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...............
Page 5
2.6 Technical Specification ............. A9 3 Preparation Before Operating the Machine........A11 3.1 Shipping ...................A11 3.2 Transportation & Centre of Gravity .........A11 3.3 Construction Layout..............A12 3.4 Installation................A13 3.5 Operation Space ..............A14 3.6 Operating Elements..............A15 3.7 Instructions for Loading PP Strap ........... A17 3.8 Auto Strap Feeding Process ............
Page 6
5.6 Adjustment on Tensioning Rollers for High Tension....A29 6. Troubleshooting ................A30 6.1 LCD Display ................A30 7. Maintenance ..................A32 PART II 1. Wiring Diagram ……………………………………………………..B1 PART III 1. Strapping Head Unit ………………………...………………………C1 2. Bandway Unit ……………………………………………..……….C43 3. Accumulator Unit ………………………………………………….C63 4.
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. ...
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.
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 ...
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 Verify that the power line voltage is correct. ...
1.9 Signs and Symbols Meaning Symbol Warning for dangerous voltage! Contact with live electrical parts will result in severe injury or death. Warning for hot surface! Welding area is approximately 270 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...
2 Machine Information 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.
And 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. 2.3 Storage The store room must be dry Do not expose the machine to extreme cold or heat environment ...
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.
If it is necessary to make adjustments inside the machine during operation, after a strap jam for example, the rear table top can be unscrewed. Observe caution as the machine is still fully functional with the covers removed. When the front table top is opened, safety switch B6-1 is activated.
Page 19
2.6.2 Technical Data Strap width 12mm Strap thickness 0.45mm up to 0.65mm (0.017” – 0.026”) Coil diameter 200mm (8” nominal) Strap coil diameter Outside diameter 420mm (16.5”) Width(Face) 190mm (7.5”) Minimum – 820mm (32.3”) Table height Maximum – 920mm (36.2”) Weight 167 kg (368 lbs) Noise emission...
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 Transport the strapping machine on a pallet. Lift the unit using forklift truck or other lifting device.
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. 3.3 Construction Layout 1.
16. Strap Accumulator Motor M4 17. Automatic Feed Motor M5 18. Proximity Sensor SQ1 19. Proximity Sensor SQ2 20. Proximity Sensor SQ3 21. Fan (M11) 22. Heater 23. Photo Eye (Option) Timer Box (Option) Foot Bar (Rear)(Option) 3.4 Installation 1. Remove the packing material and check that the machine is complete and without any shipping damage.
Page 24
Step 9 Step 6 Step 11 Fig. C Step 10 Fig. D For 1050W/1650W For 1250W/1650W Fig. E Fig. F f. Make sure the Arch Unit is vertical (90 ) to the machine frame and then fix 6 sets of Item D (HBS0616+SW06+PW06A) which are on both sides of Arch Unit. g.
Page 25
i. Use Item H parts to fix Control panel onto the right upper side of the Arch Unit. j. Use Item E parts to connect the M7-2-101500 Plate on the left and T7-2-10290 Arm together. (refer to fig. D step 10) k.
Page 26
Step 15 Fig. H Item F Fig. I Item F 3. Adjust the table height by repositioning the screws underneath the machine frame (refer to below drawing). After adjustments, be sure to tighten all the fixing screws. Caution! Be sure to take out the wire for the proximity switch underneath the left side of machine to avoid any damage before adjusting the table height.
Page 27
4. After positioning the machine ready for working, be sure to lock two front casters (with brake) to avoid machine‟s movements. 5. When moving the machine, be sure to un-lock the two lockable casters. Re-lock the two casters after re-positioning the machine. 6.
3.5 Operation Space Keep the area (A) and (B) free for the operator. The area (A) is necessary for operation strapping machine. The area (B) is necessary for changing the strap or adjusting strap amount in the accumulator. -A14-...
3.6 Operating Elements 1. Main Power Switch: Provides the machine with power. Switch to “1” position for turning the main power on. After strapping, switch it to “0” to turn off the machine. 2. LCD Display: Display strapping message. 3.
Page 30
7. Reel Release Switch: To release the dispenser for easily taking out strapping from it. 8. Foot Bar : To initiate a strapping cycle. To clear up machine fault. (reset) 9. Foot Pedal Switch (Option): To initiate a strapping cycle. To clear up machine fault.
11. Foot Bar (Rear)(Option): To initiate a strapping cycle. To clear up machine fault. (reset) 3.7 Instructions for Loading PP Strap 3.7.1 Specifications Polypropylene Strap Width: 12mm Thickness: 0.45 -0.65 mm Strap which has excessive camber as illustrated in figure below cannot be used. Height of 5mm (0.2”) or above (78.7”) -A17-...
Page 32
3.7.2 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.
3.8 Auto Strap Feeding Process 1. Turn Main Power Switch on the control panel 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.
Page 34
Fig. e. Fig. d. 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.
4. Operating the Machine Switch Main Power Switch to After switching on the strapping machine, heater Position “1” starts to warm up and LCD display continues to be 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...
4.3 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 seconds, Press encoder turn the knob to choose the timer needed to be over 2S changed.
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.
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.
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 „‟...
Page 40
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”...
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 upper table rear was screwed by captive screws. To take it out, please loosening the captive screws about 5mm first and then lift the end side of rear side up and slide it out.
Page 42
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.
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”...
6. Troubleshooting 6.1 LCD Display When the machine has a malfunction, the LCD will flash and display a failure message. Message shown on the LCD could be as 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.
Page 45
b-1. Open Upper Table Front Ass'y M7-5-210020. b-2. Lift up the Lever (M7-2-101400/M7-2-101410) with left hand and take out the Cover (M7-1-311220) for the Upper Guide with right hand at the same time. b-3. Take out the jammed strap and cut it. b-4.
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.
Page 47
Weekly: Lubricate (front bar, press bar and 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.
Page 48
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 printed circuit board is firmly fixed. Check if the safety switch on front table or right door functions well. Make machine ready for operation.
STRAPPING HEAD UNIT M7-1-900051 REF. PART NO. DESCRIPTION Q'TY Greenbridge PART # M7-1-100011 Cam Group (SEE PG. C3) X M7-1-200000 Bar Guide Group (SEE PG. C19) 191709 M7-1-300021 Feed Group (SEE PG. C27) X M7-1-400021 Tension Group (SEE PG. C37) X...
Page 82
BAR GUIDE GROUP M7-1-200000 REF. PART NO. DESCRIPTION Q'TY Greenbridge PART # M7-1-201100 Bar Guide 191527 191724 M7-1-201200 Bar Guide Lid 191550 M7-1-201200S Bar Guide Lid (Stainless Steel Model)(Option) 191626 M7-1-201300 Cutter Holder 191549 M7-1-201300EN Cutter Holder (Stainless Steel Model)(Option)
Page 83
1-2-1 FRONT BAR ASS'Y M7-1-210001 -C21-...
Page 84
1-2-1 FRONT BAR ASS'Y M7-1-210001 REF. Greenbridge PART # PART NO. DESCRIPTION Q'TY M7-1-210001 Front Bar Ass'y 191477 191614 M7-1-210001S Front Bar Ass'y (Stainless Steel Model)(Option) 191602 M7-1-211101 Front Bar M7-1-211101S Front Bar (Stainless Steel Model)(Option) TA-073 Spring Hook 191747...
Page 85
1-2-2 PRESS BAR ASS'Y M7-1-220000 -C23-...
Page 86
1-2-2 PRESS BAR ASS'Y M7-1-220000 REF. Greenbridge PART # PART NO. DESCRIPTION Q'TY M7-1-220000 Press Bar Ass'y 191478 191615 M7-1-220000S Press Bar Ass'y (Stainless Steel Model)(Option) 191633 M7-1-221200 Press Bar M7-1-221200S Press Bar (Stainless Steel Model)(Option) TA-073 Spring Hook 191747...
Page 102
1-4-1 TENSION CRANK ASS'Y M7-1-410020 Greenbridge PART # PART # 188671 191611 -C40-...
Page 103
1-4-2 TENSION ARM ASS'Y M7-1-420011 -C41-...
Page 104
1-4-2 TENSION ARM ASS'Y M7-1-420011 REF. PART NO. DESCRIPTION Q'TY Greenbridge PART # M7-1-421101 Tension Arm M7-1-421200 Shaft M7-1-421400 Spring Support 205490 M7-1-421520 Spring 191729 205491 M7-1-421600 M7-1-421700 Collar M7-1-421800 Connecting Rod (Upper) 203918 M7-1-421900 Connecting Rod (Lower) M7-1-420100 Connecting Rod Set...
Page 108
ARCH GROUP M7-2-100010 REF. PART NO. DESCRIPTION Q'TY Greenbridge PART # M7-2-100010 Arch Group M7-2-100010S Arch Group (Stainless Steel Model) M7-2-101310 Rod (For 650W) M7-2-101360 Rod (For 850W) M7-2-101340 Rod (For 1050/1250W) M7-2-101350 Rod (For 1650W) M7-2-101400 Lever (For 650W)
Page 141
3-2-3 M4 MOTOR ASS'Y M7-3-230020 -C77-...
Page 142
3-2-3 M4 MOTOR ASS'Y M7-3-230020 REF. PART NO. DESCRIPTION Q'TY Greenbridge PART # M7-3-231120 Accumulator Main Roller 191546 191538 M7-3-230100 M4 Motor Set TB-223 Washer 191567 T7-3-20110 Motor Support MB1010 Metal Bushing, 1010 191568 KYA050515 Key, 5×5×15 190848 HBS0512N HBS, M5×12 (N)
BODY FRAME UNIT Greenbridge PART # PART # -C100-...
Page 165
BODY FRAME UNIT REF. PART NO. DESCRIPTION Q'TY Greenbridge PART # M7-5-300041 Extension Table Group (For 1050W) (SEE PG.C127) X M7-5-300041S Extension Table Group (Stainless Steel Model) (For 1050W) M7-5-300051 Extension Table Group (For 1650W) M7-5-300051S Extension Table Group (Stainless Steel Model) (For 1650W) (SEE PG.C135)
ELECTRIC CONTROL UNIT REF. PART NO. DESCRIPTION Q'TY Greenbridge PART # M7-6-900022 Electric Control Unit (For 220V~ 240V, 650W) M7-6-900022S Electric Control Unit (Stainless Steel Model) (For 220V~ 240V, 650W) M7-6-900032 Electric Control Unit (For 110V, 650W) M7-6-900032S Electric Control Unit (Stainless Steel Model)
Page 203
ELECTRIC CONTROL UNIT REF. PART NO. DESCRIPTION Q'TY Greenbridge PART # M7-6-100160 Control Panel Group (America) (For 1250W/1650W) M7-6-100160S Control Panel Group (Stainless Steel Model) (America)(For 1250W/1650W) SEE PAGE C145 X M7-6-200002 Electric Control Group (Without Wire) (For 220V~240V) M7-6-200002S...
Page 206
CONTROL PANEL GROUP REF. PART NO. DESCRIPTION Q'TY Greenbridge PART # M7-6-100040 Control Panel Group (Europe)(For 650W) M7-6-100040S Control Panel Group (Stainless Steel Model) (Europe)(For 650W) M7-6-100120 Control Panel Group (Europe) (For 850W/1050W) M7-6-100120S Control Panel Group (Stainless Steel Model)
Need help?
Do you have a question about the PC1000 and is the answer not in the manual?
Questions and answers