Polychem GP44 User manual

GP44 Semi-Automatic Strapping Machine
OPERATION -1-
GP44
Semi-Automatic Strapping
Operation and Maintenance Manual

GP44 Semi-Automatic Strapping Machine
OPERATION -2-
TABLE OF CONTENTS
Page
REVISION HISTORY…………………………………………………………………………………………….. 4
INTRODUCTION……………………………………………………………………………………………….… 5
SERIAL NO. LOCATION………………………………………………………………………………………… 5
SAFETY………………………………………………………………………………………………………….… 6
DESCRIPTION
SPECIFICATIONS…………………………………………………………………………….. 7
KEY COMPONENTS………………………………………………………………………… 8
FUNCTION OF CONTROLS/SWITCHES…………………………………………………... 14
INSTALLATION AND START-UP
GENERAL………………………………………………………………………………………. 16
LOADING STRAP……………………………………………………………………………… 17
ADJUSTMENT OF STRAP TENSION (EXTERNAL) ……………………………………… 19
SEQUENCE OF OPERATION…………………………………………………………………………………… 20
TROUBLESHOOTING……………………………………………………………………………………………. 23
MAINTENANCE …………………………………………………………………………………………………. 31

GP44 Semi-Automatic Strapping Machine
OPERATION -3-
STANDARD ADJUSTMENTS……….………………………………………………………………………….. 36
STRAP FEED/RETRACTION PRESSURE………………………………………………… 36
HOME POSITION……………………………………………………………………………… 39
ELECTRO MAGNETIC BREAK………………………………………………………………. 41
ELECTRICAL
ELECTRICAL SCHEMATICS……….………………………………………………………… 44

GP44 Semi-Automatic Strapping Machine
OPERATION -4-
REVISION HISTORY
REVISION DATE DESCRIPTION
- 04-12-2005 Original release

GP44 Semi-Automatic Strapping Machine
OPERATION -5-
POLYCHEM CORP.
MODEL NO.
SERIAL NO.
INTRODUCTION
This manual supplies all the necessary information for the correct use of the machines supplied by Polychem
Corporation.
Instructions, drawings, tables and any other information contained in this manual are all confidential. They
may not be reproduced, either fully or partially, without the authorization of Polychem Corporation. Polychem
reserves all exclusive rights on this matter, and is enabled to carry out all changes that will be required.
This manual should be kept in good condition and in an easily accessible place, along with the spare parts
manual, so that they may be quickly referenced when necessary.
The machine serial number should always be included when a request for information is made. This helps
insure that the correct replacement parts are specified for the machine.
Polychem Corporation
SERIAL NUMBER LOCATION
There are two identifying markers on the machine. The bottom frame is stamped on the cross brace where
the machines frame is bolted to the caster frame. The machine will be stamped as shown below:
COR-0067
A Polychem tag is also affixed to the machine. It appears as shown below.

GP44 Semi-Automatic Strapping Machine
OPERATION -6-
SAFETY INSTRUCTIONS:
1. This manual provides specific information regarding Operation and Maintenance for your new machine.
Please read through this manual and familiarize yourself completely before operating the machine.
2. Only trained and authorized personnel should operate or service this machine.
3. We put many safety features into all of its equipment, including this one, to provide its customers with the
safest equipment possible. Extreme caution should be exercised any time an operator is near moving parts.
4. Never work on the interior of this or any machine without disconnecting the power supply.
5. The use of safety glasses is highly recommended.
6. Never operate this or any other machine that has safety switches or equipment that has been altered or is
not functional. Report these conditions to a supervisor immediately.
7. Always check to see all guards are in place before operating this machine.
8. Never put any part of your body near, or into moving machinery. Keep hands away from the strap during
tensioning. Never adjust, lubricate, or service moving machinery
9. Shut off all electrical power when machine is not in use.
10. Keep the machine clean and follow a recommended maintenance program.
11. Observe all warning placards throughout the machine and warning notations made throughout the manual.

GP44 Semi-Automatic Strapping Machine
OPERATION -7-
SPECIFICATIONS
Model : GP-44 Automatic strapping machine
Sealing Method : Heat seal
Strap Size : 5mm,6mm, 1/4”, 7mm, 8mm, 9mm, 3/8”, 12mm, 1/2”
Strap Core Size : Inside φ200mm, Width 200mm
Electric Power : Single Phase
115v, 50/60Hz
Strap Cycle Time : Maximum 44 cycles per minutes
Machine Size :
Arch Size
Width
( mm )
Height
( mm )
Height
( mm )
[ a ]
Width
( mm )
[ b ]
Depth
( mm )
[ c ]
Table Height
( mm )
[ d ]
Weight
( kg )
600 400 1295 1242 623 787 170
600 500 1395 1242 623 787 170
600 600 1495 1242 623 787 170
800 400 1295 1382 623 787 175
800 500 1395 1382 623 787 175
800 600 1495 1382 623 787 175
800 800 1695 1382 623 787 175
1000 600 1495 1582 623 787 175
1000 800 1695 1582 623 787 175
1000 1000 1895 1582 623 787 175
1200 400 1295 1782 623 787 180
1200 600 1495 1782 623 787 180
1200 800 1695 1782 623 787 180
1600 600 1495 2182 623 787 185

GP44 Semi-Automatic Strapping Machine
OPERATION -8-
KEY COMPONENTS (Refer to Strap Path Schematic)
Ref Description Location Function
EB1 Electric Brake Cam Motor (M1) In back of M1 Stops cam in home position, primary
tension position and final tension position.
EB2 Electric Brake Feed/Retract Motor
(M2)
In back of M2 Stops feed/retract motor when strap is not
feeding or retracting
EB3 Reel Brake On reel shaft Stops reel when not loading strap
M1 Cam Shaft Motor Under conveyor Rotates camshaft
M2 Strap Feed/Retract Motor Under conveyor Rotates feed/retract wheels
M5 Accumulator Load Motor Before accumulator box Feeds strap into the accumulator box
SA 1 Tabletop Safety Switch Side of conveyor top Verifies that the tabletop is closed
SA2 Tabletop Safety Switch Side of conveyor top Verifies that the tabletop is closed
SOL3 Real Brake Solenoid On reel shaft Provides some drag on the reel to prevent
it form “free wheeling”
SOL4 Strap Feed/Retract Solenoid Under conveyor Presses the strap against the feed/retract
wheel to feed/retract strap
SOL7 Initial Feed Solenoid Behind accumulator box Engages only during initial load to create a
path for strap to initially load into the
strapping head/arch.
S1 Strap End Detect Switch Under slide plate Detects if the end of the strap has made it
entirely around the arch
S2 Camshaft Home Proximity Switch Near camshaft Stops the cam in the home position (TR12)
and the primary tension position (TR 93).
S3 Strap Present Proximity Switch After reel Verifies that strap is present and flowing
into the accumulator box

GP44 Semi-Automatic Strapping Machine
OPERATION -9-
S5 Accumulator Level Switch In accumulator box Detects when the strap in the accumulator
box has overcome the weight lever
S6 Primary Tension Complete Switch Right side of seal area Signals that primary tension is complete
(strap is around the package) and for cam
to rotate to final tension position
S7 Package Present Safety Switch Hole in table top Verifies that a package is in the strapping
area
S10 One Shot ON/OFF Near accumulator box
inside machine (bottom)
In Automatic mode.
OFF: Allows machine to run continuously
when S7 is covered.
ON: Machine will cycle only once when S7
is covered.

GP44 Semi-Automatic Strapping Machine
OPERATION -10-
INTRODUCTION
This manual gives you operation, safety, and maintenance instructions for the
GP-44 automatic strapping machine. The GP-44 machines are automatic strapping devices. This model is designed to
strap packages or bundles with plastic strap. The strap ends are joined by heat sealing process.
SIMPLE DESCRIPTION OF THE MACHINE
The figure below shows the exterior of the machine.
A package to be applied strapping is placed on the front and rear table under the arch.
A strapping cycle can be separated into four distinct operations:
1. Strap feed
2. Grip and Tension
3. Weld, cut and release
Strap feed for next cycle
Depressing the Manual Strap Switch or foot switch pedal initiates a strapping cycle. The strap is pulled back into the
pool box and tightened around the package. The strapping head, located within the cabinet of the machine, performs the
end gripping, cutting off and welding the strap. When a sealing cycle has been completed, the strap is drawn from the
pool box by the feed/tension system of the strapping head and then fed around the arch.
Arch
Rear Table
Front Table
Power Switch
Reel
Tension Knob
Control
Front Door

GP44 Semi-Automatic Strapping Machine
OPERATION -11-
PROCEDURE OF ASSEMBLING ARCH UNIT
1.Remove Arch Cover D.
2.Unscrew cap screws and remove the top table support. (Cap screw is M6×15)
3.Mount the arch unit on the frame and drive cap screw softly. (Cap screw is M8×25 and M10×35)
4.Fix the arch unit firmly on Head by cap screws. (Cap screw is M6×35)
5. Fix the arch unit firmly on the installed Bracket for E Rail by pan head screws.
6.Tighten cap screws driven softly in No3.
7.Install the top table support removed in No2 to head.
8.Fix Arch Cover D on the arch unit.
Arch Cover B
Arch Cover C
Arch Cover D
Arch Unit (23” wide)
Pan head screw
Cap screw
M6×15
Cap screw
M8×25
Cap screw
M10×35
Top Table support Head Bracket for E Rail
Cap screw
M6×35
Button bolt
M5×8

GP44 Semi-Automatic Strapping Machine
OPERATION -12-
PROCEDURE OF ASSEMBLING ARCH UNIT
1.Remove Arch Cover A and Arch Cover D.
2.Unscrew cap screws and remove the top table support. (Cap screw is M6×15)
3.Mount the arch unit on the frame and drive cap screw softly. (Cap screw is M8×25 and M10×35)
4.Fix the arch unit firmly on Head by cap screws. (Cap screw is M6×10)
5. Fix the arch unit firmly on the installed bracket for E Rail by pan head screws.
6.Tighten cap screws driven softly in No3.
7.Install the top table support removed in No2 to head.
8.Fix Arch Cover A and Arch Cover D on the arch unit.
Arch Unit (31”- 63” wide)
Arch Cover C
Arch Cover D
Arch Cover B
Arch Cover A
Top Table Support
Cap screw M6×15
Head
Bracket for E Rail
Cap screw
M10×35
Button bolt
M5×8
Cap screw
M8×25
Pan head screw
Cap screw
M6×10
Cap screw
M6×35

GP44 Semi-Automatic Strapping Machine
OPERATION -13-
NAME OF PART and FUNCTION
1.Control Box
2.Reel Coil
3.Reel Nut
4.V-Roller
5.Sensor: Strap detect sensor (53)
6.Front Door
7.Front panel
8.Arch B
9.Arch C
10.Arch D
11.Tension Adjust Knob: Turn right to increase tension.
12.Sensor: Parcel detect sensor (57)
1
2
3
4
5
6
7
8 9
10
11
12

GP44 Semi-Automatic Strapping Machine
OPERATION -14-
MAGNETIC OPERATION CONTROL BOX (GP44)
Note: Control Box can be re-posted on either side of the machine.
1. Strap Feed Complete Light
Green light glows when strap has fed into the arch completely.
2. Manual Strap Switch
Press this switch to start strapping operation, when in manual mode.
3. Auto/Manual Select Switch
Strapping procedure can be selected by this switch.
Auto: Strap cycle initiated by photo eye S7
Manual: Strap cycle initiated by Manual Strap Switch or Foot Switch
4. Reset Switch
Strap Feed Complete Light
Manual Stra
p
Switch
Auto/Manual Select Switch
Reset Switch
Circuit Power Switch (With Light)
Emergency Stop Switch

GP44 Semi-Automatic Strapping Machine
OPERATION -15-
When the machine stops due to some trouble, press this switch so that the machine goes back to
the home position.
Strap is cut and remains in the arch and it must be removed by hand.
NOTE: Turn strap feed switch (located on the side of the machine) OFF then back ON to feed strap
around arch.
5. Circuit Power Switch (with light)
Power light glows when all safety switches are clear and Circuit Power Switch is pressed
The machine can be ready for using after 30seconds (after heater blade warms up).
6. Emergency Stop Switch
When it is pressed, all operation of the machine and all pilot lights are turned “OFF”.
NOTE: Power still remains in the machine when Emergency Stop Switch is pressed.
Make sure to disconnect power cable when you inspect the inside of the machine.

GP44 Semi-Automatic Strapping Machine
OPERATION -16-
SET-UP
1) UNCRATING THE MACHINE
a) Remove the bolt holding the top of the crate to the pallet.
b) Remove the cross-braces that are nailed in to keep the machine from shifting.
c) Lift the top of the crate off of the pallet and set it aside.
d) Carefully remove stretch wrapping from the machine.
2) INSTALLING THE MACHINE
a) With a forklift placed under the framework of the machine, gently lift up the machine a minimal
distance to clear the pallet.
b) CAUTION: Make sure the forks are all the way through the far side of the frame.
c) Slide the pallet out from under the machine.
3) POWER REQUIREMENTS
DANGER: The following procedure should be preformed by a trained electrician.
a) Install a quick disconnect power plug onto the end of the cord.
b) Make sure to properly ground the machine to avoid a shock hazard.
c) Next check the machine for proper phasing of the three phase power if so equipped. The M2 (strap
Feed/Retract) motor is the only motor on the machine that is phase sensitive.
d) Load strap in the machine per the “Strap Loading Instructions’. If phasing is not correct, strap will load
up to the head, but will not complete loading around the arch, and Strap Feed light will not illuminate.
If this occurs, reverse phasing.
e) Load strap again, and strap should feed completely around the arch. The Strap Feed light will
illuminate signaling that strap feed was successful.
f) Make sure to verify that the machine is wired for correct voltage. See the “Electrical Hook-up” section
of the manual.

GP44 Semi-Automatic Strapping Machine
OPERATION -17-
TESTING AND OPERATING THE MACHINE
1. INITIAL SET-UP OF THE MACHINE
After installing the plug for the three phase power, and testing for the proper motor rotation, the
machine is ready for testing.
Move the machine to the line it will be used in to check the conveyor gap. The machine should set
level and have all wheels in contact with the floor. If not, the wheel should be lowered until in
contact. Some machines are equipped with rubber wheels and there will be a slight rocking when the
machine is stopping, strapping, and releasing a parcel. This is normal. If equipped with the optional
steel wheels, this rocking will be eliminated.
2. LOADING OF STRAP
Now that the machine is ready for operation, the first thing that needs to be accomplished is loading
the strap.
1) Remove the locking nut on the reel shaft.
2) Then remove the outer flange.
3) Take a roll of plastic strapping from its box and following the directional unwinding arrows on the
reel flange, slide the coil over the inner hub.
4) Then replace the outer reel flange and the locking nut.
5) Tighten the nut snug and the cut the retaining ribbons or tape on the strapping roll.
6) After the tape or ribbon is cut and remove, tighten the locking nut firmly.
Cut the end of the strap straight.
Following the instructions on the side of the machine, load the strap in (curl down) and turn AUTO
LOAD switch to right. The upper STRAP FEED switch will illuminate if the loading process was
correct.
3. PREPARING FOR OPERATION
Once the machine is loaded and the STRAP FEED switch is illuminated, the machine can be cycled
and tested.
Place 200mm to 250mm high test parcel in the arch and push the MANUAL STRAP button. The
machine should apply a strap around the parcel at whatever tension the tension adjustment knob is set
at.

GP44 Semi-Automatic Strapping Machine
OPERATION -18-
HOW TO LOAD STRAP
1. Make sure strap is clear from photo eye S3.
2. Turn Auto Load Switch to the left.
3. Load a coil on the reel as per drawing so that a tip of strap may be pulled and then
Reel Cover and Reel Nut may be installed and Reel Nut may be tightened firmly.
4. Thread strap through the guide roller and insert the strap into the entrance until
the strap reaches the feed roller. S3 will sense the strap.
5. Turn Auto Load Switch to the right so that the strap feeds into the arch completely.
NOTE: Strap Feed Complete Light glows green when strap has successfully fed around the arch.
ADJUSTING OF STRAP TENSION
Reel Coil
Reel Cover
Reel Nut
Auto Load Switch
Tension Knob
Entrance
Emergency Stop Switch
Circuit Power Switch
(With Light)
Strap Feed Complete Light
Strap Present
Photo Eye (S3)

GP44 Semi-Automatic Strapping Machine
OPERATION -19-
ADJUSTING OF STRAP TENSION
There is Tension Knob in the right side of the machine.
1) By turning it clockwise, the strap tension is high.
2) By turning it anti-clockwise, the strap tension is low.
NOTE: It should be turned gradually. Adjusting this knob changes the gap between the two rollers that
pull tension on the strap. (The greater the gap, the less “bite” on the strap, therefore, the less tension)
Tension Knob

GP44 Semi-Automatic Strapping Machine
OPERATION -20-
SEQUENCE OF OPERATION
STRAPPING CYCLE
All strapping machines follow the same basic strapping cycle. They all perform the following functions.
Feed strap
Grip lead end of the strap
Initial retraction/tension
Controlled tension
Release tension, cut and weld. Release strap.
FEED STRAP
With the cam in home position, the strap feed solenoid (sol 4) (PLC output Y27) is engaged which forces the
strap feed roller against the drive wheel and the strap feed motor is engaged in the forward direction. This
sends the strap through the arch until the end of the strap hits the strap end detect switch (M switch) (PLC
input X03) to signal the machine is ready to cycle.
GRIP LEAD END OF STRAP
The package detect photo eye (PLC input X13) is signaled in automatic mode (or the machine is cycled
manually) to start a cycle.
When the cycle starts, the cam shaft motor M1 (PLC output Y01) turns, this causes the first gripper to extend
to the first position with moderate pressure on the strap against the slide plate. Also the slide plate retracts
approx. 3/8” to allow the strap to clear the strap end detect switch area (the switch turns off). The cam shaft
turns until it turns on the cam proximity switch (B switch) (PLC input X05). It then starts a short timer in the
PLC, which then stops the motor by applying a brake. The camshaft should now be in the initial retraction
position (2nd detent). NOTE: If the package detect photo eye looses sight of the package during the cycle,
the feed retract motor will stop.
INITIAL RETRACTION/TENSION
When the cam proximity switch (B switch) (PLC input X05) is made, it starts the primary tension motor M2
(PLC output Y02) (in reverse). When the motor starts, it also engages the strap feed solenoid (Sol 4) (PLC
output Y04) to pull initial (soft) tension. This pulls the strap out of the arch. As the strap exits the arch and
tightens on the bundle, it trips the primary tension complete switch (PLC input X06). Initial retraction is now
complete.