Mercury PC1000 User manual

PC 1000 Manual
For 5/6mm & 3/8”

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.......................................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 ...................................................................... A15
3.6 Operating Elements................................................................. A16
3.7 Instructions for Loading PP Strap............................................ A18
3.8 Auto Strap Feeding Process..................................................... A20
4. Operating the Machine..................................................................... A22
4.1 Soft Tension Operation............................................................ A22
4.2 High Tension Operation.......................................................... A22
4.3 Function Encoder .................................................................... A23
5. Adjustments ..................................................................................... A24
5.1 Strap Amount in the Accumulator Box.................................... A24
5.2 Adjustment for Feeding Pressure to the Accumulator Box..... A25
5.3 Adjustment for Heater Temperature........................................ A26
5.4 Necessary Adjustments After Changing Strap Width Between
5mm and 6mm and 9mm......................................................... A26

5.5 Adjustment for Feeding/Reversing Pressure........................... A29
5.6 Adjustment on Tensioning Rollers for High Tension.............. A31
6. Troubleshooting ............................................................................... A32
6.1 LCD Display ........................................................................... A32
7. Maintenance..................................................................................... A34
PART II
1. Wiring Diagram ……………………………………………………..B1
PART III
1. Strapping Head Unit ………………………...………………………C1
2. Bandway Unit ……………………………………………..……….C43
3. Accumulator Unit ………………………………………………….C67
4. Reel Control Group ………………………………………………..C93
5. Body Frame Unit ………………………………………………....C101
6. Electric Control Unit ………………………………………..…….C141

PART I

-A1-
1General 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.

-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. This product is equipped with a cord that has a
grounding wire and an appropriate grounding plug. The plug must be plugged into an
outlet that is properly installed and grounded in accordance with all local codes and
ordinances.
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
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 40kg (88 lbs), but it may be necessary to use
lifting aids for handling products that exceed 25kg(55 lbs)
The size of the package should not be less than 70 mm × 20 mm (2.75 inches × 0.75
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.

-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(520℉)
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.

-A6-
2Machine 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.

-A7-
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
Place the machine on an even floor in order to avoid any distortion
2.4 Machine Description
Automatic strapping machine for polypropylene (PP) strapping material.
Strap width from 5mm to 9mm.
Electronic heater temperature control.
Hinged front table.
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
Table surface made of stainless steel.
Strap tension adjustable from soft to extremely high.

-A8-
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 front table opening
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-
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. 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) 1L+N+PE (Ground)
Nominal power: 0.5kW 0.5kW
Rated current: 3A 5A
Rated voltage: 220V/230V/240V 110V
Rated frequency: 50Hz 60Hz
Type of current AC - single phase AC - single phase

-A10-
2.6.2 Technical Data
Strap width 5mm, 6mm, 9mm
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 Minimum – 820mm (32.3”)
Maximum – 920mm (36.2”)
Weight 158kg (348 lbs.)
Noise emission 78dBA
Ambient temp 5℃~ 40℃(41℉~104℉)
Minimum package size: 70mm W × 20mm H (2.75” W × 0.75” H)
Maximum package size:
arch size minus 50mm (1.97”)
EX: arch size: 550W×400H
Max. package size: 500mm W×350mm H
(19.7” W × 13.8” H)

-A11-
3Preparation 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. Proper
packaging requires that the casters rest in a recess. Cover
the machine with a sturdy box for protection. Secure the
unit to the pallet with plastic strapping. Place the
strapping across the top plates. Use cardboard to avoid
marring. Use plastic strapping to hold the cover to the
pallet.
The machine can be removed from the pallet using
forklift truck or other lifting device.
CAUTION!
Do not carry machine by having the
forklift’s fork under the arch, but only
under the machine frame.
Center-of-gravity position

-A12-
3.3 Construction Layout
1. Arch
2. Upper Table Front
3. Adjustment Leg
4. Reel
5. Foot Bar (Front)
6. Caster (Brake)
7. Reel Brake Release
8. Caster (Free)
9. Foot Pedal (Option)
10. Side Door
11. Control Panel
12. Power Cord
13. Strapping Head Unit
14. Main Motor M1
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.

-A13-
15. Feed Motor M2
16. Tension Motor M3
17. Strap Accumulator Motor M4
18. Automatic Feed Motor M5
19. Proximity Sensor SQ1
20. Proximity Sensor SQ2
21. Proximity Sensor SQ3
22. Fan (M11)
23. Heater
24. Photo Eye (Option)
25. Timer Box (Option)
26. Foot Bar (Rear)(Option)
3.4 Installation
1. Remove the packing material and check that the machine is complete and
without any shipping damage.
2. Installation for Gas Spring
To protect the Gas Spring, the PIN on one side of the Gas Spring would be
detached before shipment and the Reel Group would be also fixed by Cable tie
(shown as following drawing). Before operating the machine, the Gas Spring
must be installed well.
a. Open the Right door of the machine and take out the plastic bag. Inside this bag,
there are an operation manual and parts as listed in following chart.
b. Cut the Cable tie which is fixing the Reel Group.
Part No. Description Q’ty
Operation 1
M7-4-101200 Shaft 1
THS0508N THS, M5×8 (N) 2
SW05 SW, M5 2
PW05 PW, M5 2
Cable tie
A

-A14-
c. Have M7-4-101200 Shaft threading from inside of the machine and then lift the
Reel Group and move the Gas Spring to make the PIN also goes through the hole
and use 2 Allan Key with 3mm to fix THS0508N+PW05+SW05 all together.
3. Installation ofArch Unit
a. Unpack the Arch Unit from the pallet.
b. Open the Upper Table Front and take out the package of spare parts from the
machine inside. These spare parts are listed as below.
c. Loosen the fixing bolt (about 2-3 turns) of Upper Table Rear and then remove it
(pull it up and then remove it backward).
d. Loosen M7-1-102000 Spring on M7-1-131101 Slide Table Frame and then move
M7-1-131600 Slide Table backward.
e. Install the Arch Unit to the fixing position and then have 9 sets of spare parts Item
D (HBS0616+SW06+PW06A) install in both sides of the Arch Unit, Strap
Guide(R) and Strap Guide (L); hand tied them.
M7-4-101200+THS0508N
+SW08+PW08
PW05
SW05
THS0508N

-A14-1-
ITEM Description Q’ty
A M7-1-101300 1 pc
B T7-2-10120 (Guide) 2 pcs
C HBS0308N + SW03 2 sets
D HBS0616N + SW06+PW06A 11 sets
E HBS0630N + PW06A +
T7-3-10530+ PW06A +
SW06 + HN06
1 sets
F HBS0620N + SW06 +
PW06A
(For arch size ≧W850mm)
2 sets
or 1set
G PMS0316 + SW03 (For SQ6)
(OPTION)
2 sets
H FMS0508N 4 pcs
I HBS0508N + SW05 + PW05
(For 850W / 1050W /
1650W)
2 sets
J HBS0640HN + PW06B +
T7-2-20470
(For 1250W / 1650W)
2 sets
Package of spare parts
Step 1
Step 8
Step 2
Step 5
Step 4 & 8
Step 3
Fig. B