Fully-Auto: Mercury Transit

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FULLY-AUTO

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

1 General Safety Instructions ................................................................ A1

1.1 Basic Operation ......................................................................... A1

1.2 Basic Safety Precautions ........................................................... A1

1.3 Safety Instructions Governing Specific Operational Phases ..... A2

1.4 Warning of Electrical Dangers .................................................. A3

1.5 Grounding Instructions Shall Include the Following ................ A3

1.6 Before Operating ....................................................................... A4

1.7 During Operation ...................................................................... A4

1.8 After Operating ......................................................................... A4

1.9 Signs and Symbols .................................................................... A5

2 Machine Information ......................................................................... A6

2.1 Areas of Application ................................................................. A6

2.2 Environment Information .......................................................... A6

2.3 Storage ...................................................................................... A7

2.4 Machine Description ................................................................. A7

2.5 Safety Devices........................................................................... A8


2.6 Technical Specification ............................................................. A9

3 Preparation Before Operating the Machine.......................................A12

3.1 Shipping ...................................................................................A12

3.2 Transportation & Centre of Gravity .........................................A12

3.3 Construction Layout.................................................................A13

3.4 Installation................................................................................A14

3.5 Operation Space .......................................................................A15

3.6 How to connect Upstream and Downstream Machine (B5

Connector) ................................................................................A16

3.7 Operating Elements ..................................................................A17

3.8 Instructions for Loading PP Strap ............................................A19

3.9 Auto Strap Feeding Procedure .................................................A20

4. Operating the Machine ......................................................................A23

4.1 Manual Operation mode...........................................................A23

4.2 Transit Operation mode............................................................A24

4.3 Automatic Operation mode ......................................................A24

4.4 Function Encoder .....................................................................A25

5. Adjustments ......................................................................................A26

5.1 Strap Amount in the Accumulator Box ....................................A26

5.2 Adjustment for Feeding Pressure to the Accumulator Box ......A27


5.3 Adjustment for Heater Temperature .........................................A28

5.4 Some adjustments for straps ....................................................A28

5.5 Adjustment for Feeding/Reversing Pressure ............................A30

5.6 Adjustment on Tensioning Rollers for High Tension ...............A32

5.7 Speed and Pressure Adjustment of Press Bar...........................A33

5.8 Change Bundle Flow Direction ................................................A34

5.9 Height Adjustment of Press......................................................A34

6. Troubleshooting ................................................................................A35

7. Maintenance ......................................................................................A38

PART II

1 Pneumatic System Diagram ................................................................ B1

2 Wiring Diagram .................................................................................. B2

3. Inverter Parameters Setup ................................................................... B33


PART III

1. Strapping Head Unit ………………………...………………………C1

2. Bandway Unit ……………………………………………..……….C45

3. Accumulator Unit ………………………………………………….C73

4. Reel Control Group ………………………………………………..C97

5. Body Frame Unit ……………………………………………..…..C111

6. Electric Control Unit ……………………………………………..C129

7. Transmission Unit ………………………………………………..C145

8. Pneumatic Unit …………………………………………………...C171


PART I
1 General Safety Instructions
1.1 Basic Operation
 Read the operation and safety manual prior to using the strapping machine.
 The operation and safety manual should remain attached to the machine at all times.
 The machine may only be operated in accordance with its designated use.
 The strapping machine was built in accordance with state-of-the-art standards and
recognized safety rules. Nevertheless, improper use can still result in injury to personnel
or damage to the machine and other material property.

 Machine shall only be operated by trained personnel.


 Perform inspections and maintenance at regular intervals. Refer to the Maintenance
section of the manual.
 The machine may not be put in operation before checking the respective devices.
 Safety devices must never be bridged or eliminated by any means.
 To transport the equipment only use lifting apparatus and loading devices with sufficient
capacity.
 Always disconnect from external power supply when changing the location of the
machine, even if the location should only be slightly changed. Connect power supply
properly before returning to service.
 Do not alter or bypass protective interlocks.
 Do not alter circuits and machine unless authorized to do so by the manufacturer.

1.2 Basic Safety Precautions


 In addition to the instructions for operation, the user is to be instructed in all generally
applicable legal or mandatory regulations relevant to safety or the environment.
 Long hair, loose-fitting garments, or jewelry can be a safety hazard. These items must
be secured prior to equipment operation.
 Use protective equipment whenever appropriate or when required by law.
 Carefully observe all safety instructions and warnings attached to the machine. Keep
safety labels clean and legible.
 People that are being trained to operate or service the equipment must be supervised by
experienced personnel.
 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.

-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.

 Do not place any tools or parts onto the machine.

 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.

1.5 Grounding Instructions Shall Include the Following


 This product must be grounded. In the event of an electrical short circuit,
grounding reduces the risk of electric shock.
 If repair or replacement of the cord or plug is necessary, connect the ground wire to the
ground terminal of the plug. The wire with green insulation (with or without yellow
stripes) is the grounding wire.
 Check with a qualified electrician or service person if the grounding instructions are not
clear or if in doubt about the proper grounding of the machine. Do not modify the plug
provided; if it will not fit the power outlet, have the proper outlet installed by a qualified
electrician.

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.

1.7 During Operation

 The weight of the package cannot exceed 35kg.


 The size of the package should not be less than 120 mm(W) × 130mm(L) × 10 mm(H)
(4.72 inches × 5.12 inches × 0.39 inches).
 While running, check the unit for any unusual sounds or smoke emissions.
 Keep away from the inside of the arch while the machine is operating; do not put your
hands or body into the arch when the machine is running.

NOTE: It is normal for the heater tongue to smoke during the sealing operation.

1.8 After Operating

 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

Warning for dangerous voltage!


Contact with live electrical parts will
result in severe injury or death.

Warning for hot surface!


Welding area is approximately 270oC(520oF)
Allow sufficient time for the heater to cool
down before any work in welding area.

Warning for danger!


Do not put your hands or body into
arch working area when machine is
operating.

Warning for danger!


Do not put your hands or body into
arch working area when machine is
operating.

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.

2.2 Environment Information


The strapping machine shall be installed in the following conditions:

 Supply voltage: 0.9 - 1.1 nominal supply voltage


 Source frequency: 0.99 - 1.01 nominal frequency
 Ambient temperature: 5°C - 40°C (41℉-104℉).
 Altitude: shall be at altitudes up to 1000m above mean sea level.
 Relative humidity: not exceed 50% at 40°C.
 Atmosphere: Free from excessive dust, acid fume, corrosive gases and salt.
 Avoid exposing to abnormal vibration.
 Don't use machine in dangerous environment.
 Don't use machines in damp or wet locations, or expose them to rain.
 Please provide a suitable illumination around the machine for safety operation.
 Work place of user should have a fire extinguisher or other devices that meet their local
safety regulations, and always be careful.
 Internal parts requiring frequent inspection and adjustment, and maintenance areas must
be provided with a suitable illumination around the machine.

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

 The store room must be dry


 Do not expose the machine to extreme cold or heat environment
 Place the machine on an even floor in order to avoid any distortion

2.4 Machine Description

 Fully automatic strapping machine for polypropylene (PP) strapping material.


 Transit model with stepless speed belt-driven table
 Electronic heater temperature control.
 Hinged table top.
 Automatic strap loop ejection in case of strapping cycle without package.
 Extra tough construction.
 Simple, safe and user-friendly operation.
 Automatic strap feeding system.
 Automatic strap end detection.
 Mobile, with large table area and high capacity strap reel
 Up and down stream interlock with complete plug connection

-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.

The machine is equipped with the following safety devices:


1. Warning signs at the danger points of the machine
2. Automatic shunt down of machine when table top opened
3. Live parts are secured by cover

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.

2.6 Technical Specification

2.6.1 Electrical Specification

System configuration: 1L+N+PE (Ground) 3L+PE (Ground)


Nominal power: 1.0kW 1.0kW
Rated current: 5A 10A 5A 3A
Rated voltage: 230V 110V 220V 400V
Rated frequency: 50/60Hz 50/60Hz
Type of current AC - single phase AC - 3 phase

-A9-
2.6.2 Technical Data (TP-702B)

Strap width 5mm / 6mm / 9mm / 12mm


Strap thickness 0.35mm up to 0.65mm (0.014” – 0.026”)
Coil diameter 200mm (8” nominal)
Strap coil diameter Outside diameter 420mm (16.5”)
Width(Face) 190mm (7.5”)
Standard Minimum – 800mm (31.5”) Maximum – 900mm (35.4”)
Table height
Optional Minimum – 750mm (29.5”) Maximum – 900mm (35.4”)
Weight 225 kg (496 lbs)
Noise emission 78 dBA
Ambient temp 5℃ - 40℃ (41℉ - 104℉)
120 mm(W) × 130mm(L) × 10 mm(H)
Minimum package size:
(4.72“W × 5.12”L × 0.39”H )
arch size minus 50mm (1.97”)
EX: arch size: 650W×500H
Maximum package size:
Max. package size: 600mm W×450mm H
(23.6” W × 17.7” H)

-A10-
2.6.3 Technical Data (TP-702BP)

Strap width 5mm / 9mm / 12mm


Strap thickness 0.35mm up to 0.65mm (0.014” – 0.026”)
Coil diameter 200mm (8” nominal)
Strap coil diameter Outside diameter 420mm (16.5”)
Width(Face) 190mm (7.5”)
Standard Minimum – 800mm (31.5”) Maximum – 900mm (35.4”)
Table height
Optional Minimum – 750mm (29.5”) Maximum – 900mm (35.4”)
Weight 250 kg (551 lbs)
Noise emission 78 dBA
Ambient temp 5℃ - 40℃ (41℉ - 104℉)
120 mm W × 130mm L × 10 mm H
Minimum package size:
(4.72“W × 5.12”L × 0.39”H )
arch size minus 50mm (1.97”)
EX: arch size: 650W×500H
Maximum package size:
Max. package size: 600mm W×450mm H
(23.6” W × 17.7” H)
-A11-
3 Preparation Before Operating the Machine
3.1 Shipping
The equipment is delivered in transport units.
Each transport unit is loaded onto a wooden pallet,
secured by polyester strapping.

3.2 Transportation & Centre of Gravity


The machine must be secured on a pallet for
transportation. A forklift (or other lifting device) is
necessary for lifting the machine to the pallet. The
casters must be fit nicely in the recess on the pallet for
proper packaging. Secure the machine to the pallet
with plastic strapping across the top plates with a
layer of cardboard on it to avoid damage. Cover the
machine with sturdy box for protection and hold the
whole box to the pallet with plastic strapping.

The machine can be removed from the pallet by using


forklift truck or other lifting device. Center-of-gravity position

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.

5. The maximum power line fuse must not exceed 16 Amp.

-A14-
6. Pneumatic connection (for TP-702BP)

 The strapping machines require 3/8” air hose B


connection (A)
 The operating pressure is 6 bar (87psi), its
value is set by the pressure reducing valve (B)
 To alter operating pressure, the knob (B) has
to be pulled upward. By turning the knob (B)
the pressure can be adjusted. Knob (B) is
locked by pressing it down again. A

3.5 Operation Space


Keep the area (A) and (B) free for the operator.

The area (A) is necessary for operating strapping machine and changing the strap.

The area (B) is necessary for checking the Electricity.

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.

2. Emergency Stop switch


The switch functions for urgently stop the
machine. When pressing this STOP switch, 2
the power supply will be shut down
immediately. After pressing the switch, it
will be locked. For releasing Stop function,
3
just gently turn it clockwise. Remember
you still need to press to let the
machine back to normal operation.
4 5
3. LCD Display:
Indicates strapping condition of machine 6 7
and error massages.

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.

6. Soft - High Tension Switch:


Switch to right ( ) for High strapping tension.
Switch to left ( ) for soft strapping tension.

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.

8. TRANSIT SPEED Adjustment Knob


External adjustment of transit speed by simple turn of a dial. Turn clockwise to
increase transit speed; turn counterclockwise to reduce transit speed.

9. Strap Tension Potentiometer:


Turn clockwise to increase strapping tension, turn counterclockwise to reduce
strapping tension. This potentiometer is only functional under High tension mode.

10. Timer (T1)


Delay time from the moment that a package is detected until the 1st strapping cycle
initiates. It is adjustable from 0 to 5 seconds.

11. Timer (T2)


Delay time (interval) between strap cycles. When multiple strapping cycles are
needed, this timer is for an operator to determine the interval between each straps.
It is adjustable from 0 to 5 seconds.

12. PRESS BAR selector switch (TP-702BP ONLY)


Bundle press functions only when PRESS BAR selector is set at "1".
Strap without bundle press when PRESS BAR selector is set at "0".

13. Start Switch:


 After turning on Main Power Switch, you must press the start switch for
machine to get ready for working.
 To initiate a strapping cycle.
 To clear up machine fault. (reset)

-A18-
14. Reel Release Switch:
To release the dispenser for easily
taking out the strapping from it.

15. Foot Pedal Switch (Option):


To initiate a strapping cycle.
To clear up machine fault. (reset)

3.8 Instructions for Loading PP Strap


3.8.1 Specifications

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.

Height of 5mm (0.2”) or above

(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.

3.9 Auto Strap Feeding Procedure

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

4.1 Manual Operation mode

1. Make selector switch to position .


2. Place a package in the middle of table beneath the
chute.
3. Adjust selector switch and Tension
Potentiometer according to required tension force.
4. Push start switch or foot pedal switch (option) to
start strapping.

NOTE!
When operating in soft tension mode, the strap tension
potentiometer does not function.

Attention!

Keep hands away from the strapping area.

If hands are caught by P.P. strap accidentally, be sure to


turn off the Main Power Switch first and then cut the
strap.

-A23-
4.2 Transit Operation mode

1. Make selector switch to position .


2. Adjust Transit Speed Adjustment Knob
properly.

Note !
If there’s no signal from downstream equipment, table belts
would not run.

4.3 Automatic Operation mode

1. Make selector switch to position .


2. Adjust Transit Speed Adjustment Knob
properly.
3. Adjust selector switch and Tension
Potentiometer according to required tension force.
4. Decide the straps numbers on a package with
selector switch.
5. Switch Press bar selector switch if required. (Only
for TP-702BP)
6. Place package in upstream conveyor and machine would
make strapping on the package according to the settings.
7. Move photo cells or make adjustment of T1 or T2 to
change the strapping position on the package.

-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

Turn encoder right

<- T5: 0 - 60
T4: Press bar delay time, Range 0-3S
000

SQ6> 0: sensor for chute home position no Turn encoder right,


select the timer
function (Disable)
needs to be altered
1: sensor for chute home position has and press encoder
function (Enable)
<- T5: 0 - 60
000

Turn encoder to
change the value
Then press encoder

<- T5 : 0 - 60
010

Turn encoder left


to <- and press
encoder to exit setting

<- Timer TEC

Turn encoder left to


<- and press encoder
to exit setting

Ready

Finish setting

-A25-
5. Adjustments

5.1 Strap Amount in the Accumulator Box

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.

Strap scraped by rollers

-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.

5.4 Some adjustments for straps

1. Adjusting “Strap Guide”

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.

3. Adjusting Brush Clearance in the Arch

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.

5.5 Adjustment for Feeding/Reversing Pressure

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

2. Adjusting the Pressure for Reversing

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

a. Flow Control (A):ascending speed adjustment of Press Bar.


Turn knob counterclockwise to increase the ascending speed of Press Bar.
Turn knob clockwise to decrease the ascending speed of Press Bar.
b. Flow Control (B):descending speed adjustment of Press Bar.
Turn knob counterclockwise to increase the descending speed of Press Bar.
Turn knob clockwise to decrease the descending speed of Press Bar.

2. Pressure

Air pressure adjustment for ascending and descending Press Bar

Regulator C: Adjustment for ascending pressure of Press Bar


Regulator D: Adjustment for descending pressure of Press Bar

-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.

5.8 Change Bundle Flow Direction

If you need to change the bundle flow direction, please do it as following steps:

a. Change the phase sequence of M6 motor. (Please refer to B2 / ED1, interchange


either 2 wires from frequency inverter to M6 motor)

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.

5.9 Height Adjustment of Press


The height for press going upward is adjustable according to different package height.
a. Remove the pneumatic source and have the press bar descending.
b. Loosen the cover of both sides.

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.

Message shown on the LCD could be follows:


1. Reminder message:
a. Push Start: Please press the Start Switch to make machine function. This is
especially necessary after the Safety Switch is released or after
you just turn on the machine.
b. Load Strap: Load a new roll of strap or re-do the Auto Strap feeding again.
c. B6 open; K1 open: When it shows this message after you press the Start Switch, it
means the Safety Switch might not be closed or the K1 in the
control box is abnormal.

2. Malfunction from switches:


a. S1 Error: This means the Start Switch or the Foot Pedal is continuously
triggered before activating them. Please check if any of these 2
Switches is defective.
b. S5 Error: This means the Reel Release Switch is continuously triggered
before activating it. Try to press it by hand to see if it’s
defective.
c. SQ1 on Error: The SQ1 is triggered when doing Auto Strap Feeding. Check if
the SQ1 or the Switch lever is defective.
d. SQ9 failure: Foot bar is not able to function properly and cause it not able to
go back to home position.

3. Malfunction from procedures:


a. ASF failed: Auto Strap Feeding failed. It might be caused by wrong
inserting direction or inserting too much strap. Please re-do the
Auto Strap Feeding.
b. Feed jam: Resulting from not being able to feed strap to the sealing
position.

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

b-1. Open Upper Table, Front Group M7-7-100230.


b-2. Lift up the Lever ○
A (M7-2-101400/M7-2-101410) with left hand and

take out the Cover ○


B (M7-1-311201) for the Upper Guide with right

hand at the same time.


b-3. Take out the jammed strap and cut it.
b-4. Put the cover (M7-1-311201) for the Upper Guide back to its position
and put the Upper Table Front Ass'y back as well. Push START switch
in the control panel to RESTART machine.

If the Feed jam problem still cannot be solved, the following causes have to be
checked as well:

Fault Cause Remedy


Strap is too curved Change strap
Insufficient feeding pressure Adjust feeding pressure according to
5.5
Feed jam
Too much strap amount in the Adjust to proper strap amount in the
accumulator box and has accumulator box according to 5.1
caused strap to be curved

-A36-
c. Other malfunctions:

Fault Cause Remedy


Too much debris on both sides Clean both sides of the heater plate by
of heater plate fine sandpaper
Sealing
Increase the heater temperature
failure
Insufficient heater temperature according to 5.3
Insufficient cooling time Increase cooling time according to 4.3
Soft-High tension switch is at
“soft” position Turn it to “high” position
Insufficient Lubricant drops into tension
strap tension roller incautious Clean the lubricant
Too much debris in the gear of
tension roller Clean the debris
No air supply Make sure the air supply is correct.
Press Bar function is not ON Enable Press Bar function (refer to
Press Bar no 4.3)
function Press Bar is not moving freely Clean and lubricate it.
Solenoid Valve is not Replace Solenoid Valve
functional

-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.

1. Cleaning and Lubrication


The high reliability and long service life of the strapping machine will depend on regular
cleaning and maintenance.

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)

The lubricant has to be non-resinous.


The lubricant is SAE 30

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.

Check the machine by strapping several bundles for any failures.


Monthly :( or 100,000 strapping cycles)
Clean both sides of heater plate and polish with fine sandpaper if necessary
ATTENTION: Make sure the welding plate is cool first!!
Check Front Bar, Press Bar, and Rear Bar for moving upward and downward neatly. The
Slide Table and Strap Track Frame should be able to go back to its home position by the
force of spring as well.
Be sure to clean any debris in the tension roller
-A39-
6 Months:(or 500,000 strapping cycles)
Check heating element, replace and re-adjust it if necessary.
Check strap cutter in sealing head, replace it if necessary.
Check if the connector at wiring housing to P.C. Board is firmly fixed.
Check if the safety switch of front table or Rear table functions well.
Make machine ready for operation. Strap one bundle manually several times, paying
attention to mal-functions, repeat procedure.
Initiating several cyclings with package manually for testing and pay attention to any
mal-functions. Make sure the strap accumulating function is well. If necessary, replace
the assistant rollers, do proper adjustments to accumulating feeding pressure or to the
clearance in the reel brake.
Slightly lubricate the sealing head (bearing points) with light lubricant if necessary.
1 year :( or 1,000,000 strapping)
Replace deflection roller if it shows visible changes.
In case of loud noise at bearings: locate them, replace the bearings.
Get machine ready for operation again, strap one bundle manually several times, paying
attention to malfunctions.

3. Cleaning / Replacing Heater


Cleaning
1. Turn off the power and open the Upper Table, Front Group and Upper Table, Rear
Group (M7-7-100230 & M7-7-200110).
2. Make sure that the heater cools down already and the temperature is not too hot to let
you get hurt.
3. Loosen the fixed screws of the heater cover (M7-1-101720) and remove it from the
machine.
4. Remove the screw (HBS0540HN) of Heater Crank (M7-1-141100).
5. Remove the Return Spring (T7-1-64130) of the Heater Crank (M7-1-141100).
6. Remove the Heater Crank (M7-1-141100) by pushing it backward.
7. Clean both upper side and down side of the Heater carefully with fine sander paper.
8. Re-installation the heater back to the machine in reverse sequence.

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

Parameter factory setting Parameter factory setting


00-03 1 04-12 18.2
00-12 1 06-00 405.0
00-13 79 06-07 30
01-00 79 07-00 2.1
01-07 100 07-01 1.8
01-08 18.2 07-02 10.0
01-09 0.1 08-00 20
01-10 0.2 08-02 0.3
01-19 1 08-04 2
02-00 1 08-15 2
02-01 2 08-18 2
02-02 2

-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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