Fully-Auto: Mercury Transit
Fully-Auto: Mercury Transit
Fully-Auto: Mercury Transit
MERCURY TRANSIT
TP-702
TP-702B (Belt-driven table)
TP-702BP (Belt-driven table with compression press)
TP-702B
TP-702BP
Original Instruction
CONTENTS
PART I
3.4 Installation................................................................................A14
Connector) ................................................................................A16
5. Adjustments ......................................................................................A26
6. Troubleshooting ................................................................................A35
7. Maintenance ......................................................................................A38
PART II
-A1-
1.3 Safety Instructions Governing Specific Operational Phases
Avoid unsafe operation of the equipment.
The machine is only to be operated when it is in good running order. Only operate the
equipment in a safe manner; all protective and safety devices must be in place and fully
functional. This includes removable safety devices, emergency shut-off equipment,
noise-protection devices and exhaust fans.
The machine is to be checked for damage and defects at least once each work shift. Any
changes, including the working behavior of the machine, are to be reported immediately.
If necessary, the machine is to be stopped and locked-out immediately.
In case of a malfunction, the strapping machine is to be immediately stopped and
locked-out until the fault has been eliminated.
Before starting the strapping machine, make sure that the area is clear and safe.
Operating personnel needs to be well trained before executing special operations and
maintenance work; this work needs to be done with the proper supervision.
Always check and tighten connections after maintenance or repair.
After completing maintenance or repair, all safety devices must be replaced and checked
for functionality before operating the equipment.
To minimize the environmental impact, all consumables and replaced parts must be
disposed of safely.
Before starting the machine, check that the accessories have been stowed away safely.
Avoid operating the machine in a fashion that could upset its stability.
-A2-
1.4 Warning of Electrical Dangers
Immediately remove power to the machine in case of trouble in the electrical system.
Replace a fuse with one with the same style and ratings; pay particular attention to
matching the specified current.
Any electrical work performed on the equipment must be conducted by a skilled
electrician or under the supervision of a skilled electrician. All work must be observed
good electrical engineering practice and follow safety rules and local wiring standards.
Inspect the electrical equipment of the machine at regular intervals. Tighten any loose
connections. Check wiring for scorch marks; replace scorched wiring and determine and
correct the reason for the overheating.
When working on live equipment, ensure that a second person is available to cut power
in case of an emergency. When appropriate, secure the working area with safety tape
and a warning sign. Use insulated tools for electrical work.
Before working on high-voltage assemblies, turn off the power supply. Carefully
discharge the supply cable and short-circuit any energy-storage components such as
capacitors.
If the equipment was moved, carefully refit and refasten all parts removed for transport
before reapplying power.
Before moving the machine, remember to disconnect the power cable.
DANGER!
Improper installation of the grounding can result in electrocution.
-A3-
1.6 Before Operating
Read the instruction manual before operating the machine for your safety.
Wear eye protection and safety gloves before operating this machine.
Eye protection must be worn Safety gloves must be worn Throw out the spacer
from the Reel
Please take out the spacer that between the Reel Outer Flange and Inner Flange when
you install the machine to prevent the machine malfunctions.
Verify that the power line voltage is correct.
The machine must be properly grounded to avoid a shock hazard. All wiring must be
in accordance with local wiring standards.
The strapping machine can only be operated with polypropylene (PP) strapping;
do not use polyester (PET) strapping or polyethylene (PE) cord strap.
NOTE: It is normal for the heater tongue to smoke during the sealing operation.
Remove dust and dirt from the unit; pay particular attention to the interior of the arch.
Turn off the power when the machine is not in use.
NOTE: Don’t spray water or liquids for cleaning the strapping machine.
-A4-
1.9 Signs and Symbols
Symbol Meaning
CAUTION!
Don’t access to moving machine parts
when machine is running.
-A5-
2 Machine Information
2.1 Areas of Application
The strapping machine is to be used for strapping packages, cartons, paper boxes,
newspapers, magazines and those materials using a polypropylene (PP) strapping for
stabilizing purposes when in transportation. Be careful for rigidity of working materials,
and don’t try to pack agri-foodstuffs or other such material.
This machine was designed for certain applications only. We strongly recommend that this
machine NOT be modified and/or used for any application other than for which it was
designed. If you have any questions relative to its application DO NOT use the machine
until you have had detail instruction from your dealer.
If there may be harmful gases, fumes or dust generated during heating, user or system
integrator must install exhaust system for the extraction of harmful substances.
The exhaust system shall be positioned according to the vent location. Please refer to
the figure.
The user should refer to a professional expert or relevant authority to prevent the
dangerous substance/ gas emitted by suitable means according to local
/national environmental/health codes/regulations.
-A6-
2.3 Storage
-A7-
2.5 Safety Devices
Danger!
Operate the machine only when all safety
devices are at their place and are functioning
correctly.
The machine has been constructed in accordance with the applicable legal regulations.
The machine is reliable in operation. Nevertheless the machine may constitute a danger
if it is operated in improper or undue condition.
Danger points that cannot be avoided due to equipment design are equipped with safety
devices. If necessary, these points are marked on the machine with warning signs, and in
the manual under working safety instructions.
B6
-A8-
The table top can be opened, if it is necessary to make adjustments inside the machine
during operation, after a strap jam for example. When the table top is opened, safety
switch B6 is activated. This will remove power but the heating element will keeping
heating.
CAUTION!
The heating unit operates at a very high temperature in order to melt the PP
strapping. To prevent burns, avoid contact with this area.
-A9-
2.6.2 Technical Data (TP-702B)
-A10-
2.6.3 Technical Data (TP-702BP)
CAUTION!
Do not carry machine by having the forklift’s fork
under the arch, but only under the machine frame.
Danger to Lift!
Suspend loads can fall down.
By inappropriate mounting or fracture of hoisting device the load
can fall down and cause serious injuries or death.
Do not step under suspended loads!
Use appropriate hoisting devices and fasteners.
-A12-
3.3 Construction Layout
1. Arch
2. Upper Table Front
3. Extension belt-driven table (Option)
4. Reel
5. Transit motor M6
6. Caster (Brake)
7. Reel Brake Release
8. Upstream & downstream interlock (B5)
9. Foot Pedal (Option)
10. Control Panel
11. Power Cord
12. Strapping Head Unit
13. Main Motor M1
14. Feed Motor M2
15. Tension Motor M3
16. Strap Accumulating Motor M4
17. Automatic Feed Motor M5
18. Proximity Sensor SQ1 (For short feed)
19. Proximity Sensor SQ2 (Detects timing lobes on the Position Cam
M7-1-112101)
-A13-
20. Proximity Sensor SQ3 (For home position)
21. Fan (M11)
22. Heater
23. Photo Eye
24. Photo eye (PH3)(Strap amount detection sensor)(Option)
25. Photo eye (PH4)(Energy saving transit with auto sleep mode sensor)(Option)
26. Photo eye (PH5)(Strapping in the centre sensor)(Option)
27. Control box
3.4 Installation
1. Remove the packing material and check if the machine is complete without any
shipping damage.
2. After positioning it, adjust the machine table height to the same level surface of
upstream & downstream equipments by adjusting the machinery pad. After the
adjustments, be sure to tighten all the Nuts.
3. Press button A and make light tree stood. (Light tree is option)
4. The electrical supply cord for the machine must have a minimum cross-section of at
least 1.5 mm2 (16 AWG) and the power cord Length should be less than 500cm.
-A14-
6. Pneumatic connection (for TP-702BP)
The area (A) is necessary for operating strapping machine and changing the strap.
B
A
-A15-
3.6 How to connect Upstream and Downstream Machine (B5 Connector)
Pin1 and Pin 2: It outputs machine signal by giving a "NO" contact. Machine would
send signal to upstream device for entering the package (Refer to B27
Wiring Diagram of PART II).
K3 Relay
Caution:
Mistake the connection (over voltage or current) may damage the K3 relay
Pin 6 and Pin 7: It is for receiving signals to the machine. To receive the signal from the
downstream device for passing through the package after strapping. If
there is no downstream device, machine would not pass through the
package after strapping (Refer to B27 Wiring Diagram of PART II).
Caution:
The downstream signal should be voltage (potential) free, or it will damage the P.C.
Board.
Caution!
If there is no downstream machine, please still plug in the B5 connector to avoid
machine waiting for this signal which will cause the transit belt not running after
the strapping cycle is completed.
-A16-
3.7 Operating Elements
1. Main Power Switch:
Provides the machine with power.
Switch to “1” position for turning the
machine on.
After finishing strapping work, switch it to
“0” to turn off the machine.
9 8
4. Selector Switch
This switch is used to select how many
(1, 2, or N) straps required for each 10 11
package.
The selector switch will function only
13 12
when selector switch is at
position (AUTO).
Note:
When N straps is required for the package.
You need to adjust the timer T2 for next
strapping until photo eye is off. (PH1).
5. Selector Switch
While selector switch is at position
(Manual), table belts will stop running and
the photo cells will not function but the
machine can strap by pushing the
(START) switch.
-A17-
While the selector switch is at position (AUTO), the table belts will run and
photo cells works so when package passes under the arch, the machine will
automatically strap the package.
When the selector switch is at position (TRANSIT), it is for transit (the table
belts will run but the photo cells do not function.
7. :Function Encoder
Turn clockwise or counterclockwise to change strapping settings.
Also, it offers settings for weld cooling time. Other settings can only be changed
by technicians with password.
-A18-
14. Reel Release Switch:
To release the dispenser for easily
taking out the strapping from it.
Polypropylene Strap
Width: 5,6,9,12mm
Thickness: 0.35 -0.65 mm (0.014” – 0.026”)
Strap which has excessive camber as illustrated in figure below cannot be used.
(78.7”)
-A19-
3.8.2 Strap Reel Installation
1. Release the Reel Nut Handle by pressing and turning it to the left.
2. Take out the Outer Flange.
3. Install a new strap coil onto the drum according to the instructions on the reel.
4. Put the Outer Flange back and the Reel Nut Handle. Turning the Reel Nut
Handle to the right to lock it.
5. Remove the protective straps (B) and the stickers (A)
Note:
The Reel Nut Handle is released by turning to the left. Tighten it by pressing and
turning it to the right.
1. Turn the Main Power Switch on the right side of machine to the right (at 1 position),
and press Start Switch. (refer to Fig. a)
2. Press “Reel Release Switch A” (as shown in Fig. a) and pull out around 60cm strap.
(refer to Fig. b)
3. Thread the strap through the Guide Roller B following to the direction showing in
Fig. c.
4. Insert the strap to outlet C (refer to Fig. d).
5. Keep threading until the tip of the strap reaches the Accumulator Main Roller.
6. Lift the lever D and insert strap between the rollers E. Feed strap for around 2-3cm
ahead the rollers. (refer to Fig. e)
-A20-
A
Fig. a.
60cm
Fig. b. Fig. c.
C E
Fig. d. Fig. e.
-A21-
A
B
B
Caution:
If strap is fed more than 6cm ahead the rollers, it could make Auto Strap
Feeding failed.
7. Press Start Switch. Machine will complete the Auto Strap Feeding in 5 sec. and
have the strap feeding to the sealing point.
Caution!
In the process of Auto Strap Feeding, only the Start Switch is functional.
Caution!
The cutting edge of the strap must be free of burrs to avoid failure in Auto
Strap Feeding.
-A22-
4. Operating the Machine
After switching on the strapping machine, heater Switch Main Power Switch to
starts to warm up and LCD display continues to be Position “1”
on until the heater reaches its operating temperature
(about 2 minutes).
Heater warms up and LCD
Caution! display keeps on lightening
Machine will not operate until heater reaches to
operating temperature.
The heater fans continue to run until heater
reaches operating temperature. Ready!
LCD display is off
NOTE!
When operating in soft tension mode, the strap tension
potentiometer does not function.
Attention!
-A23-
4.2 Transit Operation mode
Note !
If there’s no signal from downstream equipment, table belts
would not run.
-A24-
4.4 Function Encoder
Ready
LCD display will show various timers such as
cooling time, timer 1, timer 2…etc. After
pressing the function encoder for over 2 Press encoder
seconds, turn the knob to choose the timer over 2S
needed to be changed. Press this knob to
confirm the timer needed altered and turn it
<- Timer TEC
again to alter the value, and then press it again
to confirm this alteration.
Select Timer and
press encoder
<-
T5: cooling time timer, Range 0-0.6S
<- T5: 0 - 60
T4: Press bar delay time, Range 0-3S
000
Turn encoder to
change the value
Then press encoder
<- T5 : 0 - 60
010
Ready
Finish setting
-A25-
5. Adjustments
The machine has been already well set for storing enough amount of strap in accumulator
Box.
However, some adjustments may be required, depending on the actual quality or thickness
of the strap used.
The strap supply in the accumulator box should be sufficient for about 2-5 strapping
cycle.
(It depends on the package size and the arch size. Fewer cycles are available for bigger
arch or bigger package.)
Caution!
Excessive amount of strap in the Accumulator Box can lead to strap jam (too curved)
and cause feeding problem.
Insufficient amount of strap in the Accumulator Box can lead to short feed problem
or decrease strapping speed.
The adjusting mechanism for amount of strap is inside the machine, at the rear side of
machine.
In case that there is insufficient amount of strap in the Accumulator Box, loosen the Nut A
and turn the Screw Bolt B counterclockwise. After adjustments, be sure to tighten the Nut
A to avoid unstable strap accumulation.
In case that there is excessive amount of strap in the Accumulator Box, loosen the Nut A
and turn the Screw Bolt B clockwise. After adjustments, be sure to tighten the Nut A to
avoid unstable strap accumulation.
-A26-
5.2 Adjustment for Feeding Pressure to the Accumulator Box
The machine has been already well set for enough feeding pressure offering enough
strength for pulling strap from strap coil to accumulator box. It might be necessary for
some adjustments to increase feeding pressure if you are using smooth strap.
When it’s necessary for increasing the feeding pressure, please loosen the Nut A and turn
Nut C upwards to increase the strength of Spring B. Be sure to tighten Nut A by turning
it counterclockwise after adjustments.
A M4 Motor
Caution!
Too much feeding pressure could lead to feeding problem as the strap would be
scraped by the rollers easily as show below.
Insufficient feeding pressure would lead to short feed problem as the strap is
insufficient in the accumulator box.
-A27-
5.3 Adjustment for Heater Temperature
The machine has been already well set for proper heater temperature.
It might be necessary to do some adjustments according to temperature in working
environment, and the quality of PP strap to ensure better sealing efficiency.
Turn ‘’A’’ clockwise to increase the heater temperature and turn it counterclockwise to
decrease the heater temperature.
Adjusting the A (Strap Guide) according to the strap and make sure the width B is
around 0.5mm (0.02”) wider than the strap.
Caution:
If B is too wide, it would lead to sealing problem. However, if it’s too narrow, it
would lead to feeding problem.
-A28-
2. Adjusting “Right Strap Guide”
Loosen the screws on the “Right Strap Guide” and take it out. Then loosen the 2
screws B (HBS0408N) and adjust A according to the strap. Be sure D is about 0.1mm
wider than the strap. After adjustment, tighten screws B and put the “Right Strap
Guide” back.
HBS0408N
M7-2-201400
Caution:
If D is too wide, it would lead to sealing problem. However, if it’s too narrow, it
would lead to feeding problem.
The brush clearance in the left side and upper left should be about the strap width.
The brush clearance in the upper right should be about 2-3mm narrower to the strap.
The brush clearance in upper side of right chute should be the same to the clearance in
right side of upper arch. The brush clearance in the lower right should be 4-5mm
narrower to the strap.
Brush clearance
Note:
The brush clearance could be various according to different package size. The
brush clearance needs to be bigger for not having any effect on reversing especially
when the package size is close to the arch size.
-A29-
4. Adjusting Strap Amount in the Accumulator Box
Different strap widths might have effects on the strap amount in the accumulator box.
Please do the adjustment according to 5.1 if necessary.
The front and rear table top is fixed and you would need to open it by Key for doing
adjustments. The power is shut down once the table is opened as there are safety
switches underneath the table top.
-A30-
1. Adjusting the Pressure for Feeding
The machine is already well set for proper feeding pressure. However, according to
different strap characteristics (such as smoother surface or different thickness), some
adjustments for feeding pressure are still necessary.
If short feed problem happens a lot, and it is a result of improper feeding pressure,
please do the following adjustments:
Loosen Nut B and turn Nut A clockwise to increase the feeding pressure. Or loosen
Nut A and turn Nut B counterclockwise to decrease the feeding pressure. After
adjustments, be sure to tighten these 2 Nuts well.
A
The machine is already well set for proper reversing pressure. However, according to
different strap characteristics (such as smoother surface or different thickness), some
adjustments for reversing pressure are still necessary.
If machine often has incomplete reversing problem, and it is a result of improper
reversing pressure, please do the following adjustments:
Take out the part (TA-073 Spring Hook) from C position to B or A position in order to
increase the reversing pressure.
C -A31-
5.6 Adjustment on Tensioning Rollers for High Tension
The machine is already well set for proper pressure for high tension. However,
according to different strap characteristics (such as smoother surface or different
thickness), some adjustments on pressure for high tension might be necessary.
When insufficient strapping tension occurs even the Soft-High tension switch is on “high”
position and it is a result of pressure for high tension, please turn Nut D clockwise. This
can solve the problem of insufficient strapping tension at high tension and strap slipping
between A & B due to this.
Note:
When the pressure for high tension is set too high, the tension for strapping would
get lower.
-A32-
5.7 Speed and Pressure Adjustment of Press Bar
1. Speed
2. Pressure
-A33-
For doing these adjustments, be sure to lift the Regulator first and then turn it
clockwise to increase the pressure or turn it counterclockwise to decrease the pressure.
Caution:
Regulator D shows the descending pressure only when Press Bar is descending.
If the air pressure is exceed 2 bar, the descending pressure of Press Bar would be
over 250N.
When the descending pressure of Press Bar is over 250N, safety device (such as
Safety Guard) would be necessary according to CE regulation.
If you need to change the bundle flow direction, please do it as following steps:
b. Change the positions of PH1 and reflector to the other side of arch.
c. Adjusting the table belts and make sure that they are in the middle to avoid any
damage to the belts. You could make this adjustment with screws (#50
FMS0560N) showed in Part III P149.
c. Loosen HBS0525N on Press Bar Up Limiter and adjust it to required height. Then
screw HBS0525N by turning it clockwise.
-A34-
6. Troubleshooting
The LCD display would flash and show failure message when machine is not working due to
malfunction.
When Feed jam occurs, press the Start Switch or Foot bar first to let the arch open and
strap comes out of the arch. Hold the strap by left hand and then press the Start
Switch or Foot bar again. Machine would reverse the strap a little bit and cut it, and
then machine would go back to home position and feed again.
If this does not solve the problem, please take out the jammed strap by following
-A35-
steps:
○
B
○
A
If the Feed jam problem still cannot be solved, the following causes have to be
checked as well:
-A36-
c. Other malfunctions:
-A37-
7. Maintenance
Warning:
Before any maintenance or repairs on the machine, set the Main Power
Switch to "O" (OFF). Wait about 5 minutes for cooling down the heater to
avoid burns with this area.
ATTENTION!
All the important strap transportation components, such as the drive rollers and the
strap guides, must be kept free from oil and grease. (lubricant)
2. Maintenance
Only use original spare parts supplied by manufacturer.
Daily:
Use air gun to clean the following indicated positions (nearby the cutters, strap guide and
accumulating feeding rollers) daily
Remove plastic residue in the machine.
Air
Air
Air
-A38-
Air
Weekly:
Lubricate front bar, press bar, rear bar and shafts in arch weekly.
Please refer to the following mesh areas for instruction.
Before lubricating, be sure to clean the parts first to avoid mixing oil and debris which
might have a bad effect on machine’s function.
Replacing
1. Same sequence as step 1-6 mentioned above.
2. Turn over the Heater Bracket (M7-1-141300) so that you can loosen the nuts of the
heater.
3. After you loosen the nuts, turn the Heater Bracket back to its original position.
4. Take out the Heater Ass’y and make sure the insulations stay intact. If any of
-A40-
insulation fall and get broken, please replace with new one to avoid welding problem.
5. Install the new Heater Ass’y in reverse sequence.
6. Rotate the M1 Handle (T7-1-11240) forward till the Heater Ass’y goes to welding
position.
7. Make sure the clearance between Heater Ass’y and Slide Table (M7-1-131600) is about
1.8 - 2.2mm.
8. If the clearance is too big, adjust it by turning HBS0530N clockwise. If the clearance
is too small, adjust it by turning HBS0530N counterclockwise.
-A41-
PART II
1 Pneumatic System Diagram
REF.
DESCRIPTION Q’TY
NO.
1 Manual Spool Valve 1
2 Filter / Regulator Combination 1
3 Filter 1
4 Regulator (Hi-Pressure) 1
5 Pressure Gauge 2
6 Lubricator 1
7 Solenoid Valve (5/3) 1
8 Cylinder 2
9 Control Valve 3
10 Air Regulator 1
11 Regulator (Low-Pressure) 1
12 Brass Silencer 2
-B1-
2 Wiring Diagram
a. (For P.C.B. Control)
-B2-
-B3-
-B4-
-B5-
-B6-
-B7-
-B8-
-B9-
-B10-
-B11-
-B12-
-B13-
-B14-
-B15-
b. [For PLC (Option)]
-B16-
-B17-
-B18-
-B19-
-B20-
-B21-
-B22-
-B23-
-B24-
-B25-
-B26-
-B27-
-B28-
-B29-
-B30-
-B31-
-B32-
3. Inverter Parameters Setup
-B33-
PART III
1 STRAPPING HEAD UNIT M7-1-900301
M7-1-900311
REF.
PART NO. DESCRIPTION Q'TY REMARKS
NO.
M7-1-900301 Strapping Head Unit (For 5-6mm) 1
M7-1-900311 Strapping Head Unit (For 9mm) 1
M7-1-900321 Strapping Head Unit (For 12mm) 1
1 M7-1-100301 Cam Group (For 5-6mm) 1 SEE PAGE C3
M7-1-100310 Cam Group (For 9mm/12mm) 1
2 M7-1-200020 Bar Guide Group 1 SEE PAGE C19
3 M7-1-300002 Feed Group (For 5-6mm) 1 SEE PAGE C27
M7-1-300012 Feed Group (For 9mm) 1
M7-1-300022 Feed Group (For 12mm) 1
4 M7-1-400002 Tension Group (For 5-6mm) 1 SEE PAGE C37
M7-1-400012 Tension Group (For 9mm) 1
M7-1-400022 Tension Group (For 12mm) 1
-C2-
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