery pack (14a) and let the cable
hang freely down.

Fig. 13 Fig. 14

13a

14a

Warning!

Charge the battery pack only with the ErgoPack 36V charger through the
charging socket!

4.) Insert the plug of the 36V charger (16a) into the socket (15a) of the battery
pack.

Fig. 15

Fig. 16

15a 16a 15b

Attention!

Replace always defective flat fuses (15b) of the battery pack (see Fig.15) by a
new one of the same type (vehicle blade fuse 30A / 80V).
If necessary, contact your ErgoPack service partner.

-23-

5.) Alternatively, the battery pack
can be also removed from the
strapping system ...

Fig. 17

… or be comfortably pulled out

to the battery trolley (optional

equipment)...

... and be replaced by a
previously charged battery pack.

Fig. 18

Fig. 19

-24-

Fig. 20

Attention!

The charging time is approximately 10 hours. The battery pack is only fully
charged when the LED indication light on the charger is permanently shining
green!

The maximum charging current flows if the temperature of the battery is
between 5°C and 40°C. Avoid battery temperatures below 0°C while charging.

Note!

During charging, the battery pack always has to be in a horizontal position
(cover always upside). Never place the battery pack in lateral or upright

position.

You achieve the longest life span, if the battery pack is always charged
immediately after it was used and if it is only stored fully charged.

Fig. 21

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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.
The setting of the strap width with the models 713X from 9-10 mm to 12­13mm and 745X from 15-16mm to 18-19mm works accordingly.

a) Change strap width from 12–13 mm to 15–16 mm

• Switch the strapping system off

• Release three cylinder screws Torx (6). Lift the rocker lever

towards the handle, release cylinder screw Torx (7) and
remove strap guide rear13mm (8).

• Remove side cover (5).

• Release counter-sunk screw Torx (2) and remove strap guide

front 13 mm (1).

• Release counter-sunk screw Torx (4) and remove strap guide

front 13 mm (3).

• Release cylinder screw Torx (10) and remove strap guide

rear 13 mm (9).

• Fit side cover (5) (secure cylinder screw with screw locking

varnish “medium-tight”. Install strap guide rear 16 mm (8).

b) Change strap width from 15-16mm to 12-13 mm

•Release three cylinder screws Torx (6). Lift the rocker

lever towards the handle, release cylinder screw Torx (7)
and remove trap guide rear 16 mm (8).

•Remove side cover (5).

•Fit strap guide front 13 mm (1) (secure counter-sunk

screw with screw locking varnish “medium-tight”).

•Fit strap guide front 13 mm (3) (secure counter-sunk screw

with screw locking varnish “medium-tight”).

•Fit strap guide rear 13 mm (9) (secure cylinder screw

with screw locking varnish “medium-tight”).

•Fit side cover (5) (secure cylinder screw with screw locking

varnish “medium-tight”). Install strap guide rear 13 mm (8).

1

2

Fig. 22

5

6

3

10

9

Fig. 23

4

8

7

-26-

7.4 Switching on the strapping system

Instructions:

 Charge the battery pack as described under 7.2.
 Plug in the connector of the power cable (24a) into the socket of the

battery pack (24b).

 Close the cover of the battery case.
 Make sure that the EMERGENCY STOP switch (25a) is not pressed. If

necessary, unlock it by turning.

 Turn the main switch (25d) to the right to operating mode “1" and hold it

in this position for approximately 2 seconds.

Fig. 24 Fig. 25

24a 24b

25a

25b 25c

 Follow the instructions on the display after the “ErgoPack” logo

disappeared (after approx. 45 seconds).

-27-

25d

7.5 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
726X = 400-1360 N
745X = 400-1600 N

Press „Soft“ button (a).
The soft mode is deactivated when the

„SOFT“ display (b) changes position and

is shown outlined.

a

b

Press „Soft“ button (a).
The soft mode is activated when

the „SOFT“ display (c ) changes

position and is shown in bold.
The displayed tension force is

c

d

Fig. 26

reduced correspondingly.
On the left under the tension force
an "S" (d) also appears.

Attention!

Always use the SOFT tension mode when working with PP-strap!

By using the Soft mode, the tension wheel accelerates more slowly and avoids
excessive strap waste when sealing with PP strap.

-28-

7.6 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.

• Unused displays disappear.

 Press + (1) or – (3) button until the required tension force is displayed.

• The status indicator bar (4) shows the set tension force in relation to

the possible maximum value.

 Save: Press „tension force“ button (2) or wait for 5 seconds.

Fig. 27

Note!

• Switch between display in „N“ or „lbf“: Press the flashing „tension force“
button (2) for two seconds.

• Every time the button is pressed an acoustic signal confirms the action.

• The tension force is displayed continuously when the tool is operational.

• Setting soft tension (section 7.5).

-29-

713X

Standard N* 400 500 600 700 800 900 1000 1100 1200

Soft N 150 225 300 375 450 525 600 675 750

lbf* 90 110 135 155 180 200 225 250 270

lbf 33 50 67 85 100 120 135 150 165

726X

Standard N* 900 1100 1300 1500 1700 1900 2100 2300 2500

Soft N 400 520 640 760 880 1000 1120 1240 1360

745X

Standard N* 1300 1700 2100 2500 2900 3300 3700 4100 4500

Soft N 400 550 700 850 1000 1150 1300 1450 1600

lbf* 200 250 290 340 380 430 470 520 560

lbf 90 115 145 170 200 225 250 280 305

lbf* 290 380 470 560 650 740 830 920 1000

lbf 90 120 160 190 225 260 290 325 360

(rounded values)
* N = Newton, lbf = pound-force per square inch

Warning!
Adjusted tension force must relate to the packaged goods to be strapped.
Possible hazards caused by damages of dangerous goods or their
packaging are not considered with the design of the strapping system.

-30-

7.7 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.

1

3

Fig. 28

2

MAN/ SEMI/ AUTO

By pressing the „Operating mode“ button (1) again, or after waiting 5 seconds,

the set mode is saved. Each operating mode can also be selected for the
tension range „Soft tension“ (Section 7.5).

• MAN = Manual

The tensioning button must be pulled and held until the desired strap
tension has been reached. The welding button must then be briefly
pressed so that the straps are welded and the upper strap is cut off.

• SEMI = Semi-automatic strapping (standard/factory setting)

The tensioning button must be pulled and held until the set tension force
has been reached. The straps are then automatically welded and the
upper strap is cut off. It can be welded manually at any time by pressing
the welding button.

-31-

• AUTO = Fully automatic strapping*

The tensioning button has to be pulled (touched) once only. This triggers
the tensioning process. Once the set tension force has been reached, the
straps are automatically welded and the upper strap is cut off.

* 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. Ensure that there are no other persons in
the hazard zone.
For an emergency stop in the case of danger (trapped person):
To release the strap tension (before welding), pull the rocker lever. In
operating mode AUTO, also the tensioning or welding button can be pressed
again. After welding, cut the strap using a tool (strap cutter).

7.8 Select favourite*

The function „favourite“ activates a second settings level, whose parameters

can be set freely like those of the main level.

This enables the operator to quickly change from one setting into the other.

Deactivate favourite:

• Press „favourite“ button (1). The

star (2) changes from bold to
outlined. All parameters change
to the pre-set values of this
settings level.

Activate favourite:

• Press „favourite“ button (1). The star

(3) changes from outlined to bold. All
parameters change to the pre-set
values of this settings level.

Fig. 28 b

1
2

Fig. 28 a

3

2

* The operating mode favourite is factory blocked! Activation only through your

ErgoPack service partner possible.

-32-

7.9 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.

• + and – appear.
 Press button + (1) or – (3) until the
required welding time appears.
 Save: Press „welding time“ button (2) or wait for 5 seconds.

3

2

1

-33-

7.10 Changing strap coil

Switch on the strapping system as
described in section 7.4

For changing the strap coil

press „F2“ button (30a) and

follow the instructions
appearing on the display.

By pressing „next“ button, 1. Step appears on the display.

Fig. 30

30a

1. Step
By pressing the „Positioning ChainLance“ button, the ChainLance will

automatically reach the correct position so that the red chain link stops in the

middle of the sliding window.

For this process the sliding window must be closed!
Once the ChainLance reached the right position, the 2. Step appears
automatically.

Note!

By pressing the „Stop“ button the strap coil changing mode can be stopped at

any time and you will get back to the main menu.

-34-

2. Step
Open the sliding window (31a).

After opening the sliding window,

3. Step appears automatically.

3. Step

Fold down the pivot arm with the red
circular disk until its final stop.

Fig. 31

31a

Fig. 32

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.

Fig. 33

Note!

Do not yet remove the tape or adhesive tape, which fix the strap on the coil!

-35-

Fold up the arm with the
strap coil again in its
vertical position as
shown on the picture.

Now, remove the tapes or
adhesive tapes fixing the
strap on the coil.

Fig. 34

Fig. 35

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.

-36-

Fold up the cover of the white roll for
strap infeed, thread the strap through the
U-bolt…

…and over the white roll to the

inside. Thereafter fold the cover
back down again.

Fig. 36

Fig. 37

After pressing „Next“ on the touch

display you will finish the 3. Step
and get to the 4. Step.

Fig. 38

Fig. 39

-37-

4. Step

Press from the left hand
side on the metal clamp
lock located in the red

chain link…

…then slide the strap

from the right to the left
through the slot in the
clamp lock.

Fig. 40

Fig. 41

To finish the 4. Step, the
sliding window has to be
closed.

Fig. 42

Fig. 43

-38-

5. Step

Press the „Positioning ChainLance“
button until the ChainLance stops
automatically and the 6. Step

appears.

Fig. 44

Fig. 45

Warning, risk of injury!

Never put your fingers between the chain links.

-39-

6. Step

Remove the strap from the

clamp lock of the red chain link

and hold it straight up as
shown (Fig. 48).

Thereafter, press the „Retract
chain“ button until the

ChainLance stops and the

7. Step appears.

Fig. 46

Fig. 48

Warning, risk of injury!

Never put your fingers between the chain links.

-40-

Fig. 47

Fig. 49

7. Step

Open the eccentric latch in the
red head piece of the ChainLance
by pushing it inwards with your
finger. (See Fig. 49)

Push the strap from the back
through the head piece of the
ChainLance (as shown).

The strap must pass between the
two aluminium eccentrics.

Fig. 50

Warning, risk of injury!

Never put your fingers between the chain links.

-41-

Fig. 51

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.

Fig. 52

Place the overlapping strap
with a loop through the
small slot underneath the
left handle (as shown).

-42-

7.11 Setting pallet width

1. Step:

To set the correct pallet width, press

the „Pallet width“ button in the

main menu.

2. Step:

You can choose the required width of
the pallet to be strapped among the
factory set pallet widths.
In case the required pallet width is not

listed, you can adjust one of these

buttons to the required pallet width.

For changing one of the buttons to the
required pallet width, proceed as
follows:

Fig. 54

Fig. 53

Press and hold the button to be
changed for approx. 3 seconds. You
can then set the required pallet width
in 10 cm steps (Fig. 55). As soon as you

confirm your setting with „OK“, this

new pallet width will be saved in the

Fig. 55

preset pallet widths.

Your ErgoPack is now ready for strapping.

-43-

8.1 Strapping

Fig. 56

8. Operation

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 that the
laser line runs alongside
the pallet edge.

Fig. 57

2. Step

Move out the
ChainLance by
pushing the joystick

in „move out“

direction.

The reversing sledge

leads the strap

through and
underneath the
pallet...

-44-

Fig. 58

... and back up

again on the

opposite side.

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 cm.

Fig. 59

Attention!

Push the joystick until the ChainLance appears on the other side and falls in
your direction.

Release the joystick, so that it returns to the neutral position (central position)
and stops the ChainLance moving out further.

Catch the ChainLance as shown at the red head piece. Do not let the
ChainLance drop onto the package!

-45-

Fig. 60

3. Step

Hold the strap with your
left hand as shown,

directly at the head
piece of the
ChainLance…

... move the
ChainLance
completely back by
pushing the joystick

in „move in“

direction.

Fig. 61

Attention!

Always keep the strap slightly under tension when moving the ChainLance
backwards, to avoid that loops can be formed at the reversing sledge. Loops
may lead to malfunctions while moving back the ChainLance.

-46-

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. 62

The strap lifter lifts the second end of the strap up to working height so you
can grasp it without bending down.

Only keep the joystick pushed until the strap lifter is fully in its upper position.

The time, how long the strap lifter should remain in its upper position, can be

set in „page 3“ of the menu.

Attention!

You have to hold the strap loosely in your hand when the strap lifter comes
up.

The strapping system automatically switches off to prevent damages if you do
not let go of the strap when the strap lifter rises. The strap lifter can be raised
up again by pushing the joystick in the „move in“ direction twice.

-47-

Fig. 63

Fig. 64

Fig. 65



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…

...but about 10cm below the
strap lifter. Hold the strap
with the whole hand and
pull it out of the strapping
system.
At the same time, you have
to let the end of the strap
slide through your other
hand!

If your strapping system is
equipped with the optional
strap break relief:

Before pulling at the strap,
press down the foot pedal
at the left side.

This reduces the brake force

of the strap coil and eases
pulling out strap a lot.

-48-

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.

3. Step

Hold then both straps as shown

with the right hand.

The end of the strap should lie in your hand
and not project beyond it!

Fig. 66

-49-

Fig. 67

4. Step

Push the sealing head towards
the pallet with the left hand and
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.

With your right hand you can
now feed the strap from the top
to the bottom through the slot
in the sealing head
(similar to a credit card).

Now let go of the rocker lever.

Fig. 68

Fig. 69

Fig. 70

-50-

5. Step

The tensioning and sealing of the strap is
different according to the set mode (manual,
semi-automatic or automatic mode) (see also
section 7.7.).

5.1 Manual tensioning and sealing

Pull the tensioning button (Fig. 71) until the
required tension force is reached (see also
section 7.5).
Thereafter, press the round welding button (Fig.

72) to weld both straps and to cut off the upper
one.

5.2 SEMI-Semi-automatic tensioning and
sealing

Pull the tensioning button (Fig. 71) until the pre­set tension force is reached. Afterwards, both
straps will be automatically welded and the
upper strap will be cut off. You can also weld the
straps manually at any time by pressing the
welding button even if the pre-set tension force
was not reached.

Fig. 71

5.3 Automatically tensioning and welding*

Fig. 72

By a brief pulling (touching) of the tensioning button once, the sealing process
(tensioning and welding) will be activated. Once the set tension force has been
reached, the straps are automatically welded and the upper strap is cut off.

* 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. Ensure that there are no other persons in
the hazard zone.
For an emergency stop in the case of danger (trapped person):
To release the strap tension (before welding), actuate the rocker lever, the
tensioning or welding button. After welding, cut the strap using a tool (strap
cutter).

-51-

The tensioning process is finished, once the

indicator bar is filled in fully.

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.

6. Step

As soon as the countdown is finished and
the signal has sounded you have to pull
the rocker lever towards the handle.

Attention!

Fig. 73

Fig. 74

If after pressing the welding button, the
welding process does not start, but the

sealing head beeps, the tension button

was not pressed first.

7. Step

Now slew the sealing head to the left
while keeping the rocker lever pulled..

Attention!

It is recommended to clean the sealing
head regularly (at least daily), if there is a
lot of strap waste. Especially the tension
wheel and the tooth plate have to be
checked for damages and kept clean.
Please refer to section 10.10.

Fig. 75

-52-

Fig. 76

8.3 Sealing control

Control the sealing regularly. The welding time must be checked in accordance
with point 7.9 and changed if necessary when the straps are welded badly.

1

Fig. 77

1 Good welding: The whole sealed surface has been properly welded without

any extra material being squeezed out to the side.

2 Bad welding: The surface has been unevenly welded, the selected welding
time is too short.

3 Bad welding: Surplus material has been squeezed out to the side, the
selected welding time is too long.

Warning!

2 3

Improper welded straps cannot secure the loads and can therefore cause
injuries.

Never transport or move goods with improper welded straps.

-53-

8.4 Tensioning and sealing pallets below 70
cm height with ErgoPack standard Tool­Lift

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.

Fig. 78

Fig. 79

Fig. 80

2. Step

Strap the package exactly as
described under point 8.1.

3. Step

Overlap both straps so that the
beginning of the strap lies
underneath.

Pull the rocker lever to open
the clamp of the sealing head.

-54-

Fig. 81

Now, with your right hand,
feed the strap through the
guiding of the sealing head, by
pulling it towards yourself.

Fig. 82

Fig. 83

4. Step

The tensioning and the sealing
of the strap is different
according to the set mode
(manual / semi-automatic or
automatic mode, see point

7.7).

-55-

Fig. 84

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.

If your strapping system is

equipped with the optional

Triplex Tool-Lift:

Pull out the sealing head
horizontally, slew the sealing
head by 90° into horizontal
position and put it on top of the
pallet.

Fig. 85

Tensioning and sealing proceed
exactly as described in the
previous steps.

-56-

9. 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.

Do not place hands or other body parts between the strap and
the packaged goods during the strapping process. Ensure that
there are no other persons in the hazardous zone.

For an emergency stop in case of danger (trapped person):

• To release tension (before welding), open the rocker lever.

• After welding, cut the strap with a suitable tool (strap cutter)

Warning

Following hazards can cause serious injuries:

ChainLance, risk of tipping

When the ChainLance is moving upwards on the opposite side of
the pallet, it falls towards the operator by its own weight. Used

without paying attention, the ChainLance can fall on the head of
the operator and cause injuries. When using the system, watch

out and be concentrated and catch the ChainLance when it falls
over.

An improper welded strapping can not secure the loading and
may thus lead to injuries.

Never transport or move strapped goods with an improper weld.

-57-

Warning!

Following hazards can result in serious injuries:

Breaking strap, risk of injury

When being tensioned, the strap may break and rip. Do not stand
in line with the strap and wear eye protection.

Strap ends snapping back, risk of injury

When cutting the strap, hold the upper portion and stand aside.
Do not stand in line with the strap and wear eye protection.

ChainLance, risk of tripping

When parking the strapping system, the ChainLance must be fully
inside it. The reversing sledge must not stick out.

Strap waste, risk of tripping

Make sure any strap waste or pieces of strap, which possibly
appeared, will be removed from the floor quickly.

Sealing head and ChainLance, risk of crushing

Do not put your fingers into the area of the tension wheel of the
sealing head and into the ChainLance.

Reversing sledge, risk of crushing

Especially around the entire surroundings of the reversing sledge,
there is a risk of squeezing.

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). During
strapping, there must not be any hands or other body parts
between strap and goods.

Power source, risk of injury
Before maintenance or repair works:

Switch off the strapping system by pressing the „OFF“ switch,

remove the key from the main switch and unplug the main power
cable from the battery.

-58-

Warning!

Following hazards can result in serious injuries:

EX areas, risk of explosion

The strapping system must not be used in areas with explosive
atmospheres.

Caution!

Following hazards can result in minor or moderate injuries:

Strap coil, risk of injury

While changing the strap coil, 2 persons need to transport and
lift it, if the weight of the roll is 20 kg or heavier.

Tilting danger

Strapping pallets should, whenever possible, take place in areas

with an even surface. When using the strapping system on inclined

surfaces, after positioning and before strapping, the brakes of the
castor wheels on the strap side have to be locked.

Attention!

Avoid damages on the strapping system:

Water damages

For cleaning of the strapping system do not use water or steam.

Visual inspection

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.

-59-

10. 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“ switch, the key has to be removed from
the main switch and the main power cable must be unplugged from the
battery pack.

10.1 Cleaning the ChainLance

Clean the ChainLance with acetone or petroleum if it has become dirty with
oil. Always wear appropriate protective equipment.

Attention!

Do not place the ChainLance into cleaner.
Never use lubricants like grease or oil!

-60-

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.

2. Step
(There are 2 options)

Option 1

Set the pallet width at the display of
the strapping system to 1m and drive
out the ChainLance until the joint of
the reversing sledge folds up and
locks into this position.

Fig. 86

Fig. 87

-61-

Afterwards, switch off the strapping
system by pressing the OFF button
and disconnect the power cable
from the battery pack. For this
purpose, the cover of the battery
compartment has to be opened (by
pulling at the wheel covers). (See
Fig. 88)

Option 2

Switch off the strapping system by
pressing the OFF button and
disconnect the power cable from
the battery pack. For this purpose,
the cover of the battery
compartment has to be opened
(by pulling at the wheel covers).
(See Fig. 88)

A second person presses

downwards the „rocker“ of the

locking unit (89a), which is

connected with the magnet lock

through the folding spring bolt. At
the same time the other person
pulls the reversing sledge out of
the strapping system according to
Fig.91.

Fig. 88

Fig. 88

Fig. 89

89a

Fig. 90

-62-

Now, pull out the
reversing sledge by
about 1 m and fold up the
joint. (See Fig. 92)

Fig. 91

3. Step

Pull the ChainLance out of the

strapping system as shown and
roll it up.

Fig. 92

-63-

4. Step

Push the new ChainLance in
again in reversed order of the
removal.

Fig. 93

By pushing the end piece of the

ChainLance into the system, the

end pieces preloaded by a spring
(see Fig.94), has to be aligned
straight (see Fig. 95). Press the
chain links down with your finger
and push them into the
strapping system …

Fig. 94

Fig. 95

-64-

… so that the end of the

ChainLance can be inserted into
the groove of the ChainLance
(see Fig. 98) in the central part of
the strapping system (see Fig.

96).

Fig. 96

Fig. 97

Also for that, the preloaded

Groove of the ChainLance

chain links have to be pressed
down with your finger (see
Fig. 97).

5. Step

Fig. 98

Put the strapping system into operation in accordance with section 7.

-65-

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.

Fig. 99

2. Step

Set the pallet width at the
display of the strapping system
to 1m and drive out the
ChainLance…

…until approx. 60 cm of the chain

stands in an upward position.
Then, switch off the strapping
system by pressing the OFF button
and disconnect the power cable
from the battery pack.

Fig. 100

-66-

Fig. 101

3. Step

Push a screwdriver (blade width 5,5
mm) between the wings of two chain

links …

… and slew the chain to the side by
turning the screwdriver carefully …

Fig. 102

… until the two chain links fully

separate.

Fig. 103

Fig. 104

-67-

4. Step

Push the ChainLance manually
back into the strapping system
until the ChainLance has
completely moved out of the
reversing sledge.

5. Step

Place the reversing sledge on its
top as illustrated and use a
screwdriver to unscrew both
screws of the length adjusting
belt.

Fig. 105

Fig. 106

6. Step

The fitting of the reversing sledge is done in the reversed order of the
dismantling.

Attention!
Both screws of the length adjusting belt must be protected with medium-tight

screw retaining varnish!

-68-

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.

Attention!
After removing the chain link, the strapping system has to be restarted. After

each restart, the control unit automatically adjusts to the correct zero position
in accordance with point 8.4.

Note!

As the new shorter chain length is unknown to the control unit, it may
happen that when driving out the chain completely, the end of the chain will
not be recognized correctly any longer and the ChainLance will be pushed out
over the driving gearwheel.

This can cause a malfunction. Therefore, missing chain links should be
replaced as soon as possible.

-69-

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 „battery
compartment“ as described
under point 7.2 „charging the
battery pack“.

Now, unlock the ball lock pin by
pressing the release button and
pull it out of the storage plate.

3. Step

A second person presses

downwards the „rocker“ of the

locking unit which is connected

with the magnet lock through the

folding spring bolt. At the same
time the other person pulls the
length adjusting belt out of the
strapping system.

Fig. 107

Fig. 108

-70-

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.

Fig. 109

Fig. 110

Attention!

Make sure that the length adjusting belt is inserted into the lower groove and
that it does not slide into the upper groove of the ChainLance.

6. Step

The further installation is done in the reversed order of the dismantling.

-71-

10.6 Changing the sealing head

1. Step

Drive out the Tool-Lift forwards

so that the cover „display“ can

be disassembled.

Fig. 111

2. Step

Remove the cover „display“ by

pulling on the provided handle
holes diagonally downwards.
(The cover is fixed by magnets).

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.

4. Step

Remove the 4 screws of the red

metal cover at the holder of the

spiral cable.

Fig. 112

Fig. 113

-72-

Fig. 114

5. Step

Pull the cable with plug through the

opening in the holder of the spiral
cable.

6. Step

Pull out the locking bolt for
unlocking the sealing head and
remove the sealing head.

Fig. 115

Fig. 116

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).

Fig. 117

7. Step

The mounting of the sealing head is to be done in reversed order of the

dismantling. When mounting the cover „display“, take care to engage it first at

the display and then all along the groove of the storage plate.

washer 1 washer 2

Attention!

When mounting the sealing head again
make sure that the rough tooth system

of the two wedge-lock washers are

facing each other (Fig. 118).

tenuous
(outward)

Fig. 118

rough
(inward)

tenuous

tenuous

rough

-73-

10.7 Changing the control box joystick unit

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
remaining in the strapping system
through the head piece of the
ChainLance and dispose it.

Fig. 119

2. Step

Fold down the pivot arm.

3. Step

Remove the cover „joystick“ by

pulling on the handle holes,
provided at the bottom side
(the cover is fixed by magnets).

Fig. 120

Fig. 121

-74-

4. Step

Fold the pivot arm upwards again.

5. Step

At first, remove the plug of the
power cable and afterwards all other
plugs.

Attention!

Fig. 122

The plugs are secured with a
screw socket which has to be
unlocked by turning it counter
clockwise. Remove the plugs
afterwards only.

6. Step

Remove the nut of the ground straps
and then pull off all the ground
straps.

Fig. 123

Fig. 124

-75-

7. Step

Remove the 4 screws on the side of
the control unit.

8. Step

Now, remove carefully the cables
on the rear side of the control
unit.

Attention!

Fig. 125

For disconnecting the plug of the

Fig. 126

black/red cable, you have to
pull the flap of the plug.

9. 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 (127a)
located on the front side of the control

unit.

Fig. 127

127a

Attention!

The plug-in connection is positioned relative to one another through a plastic
nose and groove. When having the correct position, connect the plug and
secure it by the screw socket. This screw socket has to be closed by turning it
clockwise. Only then, the function of the plug-in connection is ensured.

-76-

10.8 Changing the control box display unit

1. Step

At first, remove the control box joystick unit as described in
section 10.7.

2. Step

Drive out the Tool-Lift forwards so

that the cover „display“ can be

disassembled.

Fig. 128

3. Step

Remove the cover „display“ by

pulling on the provided handle holes
diagonally downwards.
(The cover is fixed by magnets).

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. 129

Fig. 130

-77-

5. Step

Remove the 4 screws on the side of

the control unit and…

… remove the control box and

thereby pull the cable carefully

through the cable duct.

Fig. 131

Fig. 132

6. Step

The installation of the control unit is done in the reversed order of the
disassembling.

-78-

10.9 Changing the motor

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
remaining in the strapping system
through the head piece of the
ChainLance and dispose it.

Fig. 133

2. Step

Fold down the pivot arm.

3. Step

Remove the cover „joystick“ by

pulling on the handle holes,
provided at the bottom side (the
cover is fixed by magnets).

Fig. 134

Fig. 135

-79-

4. Step

Fold the pivot arm upwards again.

5. Step

Unscrew the two plugs guided to the
motor from the right side of the
control box „joystick“ unit.

Fig. 136

Attention!

The plugs are secured with a
screw socket which has to be
unlocked by turning it counter
clockwise. Remove the plugs
only afterwards.

Fig. 137

-80-

Fig. 138

6. Step

Remove the 4 screws (139a) on

the motor support plate and …

… remove now the motor

carefully.
Take care not to lose the feather
key (140a).

Fig. 139

139a

Fig. 140

7. Step

140a

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. When having the correct position, connect the plug and
secure it by the screw socket. This screw socket has to be closed by turning it
clockwise. Only then, the function of the plug-in connection is ensured.

The feather key at the motor output has to be positioned exactly to the
groove in the shaft.

-81-

10.10 Cleaning/replacing the tension wheel
at the sealing head

Cleaning the tension wheel without
disassembling

 There is an access hole (141a) in the

protection cover below the motor. The
tension wheel and the tooth plate can be
cleaned with compressed air through this
access hole.

 When heavily soiled, the tension wheel

has to be disassembled.

Warning !

Wear eye protection when cleaning with compressed air!

Cleaning the tension wheel with

disassembling / replacing the tension wheel

Release 4 cylinder screws (Torx) (4),
remove strap guide rear (5) and side cover (3).

 Remove tension wheel (1) carefully.
 Remove ball bearing (2) from tension wheel.
 Clean the tension wheel with compressed air.

Fig. 141

141a

 If the tension wheel teeth are covered with
heavy dirt they must be cleaned carefully with the wire brush (6)
supplied.
 Check tension wheel for worn teeth. If a few teeth are broken, replace

tension wheel (observe direction, see arrow).

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Fig. 142

 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. A hard object, such as a screwdriver or
similar, must not be used under any circumstances whatsoever for cleaning.
The tension wheel must not be cleaned in an installed state when it is
rotating. Risk of breakage teeth.

10.11 Cleaning/replacing the tooth plate at
the sealing head

Warning !

Wear eye protection when cleaning with compressed air!

 Remove pan head screw (1).
 Lift the rocker lever towards the handle

and remove tooth plate (2).

 Clean tooth plate with compressed air.
 If the tooth plate teeth are covered with

heavy dirt, they must be cleaned carefully with the wire brush supplied.

 Check tooth plate for worn teeth, if necessary, replace tooth plate.
 Installation is done in the reversed order of the disassembling.

 Secure pan head screw (1) with screw locking varnish "medium-tight“.

Fig. 143

Attention!

The tooth plate (2) must be placed so that it can move freely in the rocker!

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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) and replace knife.

 Installation is done in the reversed order of the disassembling.
 Before installing the knife (1), check that the compression spring (7) on

top of the knife is still mounted.

Fig. 144

 Secure the pan head screw (5) with screw locking varnish "medium-tight“.

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11. Software Updates

Attention!

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“ in accordance with the instructions in point 10.8, step

1 to 3.

2. Step

Remove the rubber plugs from the USB-ports (145a/146a).

Fig. 145 Fig. 146

145a

146a

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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. 147

4. Step

Firmware chain axis:
After unlocking, insert the USB
stick with the current firmware
into the USB port of the control

unit „joystick“ and start the
update by confirming with „OK“.

As soon as the update was

finished, the new version will be
shown on the display!

Fig. 148

5. Step

Firmware display:
After unlocking, insert the USB
stick with the current firmware
into the USB port of the control

unit „display“ and start the

update by confirming with „OK“.

Proceed further as described on
page 87.

Fig. 149

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6. Step

Procedure of the update “display”:

After confirmation, the start center appears.

Select now „settings“.

Click on the file „Service & Commissioning“.

Select then „Projekt Download“.

HMI Touchpanel

Start Center

Settings

Service &

Commissioning

Projekt

Download

Search your USB stick by clicking on „Search“. When
the USB stick was found, click on next „>“ on the

bottom right of the page.

Let the system search for the upload by clicking

„Search“. When the upload was found, click on

next „>“ on the bottom right of the page.

At point 3/4 nothing has to be selected. Go to next

„>“ on the bottom right of the page.

After confirming with „Accept“, the upload will be

started and installed automatically. Once the
installation was finished, you will return again to the
„menu“ where the new version will be displayed.

1/4 USB (2.0)

Search

2/4 Projects

Search

3/4 Check befor

Loading

4/4 Accept,

Start Upload

Fig. 150

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12. Spare parts list

Spare parts lists with explosion drawings as well as the wiring plan and details
about the updates of the control units can be found on our website

www.ergopack.de under “Downloads“ as a PDF file.

Please make a note of the type and serial number of your strapping system
for the selection of your proper spare parts list.

Please always state the number of the article when ordering spare parts (not
the position number of the part on the explosions drawing).

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13.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.
The duty wearing a helmet can be avoided, if the user was
taught about the risk of injury by the plastic chain falling and
that particular caution is required.
This instructions have to be recorded in writing.

Protect yourself!
Wear eye and hand protection (cut
proof gloves) and also safety shoes.

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14. 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.

Work area safety

a) Keep the work area clean and well lit. Cluttered or dark areas invite

accidents.

b) Do not operate power tools in explosive atmospheres, such as in the

presence of flammable liquids, gases or dust. Power tools create sparks

which may ignite the dust or fumes.

c) Keep children and bystanders away while operating a power tool.

Distractions can cause you to lose control.

Electrical safety

a) Power tool plugs must match the outlet. Never modify the plug in any

way. Do not use any adapter plugs with earthed (grounded) power
tools. Unmodified plugs and matching outlets will reduce the risk of

electric shock.

b) Avoid body contact with earthed or grounded surfaces such as pipes,

radiators, ranges and refrigerators. There is an increased risk of electric

shock if your body is earthed or grounded.

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c) 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. Damaged or entangled cords increase the risk of

electric shock.

e) When operating a power tool outdoors, use an extension cord suitable

for outdoor use. Use of a cord suitable for outdoor use reduces the risk

of electric shock.

f) If operating a power tool in a damp location is unavoidable, use a

residual current device (RCD) protected supply. Use of an RCD reduces

the risk of electric shock.

Personal safety
a) Stay alert, watch what you are doing and use common sense when

operating a power tool. Do not use a power tool while you are tired or

under the influence of drugs, alcohol or medication. A moment of

inattention while operating power tools may result in serious personal
injury.

b) Use personal protective equipment. Always wear eye protection.

Protective equipment such as dust masks, non-skid safety shoes, hard hat
or hearing protection used for appropriate conditions will reduce the risk
of personal injuries.

c) Prevent unintentional starting. Ensure the switch is in the off-position

before connecting to the power source and/or battery pack, picking up
or carrying the tool. Carrying power tools with your finger on the switch

or energising power tools that have the switch on, invites accidents.

d) Remove any adjusting key or wrench before turning the power tool on.

A wrench or a key left attached to a rotating part of the power tool may
result in personal injury.

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e) Do not overreach. Keep proper footing and balance at all times. This

enables better control of the power tool in unexpected situations.

f) 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.

g) If devices are provided for the connection of dust extraction and

collection facilities, ensure these are connected and properly used. Use

of dust collection can reduce dust-related hazards.

Power tool use and care
a) Do not force the power tool. Use the correct power tool for your

application. The correct power tool will do the job better and safer at the

rate for which it was designed.

b) Do not use any power tool with a defective switch. Any power tool that

can not be controlled with the switch is dangerous and must be repaired.

c) Disconnect the plug from the power source and/or the battery pack

from the power tool before making any adjustments, changing
accessories, or storing power tools. Such preventive safety measures

reduce the risk of starting the power tool accidentally.

d) Store power tools out of the reach of children and do not allow persons

unfamiliar with the power tool or these instructions to operate the
power tool. Power tools are dangerous in the hands of untrained

operators.

e) Maintain power tools. Check for misalignment or binding of moving

parts, breakage of parts and any other condition that may affect the

power tool‘s operation. If damaged, have the power tool repaired

before use. Many accidents are caused by poorly maintained power
tools.

f) Keep cutting tools sharp and clean. Properly maintained cutting tools

with sharp cutting edges are less likely to bind and are easier to control.

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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.

Battery tool use and care
a) Recharge the battery packs only with the charger specified by the

manufacturer. A charger that is suitable for one type of battery pack may

create a risk of fire when used with another battery pack.

b) Use power tools only with specifically designated battery packs. Use of

any other battery packs may create risk of injury and fire.

c) When the battery pack is not in use, keep it away from metal objects,

like paper clips, coins, keys, nails, screws or other small metal objects,
that can make a connection from one terminal to another. Shorting the

battery terminals together may cause burns or fire.

d) Under abusive conditions, liquid may be ejected from the battery; avoid

contact. If contact accidentally occurs, flush with water. If liquid
contacts eyes, additionally seek medical help. Liquid ejected from the

battery may cause irritation or burns.

Service
a) Have your power tool serviced by a qualified repair person using only

identical replacement parts. This will ensure that the safety of the power

tool is maintained.

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