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