Polychem B1000 Guide

B1000
POLYCHEM CORPORATION
6277 HEISLEY ROAD, MENTOR, OHIO 44060
PHONE: [phone], FAX: [phone]
WWW.POLYCHEM.COM
ED.06/17
OPERATION MANUAL |SPARE PARTS LIST
BATTERY POWERED PLASTIC STRAPPING TOOL
READ ALL INSTRUCTIONS BEFORE OPERATING THE TOOL

TABLE OF CONTENTS
1) Safety instructions
2) Technical data
3) Warranty and liability
4) Installation-accessories
5) Operating elements / adjustments
6) Operation
7) Servicing and cleaning
8) Troubleshooting
9) Layout – spare parts list
READ THE OPERATING INSTRUCTIONS CAREFULLY
WEAR EYE, FACE, AND HAND PROTECTION WHEN OPERATING THE
TOOL.
GENERAL SAFETY INSTRUCTIONS:
:
The tool must be used by properly trained people. Failure to follow the operating instructions or
improper use could cause strap breakage, injuries, or package damages.
Check tool daily, do not use tool with worn or damaged parts. Use original spare parts for
replacement. Never modify any tool part.
Do not put fingers, hands or other body parts between the strap and package during the cycle.
It is your responsibility to check the seal joints made by your tool. Training about the weld time
adjustment will be useful to check the seal quality in order to avoid severe injury. Never move goods
with bad quality seals. Only use specific strap dispenser to dispense the strap. Keep your working
area clean and always use the tool in good balance and safety conditions. Never use straps as a
means of pulling or lifting goods.
Always use a proper safety strap cutter and keep other people and yourself at a safe distance from
strap, always stand to side of strap, away from direction of strap trajectory once cut. Hold the upper
strap portion and pay attention that the lower strap will snap forward away from you.
Improper operation, excessive tensioning, use of non-recommended strap, or sharp corners on the
package could cause a loss of strap tension and/or strap breakage that could lead to packaging
failure or injury. The following is recommended; use edge protectors if package has sharp corners,
place the strap correctly around a properly positioned package, stand in safety position (on one side
of strap) during strapping cycle, and use the correct strap quality, width, thickness, and break
strength as recommended in this manual.
Please save this manual, as it is a part of the tool. This tool is manufactured without any substances
which could be dangerous to health. National instructions must be observed for disposal of all the
parts.

TOOL SIZE
Length:
12.4”
Width:
5.5”
Height:
7.2”
Weight with battery:
8.4 lbs.
POWER REQUIREMENT
Battery
14.8V - 3A/h LI-PO
PERFORMANCES
Max.Tension force:
5000N
Tensioning speed:
12mt/m
Sealing:
Friction weld seal
Joint strength:
80% plastic strap
strength*
Level sound emission.
Measurement type A (2003/10/CE)
81 dB (A)
Vibrations at handle (2002/44/CE)
2.2 ms2
* depends of strap quality
Working temperature: The tool should be used between 0C° (32F) and +45C° (+113 F). When using in low
temperatures the display may signal low battery. In this case insert the battery for 2 mins. in charger for a "refreshing".
CHART OF TYPES
ITEM
MODEL
STRAP
THICKNESS
T239997
B1000 - 5/8”-3/4”
PET - 5/8”
PET - 3/4”
0.041”
0.031” - 0.050
Polychem Corporation warrants all its tools and battery chargers during a period of 6 months from the
shipping date document. Wear parts are warranted for 45 days, otherwise wear parts are excluded from
regular warranty, wear parts are shown on spare parts list (in tool manual).
Warranty includes free replacement parts. The warranty is not valid in case of improper use, lack of
maintenance, tampering, arbitrary modifications and reparations, use of non-original parts, disregard of
instructions of the operation manual, or missing serial number. No compensation can be claimed for
production shutdowns and for damages to people and objects due to tool defects. Polychem Corporation
reserves the right to modify the tools and documentation without any obligation to update previous ones.
Polychem warrants all its batteries during a period of 120 days from the shipping date document. The
manufacturer is committed to replace it with a free battery only when there are manufacturing defects that
make it unfit for use.
3)
WARRANTY CONDITIONS AND LIABILITY

The LI-PO (Lithium-Polymer) battery comes fully charged. In order to begin, insert the battery in the tool until it locks in
place with the security lever. Illustrated in the following figure:
IT IS RECOMMENDED TO ONLY USE POLYCHEM ACCESSORIES
BATTERY:
SAFETY INSTRUCTIONS: Only use the battery for our strapping tool and only recharge it with our battery charger. If
used for other purposes or applications our warranty will be void. Failure to follow the operating instructions or improper
use could cause injuries and battery damage.
The battery is supplied fully charged. The lithium polymer rechargeable battery can be charged at any time without
reducing its service life; interrupting the charging procedure does not cause damage. To use and charge the battery,
please follow the operating instructions.
Check battery daily; do not use it with worn or damaged parts.
Do not disassemble it, never modify any part, do not connect the positive (+) and negative (-), it may result in a short
circuit. Do not transport or store the battery with metal objects. Do not try to charge it with a different charger. Do not put
metal keys between contacts. Do not use the battery for purposes other than those specified.
Battery must not be left in charging mode without supervision.
Do not throw the battery into a fire, do not store at high temperature or direct sunlight, and do not put in microwave oven
or a pressure cooker. Keep it away from any exposed flame. Do not dip the battery in water, and protect it from
humidity. Do not apply impact to the battery, or throw, drop, drill it. In case of smoke or fire immediately stop using it
and replace it.
In case electrolyte comes into contact with eyes or hands, immediately rinse thoroughly with clean water and consult a
physician.
The battery must be recycled or disposed of in an environmentally friendly way. Defective or dead batteries must be
recycled according to national / local guidelines.
TECHNICAL DATA : Li-Po (Lithium-Polymer) 14.8V – 3.0 Ah Weight : 1 lb. Part # - B800BAT
Charge time is 30 min. Operating environment charging and discharging: 0C° (32F) and +45C° (+113 F)
SECURITY LEVER
TOOL ACCESSORIES
SERIAL NUMBER

BATTERY CHARGER:
SAFETY INSTRUCTIONS: Only use the charger to charge our lithium polymer battery. If used for other purposes or
applications the warranty and liability is void. The charger should be used by properly trained people. Failure to follow
the operating instructions or improper use could result in injuries or battery damage. Check charger and main supply
cable daily; do not use it with worn or damaged parts. Do not disassemble it or modify any part. Check the contacts
before using. Do not put metal keys between contacts. Do not use for purposes other than those specified. BATTERY
MUST NOT BE LEFT IN CHARGING MODE WITHOUT SUPERVISION. Do not store at high temperature, direct
sunlight, do not cover fan clefts. Do not dip it in water and protect from humidity. Do not apply impact, or throw or drop
or drill it. In case of fire or smoke immediately stop using and replace it. Place the charger on flat, non-flammable and
heat resistant surface. Keep away from any volatile and flammable substance. Disconnect from main power supply
when not in use. Service should be done by authorized dealers. The Charger must be recycled or disposed of in an
environmentally friendly way according to the national / local guidelines.
CHARGING PROCESS: Put the battery into the charger correctly (do not invert the polarity), the charge will start
automatically and the signaling led becomes RED. It will remain in this condition up to 80% of the charge then the
signaling led will become blinking GREEN, this indicates the charge is 80% to 99% complete. The charging process is
complete when the signaling led is solid GREEN; remove the battery from charger.
FAILURE: If the signaling led is blinking RED it indicates that the temperature of the battery is not sufficient for charging
or its voltage is lower than 10.4V and therefore the battery will not charge. Let the battery return to normal temperature
and try again. If the charge does not start contact the service center.
TECHNICAL DATA: PART # - 400CHG Input : 110V - 230V – 50/60Hz – 80W Output : 16V – 5A
ATTENTION: This battery charger is only used with Li-Po 14.8V batteries.
NOTE: REMOVE THE BATTERY FROM THE CHARGER ONCE THE CHARGE IS COMPLETE.
LED OF SIGNALLING
RED LED: BATTERY CHARGING – LEVEL 0 TO 80%
BLINKING GREEN LED: BATTERY CHARGING – LEVEL 80% TO 99%
GREEN LED: CHARGE COMPLETE
BLINKING RED LED: BATTERY DEFECTIVE / DAMAGED

WEARING PLATE:
The tool can be equipped with a stainless steel plate to protect the base against excessive wear when using it on
abrasive surfaces like bricks, concrete, stones, etc ... The part number for the kit is 401-0251.
SUSPENSION HOOK:
The tool can be equipped with a two position suspension hook (horizontal or vertical). The hook is fixed to the tool by
two screws (see picture below). The part number for the hook is 401-2130.

DO NOT OPERATE THE TOOL WITHOUT STRAP, YOU COULD DAMAGE THE FEEDWHEEL AND THE WELDING
/ CUTTING GROUP
LED OF SIGNALLING
AMBER
TOOL IN OPERATION
AMBER BLINKING
TOOL IN STAND-BY
Programming (pic. A):
In order to make adjustments (welding/cut and tension) first push the tension button with the feed wheel open to activate
the board. Then at the same time press the S+ (Welding) and T+ (Tension) keys for approximately 10 sec. like
illustrated in pic. A. This will illuminate the LED that indicates the value of the welding time, in order to switch to the
tension adjustment you must press the T+ or T- key.
Welding - cutting time adjustment (pic. B):
The welding/cut time can be adjusted by pressing on the S+ or S – key depending on the quality and the dimensions of
the strap. Pressing the + key will increase the welding time, pressing the – key will decrease the welding time. After 10
sec. the data will be stored into the memory of the card.
Adjusting strap tension (pic. C) :
The tension of the strap can be adjusted by pressing on the T+ or T – key depending on the quality and the dimensions
of the strap. Pressing the + key will increase the tension level, pressing the – key will decrease the tension level. After
10 sec. the data will be stored into the memory of the card.
BUTTON 1 – TENSIONING
LED OF SIGNALLING
LEVER 3 – RELEASE LEVER
LEVER 2 – CUTTING / WELDING

WELDING ADJUST KEYS
( A ) ( B )
( C )
Adjusting welding area:
Adjust the screws for uneven welds(pic.E1-E2).If the weld is mostly on the external strap side (pic.E3) slightly unscrew
the external screw or slightly screw in the internal screw for a uniform weld(pic.E4). If weld is mostly on the internal strap
side (pic.E5) slightly unscrew the internal screw or slightly screw in the external screw for a uniform weld(pic.E6).
(E1) (E2) (E3)
(E4) (E5) (E6)
TENSION ADJUST KEYS

Put the strap around the package as shown (fig. F1). Overlap the straps with the lead end on the bottom and hold the
straps in left hand (make sure the strap is clean, & oil & grease free); to open the tool squeeze the release lever. Insert
the straps in the tool making sure they are overlapped and aligned against the strap guides (fig. F1). Press the tension
button to start tensioning, when the desired tension is obtained release the button (After reaching tension the tension
button can be depressed up to 3 more times before the welding must be initiated) (fig. F2). To start the welding, pull the
welding lever. The tool will now weld and cut the strap and cool the weld (fig. F3). AFTER the amber LED lights up and
the ringing sound of the tool that indicates the end of the welding cycle, it is possible to remove the strap (fig. F4).
Damage may be caused to the tool and strap if the tool is opened before the ringing sound is made.
After welding, the LED on the keypad shows the level of the battery charge remaining. Example: charged battery (fig.
F5) – battery nearly discharged with approximately 2 cycles left (fig. F6). The last 2 bars on the right indicate the battery
is discharged (fig. F7). To replace the battery or to recharge the same one, remove the battery from the tool by
depressing the release key and pulling the battery upwards (fig. F8).
( F1 ) ( F2 )
( F3 ) ( F4 )
( F5 ) ( F6 ) ( F7 ) ( F8 )

Seal check:
A regular seal quality control is very important and it can be examined visually as follows:
G1) short sealing time/ not enough
G2) right sealing time/ correct
G3) too long sealing time/ wrong
( G1 )
( G2 )
( G3 )
BEFORE PERFORMING ANY SERVICE ON THE TOOL, REMOVE THE BATTERY FROM THE TOOL
Periodically clean the tool from strap dust, particularly the feed wheel, the gripper plates and the cutter by using
compressed air.
Bottom plate gripper replacement
To change the gripper plate, continue as follows:
Remove front strap guide (fig. H1), remove two gripper screws (fig. H2), remove the gripper plate (fig. H3). Install new
gripper plate and reassemble in reverse order.
( H1 ) ( H2 ) ( H3 )
7)
SERVICING - CLEANING

Welding foot replacement
To change the welding foot, continue as follows:
Remove screw and cover (pic. L1), remove the oscillating foot pin (pic. L2) remove the foot with the aid of one clamp
and replace it (pic. L3). Reassemble in reverse order.
( L1 ) ( L2 ) ( L3 )
8) TROUBLESHOOTING
PROBLEM
REMEDY
After inserting the battery and pushing the tension button the tool doesn’t work
Check the battery contacts in the rear of the tool and / or if there are disconnected wires
Check the microswitch under the push button – check the battery charge status (led lights on keyboard)
The tension of the strap is too low on the package
Check tension value on keypad; Check the battery charge / efficiency
Check if the tension motor is damaged or worn out ( contact the after sale service)
Check the gearbox ( contact the after sale service)
Check the electronic card (contact the after sale service)
The feedwheel slips and mills strap
Check if the feedwheel and grippers are dirty or damaged. Adjust the motor power—too much
tension force.
Check if the strap qualities are right for the strapping tool and application
The strap is breaking during tension
Adjust the tension—it may be too high. Check if the strap qualities are right for the strapping
tool and application. Check for sharp edges on the package.
The seal is not aligned
Adjust the motor power—too much tension force. Check if the strap qualities are right for the
strapping tool and application. Check strap size and adjust the guides. Check the alignment.
The lower strap isn’t locked between the gripper and feedwheel so the tool walks
during the tension
Check if the gripper is dirty or damaged. Adjust the tension value for the quality of strap.
Tensioning problem—the strap relaxes after tensioning
Check for damage to feed wheel or the locking mechanism ( contact the after sale service)

The sealing isn’t enough; the upper strap isn’t completely cut; the cutting isn’t
constant
Check the sealing time, may be too short, adjust it on keypad
Check if the sealing foot and / or the cutter are damaged or worn out — perform maintenance
Check if the sealing foot is dirty or slips on strap
Check if the strap relaxes after tensioning
Check the battery charge / efficiency
Check if the strap qualities are right for the strapping tool and application
Check if the sealing motor is worn out (contact the after sale service)
Check the electronic cards (contact the after sale service)
Too much seal time; the strap is breaking during the sealing – cutting
Improper weld timing adjustment, may be too long, adjust it.
Both straps are cut during the sealing cycle
Check if the gripper plate (under the sealing foot) is dirty or damaged (clean or replace it)
Check if the strap is over tensioned. Improper weld time adjustment, may be too long, adjust it.
The motor doesn’t start when the sealing lever is activated
Check if the welding start microswitch is worn out, or the welding cam doesn’t touch the switch.
After the cycle it is impossibile to remove the tool from the package and the opening
lever is too hard to move
Check if the opening group is working or is locked (when you squeeze the opening lever the
strap tension should be released ) (contact the after sale service)
Check the gearbox (contact the after sale service)
Check if there are some defective parts in the opening lever group and / or mechanical
obstructions.
It is difficult to adjust the tension or welding time, doesn’t stay consistent
There are probably keyboard or electronic card problems / (contact after sale service)
Progressive problems with the battery life
Check the battery charge, try to recharge and check if the battery charger is working properly.
May be that the battery is at the recharge limit.
May be that the internal cells are damaged or worn out.
Test tool with a different battery
The charger will not start to recharge the battery
The battery is damaged- do not use
The battery voltage is lower than 10V – check by electric tester; Check if the charger is still
running.

Ed. 06/17
POLYCHEM PART #
ITEM
DESCRIPTION
QNTY
!
!
190169
A000142
TENSION MOTOR GROUP
1
*
190025
A000097
SIGNALS CARD WITH LIGHT TRANSP
1
*
B800BAT
A000115
BATTERY 3A/h
1
§
*
189980
A000237
EXCENTRIC SHAFT ASSEMBLED
1
190166
A000238
WELDING MOTOR ASSEMBLED
1
*
190026
B400186
BEARING 61808-RS1
2
190028
B400188
FREWHEEL INA HF0812
1
190029
B400332
BEARING 609 ZZ SKF
1
190030
B400333
BEARING 61902 ZZ
2
190031
B500035
SCREW M4X10
9
190032
B500036
SCREW M5X12
5
190161
B500068
SCREW M3X8 UNI 5931
1
190036
B500140
SCREW M5X30
1
190037
B500158
SCREW M4X12
3
190038
B500208
SCREW BN13577 3,5X20 KA35
4
190147
B500211
LOCK. WASHER
4
190039
B500214
SCREW M4X8
2
190040
B500273
SCREW M3X10
6
190041
B500275
SCREW M2X10
2
190042
B500281
SELFLOCK. NUT M6 D985 5S
1
190043
B500336
SCREW M4X10
2
190044
B500379
SCREW M4X5
5
190045
B500384
SCREW 2.9X4.5
2
190046
B500385
SCREW 2.9X6.5
3
190047
B500395
SCREW 3.5X16
3
*
190033
B500418
SCREW TCEI UNC10-24X3/8" B18.3
4
190049
B600018
WASHER PS 10x5x0,3
1
190050
B600112
WASHER PS12X18X0.5 DIN988
2
190052
B600159
CIRCLIP A12 DIN471
2
190053
B600189
CIRCLIP RA3.2 DIN6799
1
190054
B600190
CIRCLIP D8 7435
2
190134
B600227
CUP WASHER CB12.5X6.2X0.7 D.2093
1
190057
B600343
SPRING G13-025 ISO10243
1
190059
B600345
CIRCLIP D34 UNI 7435
1
190060
B600346
CIRCLIP D15 UNI7435 R150
1
190061
B600376
WASHER PS 15X21X0.5
1
190075
B600391
WASHER PS 6X21X0.2
1
190062
B700076
PIN 4X12 DIN6325
1
190063
B700101
PIN 6X28 DIN6325
1
190143
B700103
ELASTIC PIN 3x10 UNI6873
1
190064
B700325
SPHERE DIAM.5mm
8
190066
B800366
KEYBOARD
1
*
190067
B800378
WELDING MICROSWITCH
1
*
190068
B800396
TENSION MICROSWITCH
1
*
190170
B800441
POWER CABLES KIT
1
190171
B800450
ELECTRONIC POWER CARD
1
*
190070
D000010
PIN
1
190071
D000170
GEAR SHAFT
1
190073
D000250
STRAP LOCKER
1
§
*

§
WEARING PART
*
PART THAT SHOUD BE STOCKED
POLYCHEM PART #
ITEM
DESCRIPTION
QNTY
190117
D000280
REAR STRAP GUIDE SPRING
1
190074
D000330
FREEWHEEL SUPPORT
1
190076
D000390
LOCKING COVER
1
190077
D000400
GEAR
1
190079
D001140
TENSION SPRING
1
190122
D001420
SPECIAL SCREW M4x10
3
190081
D002020
WELDING FOOT PIN
1
190082
D002030
FLANGE
1
190083
D002040
CONNECTING ROD
1
190087
D002080
SPRING SUPPORT
1
190091
D002130
CUTTER GUIDE
1
190092
D002140
COVER
1
190022
D002150
FEED WHEEL SUPPORT
1
190135
D002170
LEVER SUPPORT
1
190023
D002160
MOTOR FLANGE
1
190093
D002180
SHAFT
1
190094
D002190
HOOK
1
190095
D002200
OPENING LEVER
1
190096
D002220
WELDING MOTOR FLANGE
1
190098
D002240
SPRING PIN
1
190099
D002250
SPRING SUPPORT
1
190100
D002260
SUPPORT PIN
1
190102
D002280
WELDING LEVER PIN
1
190104
D002300
WELDING GROUP SPRING
1
*
190110
D002990
BATTERY RELEASE / CUTTER SPRING
2
*
190172
D005760
RIGHT COVER (BLACK)
1
190173
D005770
LEFT COVER (BLACK)
1
190115
D004270
TENSION BUTTON SPRING
1
*
190123
D004540
WELDING FOOT
1
§
*
190163
D004550
TENSION MOTOR PROTECTION
1
190145
D004560
OPENING LEVER SPRING SCREW
1
190124
D004600
WELDING PLATE
1
§
*
190126
D004620
CUTTER
1
§
*
190136
D004630
FRONT STRAP GUIDE
1
190158
D004640
SUPPORT
1
190137
D004650
SUPPORT WELDING FOOT
1
190138
D004660
REAR GUIDE STRAP
1
189979
D004670
CENTERING RING FOR WELDING MOTOR
1
190174
D005810
BATTERY RELEASE LEVER (BLUE)
1
190175
D005800
TENSION BUTTON (BLUE)
1
190176
D005790
KEYBOARD SUPPORT (BLUE)
1
190177
D005780
BLADE COVER (BLUE)
1
190178
D005540
FEEDWHEEL
1
§
*
190179
D005550
EPICICLOIDAL GEARBOX
1
190168
D005260
WELDING LEVER
1
190167
D005270
LINKER
1

B1000

POLYCHEM declares under own responsibility that the under mentioned machinery, to which this
declarations refers, is in conformity with CEE 98/37 Directive and successive modifications, as well
as with standards EN60745-1, EN60745-2-18, EN55014-1, EN55014-2, EN61000-3-2,EN61000-3-3
POLYCHEM CORPORATION
6277 Heisley Road Mentor, Ohio 44060
Tel.:[phone] Fax: [phone] www.polychem.com
CE DECLARATION OF CONFORMITY
MODEL:
Series
B1000
MACHINE TYPE: