Fromm P380 User manual

SERVICE MANUAL
PNEUMATIC PLASTIC
STRAPPING TOOL
MODEL P380
P380.0001.01.en.fm/MAS/© 05.12
Manual for authorized dealers and service points

1-2
INDEX PAGE
1.1 TECHNICAL DETAILS 1-3
1.1.1 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.2 Pneumatic schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.1.3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.1.4 Details of the pneumatic control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.2 CONVERSION PARTS 1-7
1.3 PERIODIC MAINTENANCE AND CONTROL 1-8
1.3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.2 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.3.3 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.3.4 Glueing rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.3.5 Lubrication rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3.6 Assembly information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.4 RECOMMENDED SPARE PARTS 1-16
1.5 ACCESSORY TOOLS 1-17
1.5.1 Use of accessory tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.6 ORDERING SPARE PARTS 1-26
1.6.1 Ordering manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.6.2 Ordering address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.6.3 Finding out of the tool type (item number), the serial number and
the version number:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
5.7 SERVICE ADDRESS 1-27

1-3
Only trained and instructed personnel is authorized to perform servicing and
maintenance works!
1.1 TECHNICAL DETAILS
1.1.1 Air supply
Air pressure
The maximum air pressure allowed is 6.0 bars / 87 psi
Air flow of air unit
min. 520 Nl/min / 18.4 cu.ft/min with a maximum pressure drop of 0.5 bar / 7.25 psi.
Air consumption
Tensioning: approx. 4.9 Nl / 0.18 cu.ft uncompressed air per second.
Sealing: approx. 8.6 Nl / 0.30 cu.ft uncompressed air per second.
Maintenance
• Checking the air-pressure daily
• Checking oil-level daily
• The water separator must be drained depending on developed water amount (unless automatic)
• The filter has to be cleaned regularly following the instructions of the manufacturer of the air- unit
• Check the function and proper adjustment of the lubricator daily (approximately 1-2 drops/min.)
Oil for the air-unit
Hl / CL ISO VG10
Shut off valve
Drain of
main air line
Lubricator
(app. 1-2 drops/min.)
Filter with
app.2%fall
Shut off valve
Pressure adjustment valve
with Manometer
water separator
Coupling min. G1/4
Main air line min. 2"
Air line min. 1/2"
Air unit G3/8
max. length 5m (16 ft.)
min. Ø-inside 10mm
Air hose

1-4
1.1.2 Pneumatic schematic
1.1.3 Functional description
Zero position
• When connecting the tool to the air line, compressed air flows through the Turn off valve (13) to
the Tensioner valve (1) and to the Welding signal valve (12).
• Directly from the main connector P compressed air is lead also to the Welding valve (5),
to the Welding motor valve (7), to the Welding turn off valve (15) and to the Cool down
signal valve (14).
Actuating the Valve lever for tensioning (a)
• The Turn off valve (13) is held by spring force in the home position and is therefore opened.
• By persistent pressing of the Valve lever for tensioning (a) the Tensioner valve (1) is held in open
position. The compressed air flows through the Tension force control valve (2) (with adjustment
knob) to the tensioning motor (3), powers the motor and is leaving it in the decompressed status
through the Exhaust silencer (4).
• If a certain back up pressure of the Tensioning motor (3), determined by the adjustment knob, is
reached, the Tension force control valve (2) throttles the air supply to the Tensioning motor (3).
This allows an adjustment of the tensioning force.
• The Valve lever for tensioning can be released now. The tension force is held by the needle free
wheeling N3.4509.
Actuating the Valve lever for welding (b)
• The valve lever for welding (b) is pressed until the lower stop and immediately released. This is
starting a sequence of automatically run down processes.
• The compressed air coming from connection P flows through the Turn off valve (13), flows
through the Welding signal valve (12) and is switching the Welding valve (5). This is going into
self locking mode.
P
1
2
34
5
6
5
1
2
3
12
1
2
3
4
13
1
2
1
1
2
3
4
2
1
2
3
4
1
3
2
4
8
1
2
9
1
3
2
4
10
1
2
3
4
14
1
2
3
4
7
1
2
3
4
15
a
b
1
2
11 16
6
4
1 Tensioner valve
2 Tension force control valve
3 Tensioning motor
4 Exhaust silencer
5 Welding valve
6 Throttle 0.6
7 Welding motor valve
8 Welding time valve
9 Welding motor
10 Cooling time valve
11 Welding cylinder
12 Welding signal valve
13 Turn off valve
14 Cooling signal valve
15 Welding turn off valve
16 Cylinder reverse stop
a Tensioner valve lever
b Welding valve lever

1-5
• At the same time the Turn off valve (13) is driven by compressed air from the left side, switches
and thus is blocking the air connection to the Tensioner valve (1). Also the upper piston surface
of the welding cylinder (11) and the cylinder reverse stop (16) is ventilated. Both cylinders
extend.The straps between welding gripper and welding stop gripper are compressed.
• Additionally the welding motor valve (7) is provided with compressed air over the throttle (6) and
switches.Through the welding motor valve (7) coming from connection P the welding motor (9) is
provided with compressed air. The welding motor is powered and the compressed air escapes
through the silencer (4). Now the upper strap is cut off.
• Furthermore the compressed air flowing through the Welding valve (5) is reaching through the
Welding time valve (8) time delayed the Welding turn off valve (15). This is switched and is
driving the Welding motor valve (7) in home position. The welding motor (9) stops.
• If the Welding turn off valve (15) is switching, there is also compressed air flowing to the Cooling
down signal valve (14). It is switching and the compressed air is flowing through the adjustable
Cool down time valve (10) time delayed to the Welding valve (5). The welding valve (5) is
switched into home position again. Hereby the upper piston surface of the welding cylinder
(11)and the cylinder reverse stop (16) is exhausted. The welding cylinder (11) and the cylinder
reverse stop (16) move into home position. At the same time the turn off valve (13), the cool
down signal valve (14) and the welding turn off valve (15) move again into home position.
1.1.4 Details of the pneumatic control system
Valve numbers correspond to the pneumatic schematic)
3Tensioning motor
9Welding motor
2Tension force control valve
2Tension force
16 Cylinder
4Exhaust silencer
control valve
4Exhaust silencer
reverse stop

1-6
aValve lever
bValve lever for welding
1Tensioner valve
12 Welding signal valve
8Welding time valve
13 Turn off valve 10 Cool down time valve
14 Cool down
15 Welding
5Welding valve
6Throttle 0.6
7Welding motor valve
for tensioning
signal valve
turn off valve

1-7
1.2 CONVERSION PARTS
When converting strap thickness or strap width the following parts must be exchanged:
Tool Item-No. 49.3801 49.3802 49.3811 49.3812 49.3821
Strap dimension 13mm x
0.40-0.64
13mm x
0.65-1.05
15mm x
0.40-0.64
15mm x
0.65-1.05
16mm x
0.40-0.64
Tensioning wheel P35.3202 P35.3203 P35.3202 P35.3203 P35.3202
Cutter P38.1168 P38.1169 P38.1168 P38.1169 P38.1168
Gripper P38.1170 P38.1172 P38.1170 P38.1172 P38.1170
Welding gripper P38.1197 P38.1198 P38.1197 P38.1198 P38.1197
Strap stop P38.1154 P38.1154 P38.1156 P38.1156 P38.1156
Strap guide P38.1158 P38.1158 P38.1158 P38.1158 P38.1159
Strap guide P38.1160 P38.1160 P38.1162 P38.1162 P38.1164
Strap guide P38.1161 P38.1161 P38.1163 P38.1163 P38.1165
Base plate P38.1188 P38.1188 P38.1190 P38.1190 P38.1192
Tool Item-No. 49.3822 49.3831 49.3832 49.3833
Strap dimension 16mm x
0.65-1.05
19mm x
0.40-0.64
19mm x
0.65-1.05
19mm x
1.06-1.35
Tensioning wheel P35.3203 P35.3202 P35.3203 P35.3203
Cutter P38.1169 P38.1168 P38.1169 P38.1169
Gripper P38.1172 P38.1170 P38.1172 P38.1172
Welding gripper P38.1198 P38.1197 P38.1198 P38.1198
Strap stop P38.1156 P38.1157 P38.1157 P38.1157
Strap guide P38.1159 P38.1159 P38.1159 P38.1159
Strap guide P38.1164 P38.1166 P38.1166 P38.1166
Strap guide P38.1165 P38.1167 P38.1167 P38.1167
Base plate P38.1192 P38.1194 P38.1194 P38.1196
Attention!
When converting tools always change the item number
on the type label.
Replace following parts:
Type label N43.9179
2 x hammer head bolts N2.4902
Enclose the suitable operation manual with the tool
after each conversion.
(see paragraph Ordering manuals)

1-8
1.3 PERIODIC MAINTENANCE AND CONTROL
Carry out 12- months cycles doing one shift work. Doing multiple shift work respectively more often.
1.3.1 Procedure
Before using check tool for following possible faults:
• Visual test of the tool for loose, lost or damaged parts
• Clean all dirty parts of the tool, especially strap abrasion in the tensioning or the welding unit by
using compressed air. (Never use any hard tools like a wire brush or a screw driver for cleaning)
• Condition of the tensioning wheel, the welding grippers and the tensioning grippers
Connect tool to the air supply and perform some test strappings.
Check the following:
• Tightness of the pneumatic system
• Strap guidance
• Strap take up and strap tensioning
• Tensioning force adjustment minimal and maximal (see operation manual P380)
• Cutting of the upper strap
• Welding time adjustment (see operation manual P380)
• Seal quality (see operation manual P380)
Proceed according to paragraph „Troubleshooting“after a fault appears.
Attention!
Before maintenance always remove the tool from the compressed air
supply.
For exchange of wearing parts see operation manual P380.
Never use water or solvents for cleaning the tool.

1-9
1.3.2 Troubleshooting
A sufficient compressed air supply and the use of the tool’s specific strap should be
guaranteed before each tool repair.
SYMPTOM CAUSE REMEDY
Tool doesn’t tension,
Tensioning motor runs
The tensioning wheel is packed with
strap residue or is worn and mills on
the strap
Clean tensioning wheel with
compressed air or replace it
Wrong tensioning wheel or tensioning
wheel is assembled reversed
Correct assembling or use the correct
tensioning wheel.
Grippers are dirty, worn or wrongly
assembled
Replace grippers, clean them with
compressed air or assemble correctly
Gearing parts from the tensioning gear
are defective
Check tensioning gear and replace
defect parts
Return stop unlocked Check piston
Tensioning motor doesn’t
run
Tensioning motor defective Check component parts and replace
damaged ones
Tensioning gear defective Check component parts and replace
damaged ones
Pneumatic control system is defective Check component parts and replace
damaged ones
Needle free wheeling assembled
reversed
Assemble correctly
Tensioning wheel turns
back immediately after the
tensioning cycle
Defective needle free wheeling
N3.4509
Überprüfen und gegebenenfalls
ersetzen
Tool doesn’t weld,
welding motor runs
Welding gripper is dirty or worn Clean and check welding gripper and
replace damaged one
Welding stop gripper is dirty or worn Clean and check welding stop gripper
and replace damaged one
Pinion P32.1023 lose at the motor or
welding eccentric, resp. The journal at
the welding eccentric is broken off.
Check component parts and replace
damaged ones
Welding piston P38.0101 not down Check component parts and replace
damaged ones
Welding motor doesn’t run Welding motor defective Check component parts and replace
damaged ones
Welding mechanism defective Check component parts and replace
damaged ones
Pneumatic control system is defective Check component parts and replace
damaged ones
Gear noise Tensioning or welding gear is worn Check component parts and replace
damaged ones

1-10
1.3.3 Checklist
Carry out several test strappings and check the following items:
• Connect the tool to the compressed air supply and check if air escapes
• Insertion of the strap
• Strap guidance
• Strap take up and strap tension
• Tension force adjustment minimal and maximal (see operation manual P380)
• Cutting of the upper strap
• Welding time adjustment (see operation manual P380)
• Seal quality (see operation manual P380)
• Type label
Welding motor does not
stop
Turn off valve or welding motor valve
jam, resp. the welding time valve is
blocked.
Check and clean parts, exchange
damaged parts
Diameter of the air supply hose is too
small.
Install air supply hose with a minimum
inner diameter of 10mm
Not enough air volume Take care that there is enough air
volume
(see paragraph 1.1.1 Air supply)
Tool badly cuts the strap or
doesn’t cut at all
Cutter is worn or damaged Replace cutter
Welding gripper is worn Replace welding gripper
Welding time too short Change adjustment
(see operation manual P380)
Welding time not
adjustable
Welding time valve dirty or damaged Clean and check component parts
and replace damaged ones
Tensioning force not
adjustable
Tension force control valve dirty or
damaged
Clean and check component parts
and replace damaged ones
SYMPTOM CAUSE REMEDY