TABLE OF CONTENTS UPF

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2 TABLE OF CONTENTS Section 1 Table Of Contents Section 2 Revision Control Section 2 Technical and Field Assistance Section 3 Warranty Section 4 Description of the UPF-2420 Flap Folder Section 5 Important Safeguards Section 6 Specifications Section 7 Set-Up Procedures Section 8 Operating Instructions UPF

3 REVISION CONTROL REV00 REV01 REVISION CONTROL Initial Release Updated Warranty UPF

4 TECHNICAL ASSISTANCE Technical Support This is the Interpack Model UPF-2420 Uniform Pneumatic Flap Folder you ordered. It has been set up and tested in our factor. If any problems occur when setting up or operating this equipment, please contact the authorized distributor from where you purchased this item. Should you need to contact Interpack Technical Support, please have the Pneumatic Flap Folder model number and serial number available. This information can be found on the nameplate of the side panel of the machine. Interpack Technical Support is available during normal business hours (Eastern Time). PHONE x4 If you have a technical question that does not require an immediate response, you may contact Interpack by fax. FAX Replacement Parts Order parts by item number, part name and quantity required. Replacement parts are available from your Authorized Interpack Distributor exclusively. Should you require assistance selecting the correct part, you may call: Intertape Polymer Group Tel: Option 3 Fax: MODEL: SERIAL NUMBER: DISTRIBUTOR PURCHASED FROM: DATE OF PURCHASE: UPF

5 FIELD SERVICE ASSISTANCE This machine is designed to provide years of trouble free operation. If any problems arise with this machine during the normal course of operation, your properly trained and qualified internal service personnel should be able to repair any issues after consulting the Trouble Shooting section of this manual. However, after consulting the Trouble Shooting Section of this manual, you cannot remedy the problem, customer paid service support is available from your Authorized Interpack Distributor. UPF

6 WARRANTY EQUIPMENT WARRANTY AND LIMITED REMEDY: The following warranty is made in lieu of all other warranties, express or implied, including, but not limited to, the implied warranty of merchantability, the implied warranty of fitness for a purpose, and any implied warranty arising out of a course of dealing, a custom or usage of trade. Any modification of the Tape Heads, Case Tapers or Case Erectors shall make this warranty null and void. Intertape sells its Interpack Tape Heads, Case Tapers and Case Erectors with the following warranties: 1. The HSD 2000 Tape Heads' knife blades, springs and wipe down rollers will be free from all defects for a period of ninety (90) days. 2. All other HSD 2000 Tape Head parts will be free from all defects for one (1) year after delivery. 3. Drive Belts will be free from defects for ninety (90) days after delivery. 4. The Gear Motors will be free from defects for one (1) year after delivery. 5. All other components for Case Tapers and Case Erectors will be free from defects for one (1) year after delivery. If any part is proven defective within its warranty period, then the exclusive remedy and Intertape s and the seller's sole obligation shall be, at Intertape s option, to repair or replace the part, provided the defective part is returned immediately to Intertape s factory or an authorized service station designated by Intertape. A part will be presumed to have become defective after its warranty period unless the part is received or Intertape is notified of the problem no later than five (5) calendar days after the warranty period. If Intertape is unable to repair or replace the part within a reasonable time, then Intertape, at its option, will replace the equipment or refund the purchase price. Intertape shall have no obligation to install the repaired or replacement part. Intertape shall have no obligation to provide or pay for the labor required to install the repaired or replacement part. Intertape shall have no obligation to repair or replace (1) those parts failing due to: operator misuse, carelessness, or due to any accidental cause other than equipment failure, or (2) parts 1. Failure or damage is due to misapplication, lack of proper maintenance, abuse, improper installation or abnormal conditions such as temperature, moisture, dirt or corrosive matter, etc. 2. Failure due to inadequate cleaning, improper operating environment, improper utilities or operator error. 3. Failure due to operations above the rated capacities, or in any other improper manner, either intentional or otherwise. 4. Failure is due to equipment, which has been altered by anyone other than an authorized representative of Intertape Polymer Group. 5. Failure is due to an attempt by the purchaser to correct alleged defective equipment. In this event the purchaser is responsible for all expenses incurred. LIMITATION OF LIABILITY: Intertape and seller shall not be liable for direct, indirect, special, incidental or consequential damages based upon breach of warranty, breach of contract, negligence, strict liability or any other legal theory. Additionally, Intertape and seller disclaim all liability if the Tape Heads, Case Tapers or Case Erectors are modified in any way. The foregoing Equipment Warranty and Limited Remedy and Limitation of Liability may be changed only by written agreement signed by authorized officers of Intertape and seller. UPF

7 DESCRIPTION OF UPF-2420 PNEUMATIC FLAP FOLDER Figure 1 Interpack Pneumatic Flap Folding machines are designed to convert a basic uniform top and bottom case sealer into a uniform semi-automatic case packing system. In one process, the operator can form, fold, pack and seal a corrugated case. The labor intensive costs of forming and packing cases are no longer necessary as the UPF 2420 will provide measurable productivity increases. The UPF 2420 requires a simple 2-step case size setup process for most case sizes to assure user friendliness. After forming, the case is retained for case packing. After packing, the case can be inserted into a semi-automatic uniform case sealer or delivered to a take away conveyor leading to a fully automatic uniform case sealer. UPF

8 Important Safeguards There are a number of safety labels used on Interpack Carton Sealers. These labels are placed at different locations (refer to Figure 2) on the machine to warn operators and service personnel o f pos sible d angers. P lease r ead t he l abels on t he machine and the f ollowing safety precautions before using the machine. Read this manual for other important safety operating and service information. Only trained personnel are to operate machine. Only fully qualified technicians are to service this machine. Wear safety glasses. Shut off power to machine (where applicable) before adjusting machine. Disconnect electrical power and compressed air (where applicable) before servicing. Follow Lock Out / Tag Out Procedures BEFORE servicing any machinery. All covers and guards must be in place before operating. Stay clear of moving parts. Never operate the machine with guards off. Note: Should any of the safety labels placed on the Flap Folder be damaged or destroyed, replacements are available through your distributor. UPF

9 Important Safeguards Figure 2 UPF

10 Important Safeguards There Are A Number Of Safety Labels Used On Intertape Machinery. The illustrated label as shown is attached to various areas on the machine. The label warns operators and service personnel of the existence of pinch points during machine operation. The machine should never be operated with any covers or guards removed. Turn air and electrical (where applicable) supplies off before servicing the machine. The label shown alerts the operator of the use of compressed air through the machine. Label is attached to the panel that allows access to the pneumatic manifold and valves. Proper lock-out/tagout procedures must be in place before accessing this panel. UPF

11 Important Safeguards Explanation of Signal Word Consequences Warning: Indicates A Potentially Hazardous Situation, Which If Not Avoided Could Result In Death Or Serious Injury Or Property Damage Caution: Indicates A Potentially Hazardous Situation, Which If Not Avoided Could Result In Minor Or Moderate Injury Or Property Damage Warning To Reduce The Risk Associated With Mechanical And Electrical Hazards: a. Read, Understand, And Follow All Safety And Operating Instructions Before Operating Or Servicing The Equipment. b. Allow Only Properly Trained And Qualified Personnel To Operate And Service This Equipment. To Reduce The Risk Associated With Pinches, Entanglement And Hazardous Voltage: a. Turn Electrical Or Air Supply Off And Disconnect Before Performing Any Adjustments, Maintenance Or Servicing The Machine. To Reduce The Risk Associated With Pinches And Entanglement Hazards: a. Do Not Leave The Machine Running While Unattended. b. Turn The Machine Off When Not In Use. c. Never Attempt To Work On Any Part Of The Machine, Load Tape, Or Remove Jammed Boxes From The Machine While The Machine Is Running. To Reduce The Risk Associated With Hazardous Voltage: a. Position Electrical Or Air Cord Away From Foot And Vehicle Traffic. To Reduce The Risk Associated With Fire And Explosion Hazards: a. Do Not Operate This Equipment In Potentially Flammable/Explosive Environments. To Reduce The Risk Associated With Muscle Strain: a. Use The Appropriate Rigging And Material Handling Equipment When Lifting Or Repositioning This Equipment. Caution To Reduce The Risk Associated With Pinch Hazards: a. Keep Hands Clear Of The Inside Of Equipment While Boxes Are Being Processed. b. Keep Hands, Hair, Loose Clothing, And Jewelry Away From Box Compression Rollers. UPF

12 Important Safeguards Warning To Reduce The Risk Associated With Mechanical and Pneumatic Hazards: a. Allow Only Properly Trained And Qualified Personnel To Operate And Service This Equipment. Operator Skill Level Descriptions Skill A : Machine Operator This Operator Is Trained To Use The Machine With The Machine Controls, To Feed Cases Into The Machine, Make Adjustment For Different Case Sizes, And To Start, Stop, And To Re-Start Production. Important: The Area Supervisor Must Ensure That The Operator Has Been Properly Trained On All Machine Functions Before Operating The Machine. Skill B Mechanical Maintenance Technician This Technician Is Trained To Use The Machine As The Machine Operator And In Addition Is Able To Work With The Safety Protection Disconnected, To Check And Adjust Mechanical Components, To Perform Maintenance Operations And Repair The Machine. He Is Not Allowed To Work On Live Pneumatic Components. Skill C Electrical Maintenance Technician This Technician Is Trained To Use The Machine As The Machine Operator And In Addition Is Able To Work With The Safety Protection Disconnected, To Check And Adjust Mechanical Components, To Perform Maintenance Operations And Repair The Machine. He Is Allowed To Work On Live Pneumatic Panels, Valves And Control Equipment. Skill D Manufacturers Technician Skilled Technician Sent By The Manufacturer Or Its Agent To Perform Complex Repairs Or Modifications, When Agreed With The Customer. UPF

13 Important Safeguards Operators Skill Level Required To Perform The Following Tasks On The Machine Operation Machine Installation & Set Up Adjusting Case Size Machine Condition Running With Safety Protections Disabled Stopped By Pressing The Emergency Stop Button Operator Skill Level Number Of Operators B & C 2 A 1 Ordinary Maintenance Pneumatics Disconnected B 1 Extraordinary Mechanical Maintenance Running With Safety Protections Disabled D 1 UPF

14 SPECIFICATIONS UPF-2420 Machine Dimensions Machine Weight: 450 lbs. (204 kg) crated Figure-3 UPF

15 SPECIFICATIONS USA 2024-SB Machine Components UPM0043 Figure-4 UPF

16 SPECIFICATIONS 1. Operating Conditions Use in a dry, relatively clean environment at 40 to 105 F (5 to 40 C) with clean dry cartons. Note: Machine should not be washed down or subjected to conditions causing condensation on components. 2. Power Requirements Compressed Air 90PSI, 8CFM 3. Carton Specifications Type Regular Slotted Containers (RSC) Material 125 To 275 PSI Bursting Test, Single Or Double Wall B Or C Flutes. Weight 0 to 40 lbs. (0 to 18 kg) Size The case sealer can accommodate most cartons within the size ranges listed below. Case Processing Stability Carton Size Specifications Carton Size Length Width Height Minimum Maximum 178mm 7 610mm mm For optimal performance, the cases should be stable when processing through the machine. Unstable cases may tilt or collapse upon contact with the flap folders causing the machine to jam mm 20 89mm 3.5 Infinite UPF

17 SET-UP PROCEDURES 1. Receiving and Handling The machine is shipped to the customer fixed to a pallet. The machine is enclosed with either a corrugated sleeve and cap or an HSC corrugated box. The sequence below is step by step instructions to remove all packing materials. Remove the strapping securing the corrugated sleeve and cap or HSC corrugated box to the pallet. Lift off the cap and corrugated sleeve or HSC corrugated box. Remove protective wrapping from machine. Remove or relocate all securing devices such as tie wraps or locking collars. Remove the mounting bolts, which secure the machine to the shipping pallet. Remove machine from the pallet and re-locate to an area to prepare for final installation. Figure-5 All contents must be verified upon reception. machine. The following items are included with each UPF-2420 Operators Manual Machine Note: After Unpacking The Equipment, Look For Any Damage That May Have Occurred During Shipping. Should The Machine Be Damaged, File A Claim With The Transport Company And Notify Your Authorized Intertape Distributor. UPF

18 SET-UP PROCEDURES 2. Caster Installation (If Purchased) Caster Installation Requires Raising The Machine To Access The Bottom Of Each Leg. Please Follow All Possible Safety Procedures Prior To And During This Process A. With A Fork Lift, Raise The Machine To Allow Access To The Bottom Of Each Leg B. Screw In A Caster Into A Leg Until It Is Firmly Seated To The Bottom Of The Leg. C. Tighten Each Caster. D. Do Not Adjust The Conveyor Height By Adjusting The Caster. Proper Conveyor Height Must Be Achieved By Adjusting The Leg Extension Of Each Leg. (See Figure-6) Figure-6 UPF

19 SET-UP PROCEDURES 3. Machine Height Adjustment Machine Height Adjustment Requires Raising The Machine To Adjust Each Leg. Please Follow All Possible Safety Procedures Prior To And During This Process The Pneumatic Flap Folder must be installed on near level ground. Use the adjustable legs to ensure that the machine is level and firmly on the ground (no rocking). Adjust the leg height with the four (4) telescopic extension legs to accommodate conveyor heights from 24 to 33 ½ inches. To adjust the machine height, lift the machine to give ample room to extend the legs. Using a 6mm hex key, loosen two (2) M8 socket head bolts per leg. Adjust the legs to the desired conveyor height and retighten the bolts. Etched lines on the legs ease leveling. Figure 7 UPF

20 SET-UP PROCEDURES 4. Machine Final Assembly The machine is shipped with all adjustment handles installed. Location of Adjustment Handles. Length Adjustment Figure-8 Width Adjustment UPF

21 SET-UP PROCEDURES 5. Connecting Utilities a. Pneumatic Regulator Figure-9 The UPF-2420 Uniform Flap Folder comes with a regulator that has a male quick disconnect adaptor. To operate the machine, a connection of clean dry compressed air will be needed. Before the machine is plugged into the air source, ensure that all materials are removed from the machine. UPF

22 OPERATING INSTRUCTIONS Case Size Set Up Functions Major Flap Folder Adjustment Length Adjustment Reset Button Width Adjustment E-Stop Button Figure-10 UPF

23 OPERATING INSTRUCTIONS Make sure the machine is off and the air has been disconnected before case size adjustments. 1. Initial Condition Figure-11 Figure-12 a. Open the side squeezers as shown in Figure-11. b. Adjust box support towards front of machine as shown in Figure Preparation Of Case To Be Processed Figure-13 a. Box Unfolding i. Unfold box from flat position as shown in Figure-13. UPF

24 OPERATING INSTRUCTIONS 3. Case Width Adjustment Figure-14 Figure-15 a. Insert the case into the machine as shown on Figure 14; if the box will not fit adjust box length as noted on page 24. b. Turn case width handle until side squeezer panels contact case as shown in Figure 15. Panels should contact the case firmly enough so case is UPF

25 OPERATING INSTRUCTIONS 4. Case Length Adjustment a. Turn case length handle as shown in Figure-16 until box length support contacts case. b. Remove box and proceed to next step. Figure Top Squeezer Adjustment Adjustment Screw a. Bring out the main box flap folders and make sure they have a clear path to actuate. The rollers can be adjusted by loosening the M8 bolt using a 6m hex key and sliding assembly to make it shorter or longer. Shown in Figure 17. Figure-17 UPF

26 OPERATING INSTRUCTIONS 6. Power On. a. Rotate The E Stop Clockwise 1/4 th Turn To Reset The Knob As Shown In Figure-18. b. Push The Yellow Reset Button To Start The Machine. Figure Contact Points. Side of Box Contact Point a. To properly activate flap folding mechanism, all three contact points must be made. b. Refer to Figure-19 for location of contact points. Major Flap Contact Points Figure-19 UPF

27 1 2 3 A - 1

28 ITEM PART # DESCRIPTION QTY. 1 U Side Frame 1 2 U Center Frame 1 3 R MI1 Pneumatic 1 A - 2

29 2 3 1 A - 3

30 ITEM PART # DESCRIPTION QTY. 1 U Centering Assembly 1 2 A1686 Right Folding Assembly 1 3 A1687 Left Folding Assembly 1 A - 4

31 A - 5

32 ITEM PART # DESCRIPTION QTY. 1 U Length Adjustment Seat 1 2 U Slide Rail Cylinder Piston Cylinder Stocktail 1 5 U Frame 1 6 ROS-0202 Shaft 2 7 ROL-0187 Roller 2 8 E Roller Cap 4 9 SF25x732L Block Shaft 2 10 LM 25UU Linear Ball Bearing A-203 Linear Bearing Block 4 12 B27.7M - 3BM1-40 Internal Ring A-204A Shaft Mount A-204A MI Shaft Mount 1 15 U Folding Arm Assembly 1 16 UF6341 SS FW M UF6363 LW M UF3179 SS SHCS M6-1 x 20mm 8 A - 6

33 A - 7

34 ITEM PART # DESCRIPTION QTY. 1 U A Front Frame 1 2 U B Pneumatic Box 1 3 U Pneumatic Box Cover 1 4 U Cover 1 5 R Emergency STOP controller 1 6 R Reset controller 1 7 R Reset 1 8 r Emergency STOP 1 A - 8

35 A - 9

36 ITEM PART DESCRIPTION QTY. 1 8A-201 Center Plate 1 2 8A-202 Actuating Arms 4 3 U Shaft Bearing ZZ Ball Bearing ZZ Ball bearing 2 6 8A-209A Handle Block 1 7 M1085R00 Handle 1 8 U Gear Shaft 1 9 U Drive Shaft 1 10 UCPA203 Shaft Fitting 2 11 E Shaft Block 2 12 RS Gear x5x25 5x5x25 Key 4 14 JIS Spur Gear A-211 Roller 4 16 C Bushing 8 17 S17 Internal Ring 4 18 MSB10-16 Stripper Bolt x5x7L Key A-206A Shaft 1 21 RS40 Chain 1 A - 10

37 A - 11

38 ITEM PART # DESCRIPTION QTY. 1 A1689 FRAME ASS'Y 1 2 U COVER 1 3 A1688 SQUEEZER ASSEMBLY 1 4 U MI MAJOR FOLDING ASS'Y 1 5 U BOTTOM SENSOR ASS'Y 1 A - 12

39 A - 13

40 ITEM PART # DESCRIPTION QTY. 1 U MI FRAME 1 2 U COVER 1 3 A1670 SQUEEZER ASSEMBLY 1 4 U MAJOR FOLDING ASS'Y 1 5 U BOTTOM SENSOR ASS'Y 1 A - 14

41 A - 15

42 ITEM PART # DESCRIPTION QTY. 1 U Support Plate 1 2 U MI Squeezer Plate 1 3 U Spring Block 2 4 U Block 2 5 G79803I Roller 2 6 MSB10-10 Stripper Bolt 2 7 MSB 0.375x0.625Lx TNW-30 Threaded Attachment 2 9 M10*19*1t M10 FW 2 10 F3M8 Spacer 2 11 CS Compression Spring 2 12 U A MI Squeezer Plate 1 A - 16

43 A - 17

44 ITEM PART # DESCRIPTION QTY. 1 U A-2 Support 2 2 U B Connector 1 3 U A-1 MI Shaft 1x1x32 in 1 4 8A-706 Bushing ZZ Ball Bearing 4 6 U MI Push Support 1 7 U Pin 4 8 G79966I Roller Square Nut 1 10 R Piston 1 11 MSB10-20 Stripper Bolt 1 12 MSB08-10 Stripper Bolt 7 13 Q Bearing Piston Tailstock 1 15 UF6387 M x 40 SHCS 1 A - 18

45 A - 19

46 ITEM PART # DESCRIPTION QTY. 1 SF16X0320L(2-M8) Shaft 2 2 8A-402 Shaft Block 1 3 LM 16LUU Shaft Bearing 2 4 U Flap 1 5 U MI Plate 1 6 8A-404 Shaft Support 1 7 8A-411 Flap Attachment Block 1 8 U Square Bar 1 9 C Bushing 2 10 U Attachment Block 1 11 U Paddle 1 12 CF8 Threaded Attachment 2 13 U Flap Support 1 14 U Flap 1 15 CUG Flap Shaft 2 16 Q L Bearing 2 17 Q Ball Bearing 1 18 U Translational Beam 1 19 U Translational beam MI 1 20 U Spacer 2 21 B27.7M - 3AM1-8 Ring Tailstock 1 23 R x40L Piston Spring Actuator 1 25 U MI L Bracket 1 26 POS6 Fish Eye Bearing 1 A - 20

47 A - 21

48 ITEM PART # DESCRIPTION QTY. 1 U Support Plate 1 2 U Spring Block 2 3 U Attachment Bar 1 4 U Block 2 5 G79803I Roller 2 6 MSB10-10 Stripper Bolt 2 7 MSB 0.375x0.625Lx TNW-30 Threaded Attachment 2 9 M10*19*1t M10 FW 2 10 F3M8 Spacer 2 11 U A Attachment Bar 1 12 CS Compression Spring 2 A - 22

49 A - 23

50 ITEM PART # DESCRIPTION QTY. 1 U A-1 Square Bar 1 2 U A-2 Support 2 3 U B Connector ZZ Ball Bearing 4 5 8A-706 Bushing 2 6 U Roller Attachment Plate 1 7 G79966I Roller 7 8 MSB08-10 Stripper Bolt 7 9 MSB10-20 Stripper Bolt 1 10 R Piston Piston Tailstock Square Nut 1 13 PHSC10 Pivot Bearing 1 14 Q Bearing 1 15 EZ-030 Bushing 3 16 U Pin 3 17 UF6387 M x 40 SHCS 1 A - 24

51 A - 25

52 ITEM PART # DESCRIPTION QTY. 1 U Adjustment Beam Attachment 1 2 U MI Flap Assembly Plate 1 3 8A-411-MI Pivot Assembly Attachment Block 1 4 U MI Flap Adjustment Plate 1 5 B27.7M - 3AM1-8 Ring Spring Actuator 1 7 U Shaft Block Attachment Plate 1 8 R x40L Piston 1 9 8A-402 Shaft Block 1 10 SF16X0320L(2-M8) Shaft 2 11 LM 16LUU Shaft Bearing 2 12 U Square Bar 1 13 C Bushing A-404 Shaft Support 1 15 U Attachment Block 1 16 U Paddle 1 17 U Adjustment beam MI 1 18 U Spacer 2 19 U Adjustment Beam 1 20 CF8 Threaded Attachment 2 21 Q L Bearing 2 22 Q Ball Bearing 1 23 U Flap 1 24 CUG Flap Shaft Tailstock 1 26 POS6 Fish Eye Bearing 1 A - 26

53 A - 27

54 ITEM PART # DESCRIPTION QTY. 1 U Frame 1 2 U Sliding Frame 1 3 U Leg Extension 4 4 8A-106A Leg Friction Plate 4 5 U Rear Cover 1 6 U Front Frame Assembly 1 7 8A-204A MI Shaft Mount 1 8 8A-204A Shaft Mount 1 9 UF0867 LW M UF1821 FW M UF0865 SHCS M X 25mm 8 A - 28

55 A - 29

56 ITEM PART # DESCRIPTION QTY. 1 U A Adjustment Seat 1 2 8A-505 Pin 1 3 8A-506 Adjusting Flap 1 4 8A-507 Bushing 2 5 8A-513 Spacer Sleeve 2 6 8A-514 Shaft 1 7 EZ-003 Bearing 1 8 8A-511 Folding Flap 1 9 EZ-030 Handle Bushing 1 10 LIH0902 Piston Fitting Cylinder Piston M16 nut 1 13 LFW-1015 Drymet FLW 1 14 E8 Ext Ring M B-M830 Handle 1 16 U Plastic sliding rail 2 17 U Plastic slider 1 18 U Plate 1 19 U Handle Shaft 1 20 UF6341 SS FW M UF6363 LW M UF3183 SS SHCS M6-1 x 12mm 4 23 UF6340 SS FW M UF7023 LW 5MM 2 25 UF3148 M5-0.8 x 16 SHCS 2 26 UF4252 BHCS M10-1.5x20mm 2 27 UF6412 SHCS M5-0.8 x UF7015 SS FW M UF0302 SS HHCS M x UF3744 SS HNR M10 x UF7003 SS SHCS M5-0.8 x 12mm 6 32 UF3818 EXT. RETAINING RING 8mm 2 A - 30