Plas-Ties XL2 User manual

14272 Chambers Road
Tustin, CA 92780
TOLL-FREE: [phone]
PHONE: [phone]
FAX: [phone]
OPERATING MANUAL
FOR
XL2 MACHINES
Email: [email protected] Website: www.plasties.com
Proprietary Information of Plas-Ties, Co. Rev 02.28.2017

Page 3
Table of Contents
PAGE
Section I: General Information
Intro................................................................... 4
Supplies and Service.......................................... 5
Safety Instructions ............................................. 6-7
Warranty ............................................................ 8
Section II: Specifications
Model Designation ............................................. 9
Performance ...................................................... 9
Power Requirements .......................................... 9
Dimensions........................................................ 9
Spool Replacement............................................ 9
Section III: Operation
Major Component Description/Adjustments ....... 10-11
Product Stages................................................... 12-13
Mounting Options............................................... 14
Pedestal Stand Assembly ................................... 15
Brake Assembly.................................................. 16-17
Loading Twist Tie Material................................... 18-19
Tying Operation .................................................. 20
Chutes and Ribbon Guide ................................... 21
Tying Adjustments .............................................. 22-23
Section IV: Maintenance
General.............................................................. 24
Lubrication......................................................... 24
Preventive Maintenance Record.......................... 25
Section V: Troubleshooting
Solutions Matrix ................................................. 26-27
Section VI: Parts
Parts List ........................................................... 28-33
Assemblies ........................................................ 34-35
Appendix A: Explosion Chart with Case & Cover .. 36-37
Appendix B: Electrical System Function & Parts.. 38-39
Appendix B: Electrical System Details ................ 40
XL2 Spare Parts Kit............................................. 41

SECTION I: General Information
Thank you for purchasing the XL2 from PLAS-TIES, manufacturers of high
quality twist-tying equipment.
Please familiarize yourself and/or any person operating this machine with all functions
by carefully reading this manual.
The XL2 is a machine that will twist-tie products inserted into the tying area. The
machine can be adjusted to tie almost any product gathered into a round or almost
round shape from 3/8-inch diameter up to a maximum of 2-inch diameter.
Model designation and electrical requirements are found on the serial plate on the
machine. It is important that you have the correct model for your input power.
Unit comes with standard vertical mount. Additional options include: (1) horizontal
mounting frame and (2) Pedestal with wheels for tying height between 3 and 5 feet.
(see page 14-15)
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With your purchase, we provide FREE on-line technical support for the first 6
months (warranty period). This support is handy for anything from initial set-up
of your machine to identifying replacement parts and basic troubleshooting.
Technicians and Web Based Support Available:
7:00am to 3:00pm
(Pacific Standard Time)

SUPPLIES AND SERVICE
PLAS-TIES twist tie material and service should be ordered from an authorized
dealer, distributor, or:
PLAS-TIES
14272 Chambers Road
Tustin, CA 92780
Telephone: [phone] or [phone]
Fax: [phone]
Email: [email protected]
When contacting Plas-Ties, please have the following
information handy:
1) Model Number and Serial Number (see name plate)
2) Date of Purchase
3) Number of cycles on machine counter
4) Type of tie material in use
5) Name of part or description (for replacement parts - see Appendix for reference
guide)
SECTION I: General Information
Page 5
REQUEST FOR REPAIRS OR SERVICE
For any repair and service requests, please contact customer service at (800)
854-0137 or [phone] to obtain an RMA number prior to sending products
back to us.
In addition to the information above and the nature of the problem, it is also important
to leave the spool of material present on the unit when the problem occurred and
send a sample of the item being tied to help in resolving repair issues.
The RMA number issued must be noted on the outside of the shipping box to expe-
dite receipt of repair unit. Please refer to the warranty section for coverage details.

SECTION I: General Information
SAFETY INSTRUCTIONS
The operating procedures outlined in this manual are prepared to
facilitate the successful operating of the XL2 machine.
1) KEEP ALL SAFETY DEVICES IN PLACE and in working order.
2) KEEP WORK AREA CLEAN. Cluttered areas invite accidents.
3) DO NOT USE IN DANGEROUS ENVIRONMENT. Do not use machines in a damp
or wet location, or where any flammable or noxious fumes may exist. Keep work
area well lit.
4) KEEP UNAUTHORIZED PEOPLE AWAY. All unauthorized people should be kept
out of work area and away from machine.
5) DO NOT FORCE MACHINE. It will do the job better and safer at the rate for which it
was designed.
6) USE THE RIGHT MACHINE. Do not force machine to do a job it is not designed to
do.
7) DO NOT USE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL
8) DIRECT ELECTRICAL CONNECTION TO WALL SOCKET IS HIGHLY
RECOMMENDED. If use of extension cord is necessary, make sure your extension
cord is UL and CE approved and in good condition. Your extension cord must also
contain a ground wire and plug pin. Always repair or replace extension cords if they
become damaged.
9) WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings,
bracelets, or other jewelry that may get caught in moving parts. Wear protective hair
covering to contain long hair.
10) MAINTAIN MACHINE WITH CARE. Keep machine clean for best and safest
performance. Follow instructions for lubricating and keeping machine free of lint.
11) DISCONNECT MACHINE before servicing and when changing spool.
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12) REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in off
position before plugging in.
13) USE THE RECOMMENDED MATERIALS AND REPLACEMENT PARTS. Listing of
recommended material and replacement parts is found in this operating manual. The
use of improper material and replacement parts may result in malfunction and
possible risk of injury, in addition to voiding the warranty.
14) CHECK DAMAGED PARTS. Before further use of the machine, any part that is
suspected of damage should be carefully checked to determine that it would operate
properly and perform its intended function. Check for alignment of moving parts,
binding of moving parts, breakage of parts, mounting, and any other conditions that
may affect its operation. A part that is damaged should be properly repaired or
replaced.
15) NEVER LEAVE MACHINE RUNNING UNATTENDED. Turn the power off, and do
not leave machine until it comes to a complete stop.
16) NEVER ALLOW UNTRAINED USERS TO RUN THIS MACHINE.
17) IF YOU ARE UNSURE OF THE INTENDED OPERATION, STOP USING THE
MACHINE. Seek technical assistance or instruction from trained personnel or
manufacturer service department.
SECTION I: General Information
SAFETY INSTRUCTIONS
Page 7

SECTION I: General Information
CAUTION:
DO NOT ATTEMPT TO OPERATE YOUR XL2
MACHINE BEFORE READING THE OPERATING
INSTRUCTIONS.
W
Purchaser acknowledges that there are no warranties, expressed or implied, made by
PLAS-TIES, its distributors or sales representatives related to the XL2 machine except
the manufacturer’s warranty against defective materials and workmanship as follows:
PLAS-TIES warrants the XL2 machine to be free from defects in materials and
workmanship at time of delivery. Liability under this warranty is limited to the repair or
exchange of any defective part or parts of the unit providing the same is returned to PLAS
-TIES, transportation prepaid, within 1 year or 300,000 cycles (based on machine
counter), whichever comes first. THE WARRANTY BEGINS FROM THE DATE OF
INSTALLATION AT CUSTOMER SITE AND NOT DATE OF PURCHASE. IN ORDER TO
ACTIVATE THE WARRANTY, THE COMPANY NAME, CONTACT, CITY/STATE, AND
SERIAL NUMBER MUST REGISTERED with PLAS-TIES or PROOF OF PURCHASE
MUST BE PROVIDED. FAILURE TO DO SO WILL RESULT IN LIMITATION OF THE
FULL WARRANTY. THIS IS TO INSURE TOTAL QUALITY ASSURANCE AND 800 TOLL
FREE TECHNICAL SUPPORT.
The warranty is void on any XL2 machine that has been subject to negligence, accident,
misuse, failure to use the equipment as instructed in the manual, or that has been
tampered with.
This warranty is void if the XL2 machine is used with anything other than genuine PLAS-
TIES twist-tie material.
IMPORTANT: If your XL2 machine does not operate properly, please bring it to the
attention of PLAS-TIES, or the dealer or distributor from whom it was purchased. If repairs
are needed, the dealer, distributor or other representative of PLAS-TIES will arrange to
repair or replace parts within the terms of the warranty.
Warranty coverage is limited to the Continental US, Alaska, Hawaii, Puerto Rico, and
Canada.
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Page 9
SECTION II: Specifications
MODEL DESIGNATION
This manual covers the model 510 XL2 machine which is equipped with a 2 amp circuit
breaker for overload protection. U.L. approved for the United States.
POWER REQUIREMENTS
120 Volts A.C.
2.0 Amp circuit breaker
60 HZ
PERFORMANCE
Up to 30 ties per minute
2-1/2 full twists on product tied
DIMENSIONS/WEIGHT
Length: 40
Height: 17.5
Width at top: 14
Width at front feet: 16
Weight: 50 pounds
SPOOL REPLACEMENTS
Recommended Spools:
Part# 313: 1500’ PL/PA 24 gauge single wire 5/32” width
Part# 314: 1500’ PL 24 gauge single wire 5/32” width

Page 10
Brake Assembly: Holds the ribbon spool and creates spool “drag”. No adjustment.
Ribbon Chute: Guides the ribbon through the scissor arms. Critical that the chute is centered
to the slot in the ribbon cutter anvil. Correct chute length must be utilized according to diame-
ter of product. To adjust, see Scissor (page 11).
Ribbon Drive Motor: Pulls ribbon through machine. Adjustment is critical to ensure that de-
sired length of ribbon is pulled through during the tying cycle. To adjust:
1) Loosen the nylon wingnut.
2) Slide the entire ribbon drive assembly and align with the desired length mark on machine
chassis.
3) Tighten the nylon wingnut.
Stop Guide: Ensures product to be tied is centered to the twister. To adjust:
1) Loosen screw.
2) Align appropriate diameter to marker.
3) Tighten screw.
Tying Diameter Adjustment Dial: Provides visual calibration for product diameter, required
ribbon chute length and ribbon length for the ribbon drive motor setting. It is also the fine-
tuning adjustment controller for ribbon length.
Motor and Cam: Controls the timing functions of overall tying operation. Timing adjustment is
critical. Correct setting has cam set in the home position when XL2 is inactive. The HOME
position is correct when the cam following bearing is positioned in notch. To confirm and ad-
just this setting:
1) Disable ribbon feed by turning idler lockout and then activate the tie cycle once.
2) Check cam position for HOME position.
3) If setting is not correct, loosen set nuts on scissor actuator rod.
4) Turn scissor actuator rod in 1/4 turn increments. (Clockwise = delay) (cc = advance)
5) Test cycle to confirm. Tighten set nuts when correct.
6) Turn idler lockout to engage ribbon feed.
SECTION III: Operation
MAJOR COMPONENT DESCRIPTION/ADJUSTMENTS

Page 11
MAJOR COMPONENT DESCRIPTION/ADJUSTMENTS
SECTION III: Operation
Scissor: Places the ribbon around the product to be twist tied. Alignment is critical. Cor-
rect setting has the ribbon chute centered to the ribbon cutter anvil slot. To adjust:
1) If motor and cam are stopping in HOME position, correct alignment of chute and an-
vil will be achieved. (see motor/cam adjustment).
Twister: Twists ribbon ends securing the ribbon around the product. Twister position is
critical. Correct position is in a vertical position when inactive. To adjust:
1) Loosen twister sprocket set screw.
2) Turn twister and shaft until twister is in a vertical position.
3) Re-tighten set screw.
Ribbon Cutter: Cuts the ribbon to length. Smooth action between knife and cutter anvil
is critical. To adjust:
1) Remove knife actuator spring tension (part# 920) and slide knife to the left.
2) Loosen the screws that secure the cutter anvil.
3) Place a .003 shim between the anvil and the knife.
4) Hold the cutter anvil against the knife, retighten the screws and remove the shim.
5) Replace tension spring.
Important Make certain that the knife is not too tight. The knife must not “stick”, but be
secure enough to cut the ribbon cleanly

PRODUCT STAGES
STAGE 1: Product to be tied is manually inserted into the tying area (A) and the product
must come into contact with trigger switch (B). Trigger switch (B) activates the XL2 tying
cycle and the stop guide (F) ensures proper positioning. Cycle time is approximately 3
seconds. *Please note that there is a second stop guide located on the underside of the
top cover. The top guide should be aligned with the bottom guide.
STAGE 2: Trigger Switch (B) activates the capacitor (N) In the main drive motor (C) to
rotate a single revolution that causes the main timing cam (D) to rotate clockwise.
STAGE 3: The main timing cam activates the cutter cam follower (E), which in turn
activates the Ribbon Cutter Knife.
STAGE 4: Simultaneously to STAGE 3, the Scissor Actuator Assembly (G) pulls the
scissors (H) forward and around the product in the tying area (A). The ribbon forming
arm (I) ensures that the precut ribbon is centered to the tying area then lifts out of the
way.
STAGE 5: With the rotation of the main timing cam being approximately one half way
through its cycle, the ribbon will be around the product and the ribbon ends are
positioned in front of the Twister (J).
STAGE 6: As the Main Timing Cam completes its cycles, the Twister (J) activates,
twisting the ribbon ends and securing the ribbon around the product. As the ribbon is
twisted, the scissor (H) retract to their HOME position.
STAGE 7: As the scissors (H) return to their HOME position, switches (K) are activated
which in turn activate the Ribbon Feed Drive Wheel (L) and it presses against the Ribbon
Idler Wheel (P). The ribbon is driven forward at this time. The ribbon continues through
the Ribbon Chute (M) where it will stop until STAGE 1 commences again.
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SECTION III: Operation

Page 13
SECTION III Operation
A
B
F
D
P
N
E
J
M
I
K
L
H
C
G
PRODUCT STAGES

Figure 3
Page 14
SECTION III Operation
MOUNTING
STANDARD MOUNT
*Standard equipment. Use with large or small brake
1) Remove the Brake Assembly from packaging and install on the brake
arm support using the two 1/4-20 x 1/2 screws provided.
2) Follow Loading Twist Tie Material Instructions. (see page 18)
SIDE MOUNT
*Optional Part #56108. Use with large brake only
1)If currently set up for horizontal operation, remove brake assembly by
removing the two screws.
2)Mount brake assembly on mounting plate with the same screws
3)Lay machine on left side so that it is supported by the mounting stand
4)Bolt the side mount stand to the XL2 external chassis bracket.
5) Follow Loading Twist Tie Material Instructions. (see page 18)
PEDESTAL STAND
(for either horizontal or vertical mount)
*Optional part # 505R033-XL, plus use special brake
#A102020.
1)Remove cover
2)Pull apart the 6 Molex connectors on harness
3)Remove legs from bottom of chassis & install pedestal mount.
4)Re-install, tighten, re-connect steps 1 and 2.
**Please note that the Brake Beam positioning as illustrated in Fig 3 has
the Roller Assembly pointed down when installed on the Pedestal Mount.

PEDESTAL STAND ASSEMBLY
Page 15
SECTION III Operation
1) Lay out all the parts on the floor. Place legs (A&B) with the wheels, parallel to each other as shown
2) Attach the upright (C) to the legs (A&B) using 4 bolts (505D031) and 4 washers (56806)
3) Attach cross bar (D) to the legs using 4 bolts (56426) and 4 washers (56806) to the front of the legs
4) Place the adjustment upright (E) inside the stationary upright (C). The adjustment upright is held in place by
the non-locking spring plunger and secured by the lever clamp.
5) Place the support plate tube (F) inside the tube on the adjustment upright and secure the lever clamp
6) Add the pedestal stand bracket (505D028) to (F) using 4 screws (P001952 ) and 4 washers (P004715 )
7) Screw 4 washers (16614) and 4 Hex Nuts (56507) to secure the bracket to (F)
8) Attach XL2 machine frame (505D173) to top of bracket (505D028) with 4 washers (P004715) and 4 screws
(P002201). Under the bracket attach with 4 washers (P004715) and 4 nuts (56507).
9) Mount the pedestal stand bracket (505D028) with attached XL2 to support plate (F).

Page 16
BRAKE ASSEMBLY
STANDARD
Small Brake Arm
Option (A)
SECTION III Operation

BRAKE ASSEMBLY
Page 17
DESCRIPTION SMALL (A) LARGE (B) SPECIAL (C)*
Complete Assembly A102022 A102021 A102020
* Used only for Pedestal Stand Assembly
BRAKE ASSEMBLIES—PARTS LISTING
Large Brake Arm
Option (B)
Special Brake Arm
Option (C)*
*Used only for Pedestal
Stand Assembly
SECTION III Operation

Page 18
SECTION III: Operation
1) Turn the power switch “OFF”, unplug the power cord and remove any ribbon pieces
and/or debris inside the XL2.
2) Remove empty ribbon spool by depressing the brake spool arm and then pulling the
spool straight away from the brake spindle. Slide the new ribbon spool onto the brake
spindle. Feed the ribbon from the top of the spool to under and around the roller
wheel on the brake assembly.
3) With the ribbon now directed toward the rear of the XL2, look at both sides of the
ribbon One side has “bump” (wire), the other is flat [A]. Pull 1 foot of ribbon off the
spool and feed into the rear of the XL2.
4) Turn the pressure release cam [B] to separate the
ribbon drive wheel and insert the ribbon through
the ribbon guide [C] ensuring that the “bump” (wire)
side is against wheel and into the cutter anvil guide
[D] but not protruding beyond the cutter space.
5) Release the pressure release cam to bring the idler wheel to the drive wheel, making
sure the ribbon is between the restraint flanges on the idler wheel.
IF THE MACHINE DOES NOT TIE PROPERLY AFTER THREADING, CHECK THE
PREVIOUS STEPS TO BE SURE IT HAS BEEN THREADED CORRECTLY. IF YOU
STILL INCUR PROBLEMS, REFER TO THE TYING ADJUSTMENTS INSTRUCTIONS
ON PAGES 22-23 AS WELL AS THE TROUBLESHOOTING SECTION ON PAGES 26-
27.
LOADING TWIST TIE MATERIAL
A

Page 19
SECTION III: Operation
B
C
D
LOADING TWIST TIE MATERIAL

1) Support the product to be twist tied with both hands and insert into the left side of the tying
area when tying in the vertical position.
*Insert into the bottom of tying area when in the horizontal tying position.
2) Hold the product in place until the product is twist tied. Tying cycle is approximately
3 seconds.
3) The product may be removed from the tying area any time after the tying cycle is complete.
*Periodically, the ribbon length will need to be either lengthened or shortened.
Slightly turn the Tying Diameter Adjustment Dial to the left to decrease ribbon length
and to the right to increase ribbon length. (See Page 22)
*Always remove any ribbon pieces from the XL2 before tying.
SECTION III: Operation
Page 20
TYING OPERATION