Greenbridge PC2000 User manual

OPERATION MANUAL |SPARE PARTS LIST
PC2000 PC2000CX
GREENBRIDGE
6277 HEISLEY ROAD, MENTOR, OHIO 44060
PHONE: [phone], FAX: [phone]
WWW.GREENBRIDGE.COM

OPERATION MANUAL |SPARE PARTS LIST
PC2000 PC2000CX
GREENBRIDGE
6277 HEISLEY ROAD, MENTOR, OHIO 44060
PHONE: [phone], FAX: [phone]
WWW.GREENBRIDGE.COM

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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

-A1-
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 itemsmust
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.

-A2-
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.

-A3-
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.

-A4-
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.

-A5-
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.

-A6-
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.

-A7-
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

-A8-
B6
2.5 ! Safety Devices
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
Danger!
Operate the machine only when all safety
devices are at their place and are functioning
correctly.

-A9-
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

-A10-
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”)
Strap coil diameter
Coil diameter 200mm (8” nominal)
Outside diameter 420mm (16.5”)
Width(Face) 190mm (7.5”)
Table height
Standard
Minimum – 800mm (31.5”) Maximum – 900mm (35.4”)
Optional
Minimum – 750mm (29.5”) Maximum – 900mm (35.4”)
Weight
225 kg (496 lbs)
Noise emission
78 dBA
Ambient temp
5- 40(41- 104)
Minimum package size:
120 mm(W) ×130mm(L) ×10 mm(H)
(4.72“W 5.12”L 0.39”H )
Maximum package size:
arch size minus 50mm (1.97”)
EX: arch size: 650W×500H
Max. package size: 600mm W×450mm H
(23.6” W ×17.7” H)

-A11-
2.6.3 ! Technical Data (TP-702BP)
Strap width
5mm / 9mm / 12mm
Strap thickness
0.35mm up to 0.65mm (0.014” – 0.026”)
Strap coil diameter
Coil diameter 200mm (8” nominal)
Outside diameter 420mm (16.5”)
Width(Face) 190mm (7.5”)
Table height
Standard
Minimum – 800mm (31.5”) Maximum – 900mm (35.4”)
Optional
Minimum – 750mm (29.5”) Maximum – 900mm (35.4”)
Weight
250 kg (551 lbs)
Noise emission
78 dBA
Ambient temp
5- 40(41- 104)
Minimum package size:
120 mm W ×130mm L ×10 mm H
(4.72“W 5.12”L 0.39”H )
Maximum package size:
arch size minus 50mm (1.97”)
EX: arch size: 650W×500H
Max. package size: 600mm W×450mm H
(23.6” W ×17.7” H)

-A12-
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.
CAUTION!
Do not carry machine by having the forklift’s fork
Center-of-gravity position
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.