Polychem SP3100 Guide

OPERATION MANUAL |SPARE PARTS LIST
SP3100
PNEUMATIC TENSIONER FOR STEEL STRAPPING
READ ALL INSTRUCTIONS BEFORE OPERATING THE TOOL
POLYCHEM CORPORATION
6277 HEISLEY ROAD, MENTOR, OHIO 44060
PHONE: [phone], FAX: [phone]
WWW.POLYCHEM.COM
ED. 09/11
CHOKE COLLAR
OPERATING VERSION

GENERAL SAFETY INSTRUCTIONS:
TABLE OF CONTENTS
1) Safety instructions
2) Technical data
3) Warranty and liability
4) Installation
5) Operating elements
6) Operation
7) Servicing and cleaning
8) Troubleshooting
9) Layout – spare parts list
READ THE OPERATING INSTRUCTIONS CAREFULLY
WHEN OPERATING THE TOOL, WEAR EYE, FACE AND HAND SAFETY PROTECTION
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.
Never operate this tool using bottled air or other gas source. Do not exceed the air pressure
range as shown in this operation manual. For all adjustments, repairs or cleaning of the tool,
always disconnect air supply. Always use dry, clean and lubricated compressed air.
1) SAFETY INSTRUCTIONS

DESCRIPTION OF THE TOOL: The tool model SP3100 is designed to tension steel strap. The strap is fed around the
package manually and inserted in the tool and tensioned as shown in the instructions.
TOOL SIZE
Length:
340mm – 13.4”
Width:
115mm – 4.5”
Height:
90mm – 3.5”
Weight:
4kg – 8.8lbs (4.3Kg-9.5 lbs.
with choke collar)
AIR
REQUIREMENT
Pressure Range:
78-99 psi
Air Consumption:
25 cuft/min
PERFORMANCES
Max. Tension force:
15000N
Tensioning speed:
6mt/m
CHART OF
TYPES:
ITEM
MODEL
STRAP
THICKNESS
T449941 Button
T449942 Choke collar
SP3100-3/4” – 1 ¼”
R 850 - 1100N/mm2
0.024” – 0.043”
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.
1) TECHNICAL DATA
2) WARRANTY CONDITIONS AND LIABILITY

It is recommended to always use a dryer unit near the compressor and a filter-regulator-lubricator
unit with pressure gauge (Polychem part # 200-0025) close to the tool air connection to avoid
water and dirt in the valves or in the pneumatic motors. Connect the tool to air with quick
connector ¼” and use minimum 8mm or 3/8” internal diameter pipe; max length for flexible pipe 10
m between tool and regulator group. Check that your compressor / air distribution plant is able to
supply the right air quantity as shown in the operation manual without losing pressure.
200-0025
3) INSTALLATION
5) OPERATING ELEMENTS AND ADJUSTMENTS
OPENING LEVER
TENSIONING BUTTON
TENSION MOTOR

Adjusting Strap Tension
The maximum strap tension can be adjusted with a screwdriver by turning the screw as shown in pic.A, on pneumatic
motor. Turning clockwise the tension will be decreased; turning counter clockwise the tension will be increased.
( A )
Feed Wheel Gap Adjustment
(B1) (B2)
It is possible to adjust the gap of the feed-wheel in order to change the feed wheel pressure on the strap; First
unscrew the locking screw (pic.B1) then turn the regulation screw so that the standard feed-wheel gap is 0.1-0.2mm
(0.0039”-0.0078”).Turning the screw clockwise will decrease the gap, and turning the screw counter clockwise will
increase the gap (pic.B2), after adjusting the gap tighten the locking screw (pic.B1).
CHOKE COLLAR TENSION

Make the strap slip into the seal and wrap it up around the package; then make strap bottom pass a second time into
the seal and bend it (pic.C1); push opening lever to open the tool and then insert top strap (pic.C2), press tensioning
button (for choke collar model turn it in clockwise) to tighten strap and hold it until tension is done (pic.C3);
When tension is complete use the SP6100 series tool to seal the strap (pic.C4); after the strap is sealed move the tool
up and down until the strap is cut off (pic.C5).
Then check to make sure the seal is sufficient (fig. C6).
(C1) (C2)
(C3) (C4)
(C5) (C6)
6) OPERATION

DISCONNECT THE TOOL FROM THE AIR LINE BEFORE PERFORMING ANY SERVICE: Clean with compressed air under the
wheel and tension foot as shown in the picture.
PROBLEM
REMEDY
Not enough strap tension
Check the air pressure (min.78 psi)
Check if the filter / lubricator group is damaged or dirty. Check if the pneumatic motor is damaged or
dirty (contact the after sale service). Check the tension adjusting screw on the pneumatic motor
The feed wheel slides and mills the strap
Check if the feed wheel is dirty or damaged
Adjust the gap between feed wheel and bottom plate (around 0,2mm—0.008”)
The seal is damaged during the tension cycle
Too much tension force—adjust the motor power. Check on foot if the seal support points are
damaged or worn out. Check if the strap characteristics are right for the strapping tool and
application
The tensioned strap is sideways and bent
Adjust the motor power—too much tension force. Check if the strap characteristics are right for the
strapping tool
Air leaking
Check the air connection. Gaskets may need replaced. (contact the after sale service)
The strap is not cut
Check if the strap characteristics are right for the strapping tool. Check if the front movable foot edge
is damaged or worn out
(7)SERVICING - CLEANING
7) TROUBLESHOOTING

Ed. 06/17
POLYCHEM
PART #
ITEM
DESCRIPTION
QTY.
189829
A000100
SHAFT SUPPORT ASSEMBLED
1
189122
B100296
PLUG 1/4" S2610 CAMOZZI
1
189105
B200309
GLUTCH MALE 1/4"
1
189830
B300130
O-RING OR3162 (D41)
1
189831
B300132
STOP OIL G 17X23X3
1
189608
B400108
BEARING 6003/C3
2
189832
B400109
ROLL BEARING BK1012
1
189833
B400110
BEARING 7202
1
189141
B500040
SCREW M6x16 UNI5931
2
189732
B500052
NUT M6 UNI5588
1
189834
B500107
SCREW M5x6 UNI5927
1
189835
B500142
SCREW M8x1x10 UNI5923
1
189819
B500143
SCREW M6x6 UNI5927
2
189836
B500144
SCREW M8x1x14 UNI5923
1
189837
B500145
WASHER M10 UNI6592
1
189733
B500174
SCREW M6x16 ISO7380
1
189838
B500175
AUTO LOCKNUT M10 DIN985
1
189839
B500176
SCREW Ø12 M10x12x90 ISO7379
1
189611
B600117
BUSHING BMC 141615
1
189840
B600122
INT. SEEGER J47 U.7437 R150
1
189841
B600123
WASHER PS 35X25X0.5
1
189842
B600124
WASHER PS 35X25X0.2
1
190060
B600346
CIRCLIP D15 UNI 7435
1
189843
B700151
CYL. PIN TMP 10X60 DIN6325
1
189633
B900355
PNEUM. MOT. BOSCH 448 BUTTON VERS.
1
189844
B900413
CHOKE COLLAR FOR BOSCH MOT.B900415
1
189655
B900414
BUTTON GROUP FOR BOSCH MOT.B900355
1
189845
B900415
PNEUM. MOT. BOSCH 448 CHOKE COLLAR
1
189846
D000870
SPACER
1
190127
D000900
ROLLER
1
§
189770
D000910
ROLLER PIN
1
189847
D000920
FOOT
1
189848
D000940
SEAL STOP
1
189849
D000950
MOVABLE PIN FOOT
1
190128
D000960
FEEDWHEEL
1
§
*
189690
D000970
SPRING 0,7x25
1
189850
D002410
WORM GEAR
1
189851
D002420
WORM WHEEL
1
189852
D002790
BEARING SUPPORT
1
189609
D002930
TENSIONING SHAFT
1
189620
D002940
BUSH
1
189760
D002960
RE-CALL SPRING
1
*
189619
D003190
FEEDWHEEL BODY
1
189853
D004320
SUPPORT PLATE
1
189854
D004330
OPENING LEVER
1
189855
D004350
SPACER
1
§
WEARING PART
*
PART THAT SHOULD BE STOCKED
9) LAYOUT-SPARE PARTS LIST

SP3100

TENSION MOTOR WITH BUTTON

No.$
ITEM $
QTY $
DESCRIPTION $
POLYCHEM$PART$#$
1 "
3"600"760"114"
1 "
MOTOR"HOUSING"/"BLUE"
189730"
2 "
3"604"090"062"
1 "
STATOR"/"370W"
X"
3 "
3"604"220"025"
1 "
ROTOR"
X"
5 "
3"605"700"005"
1 "
BEARING"FLANGE"
189728"
6 "
3"600"905"039"
1 "
DEEP-GROOVE"BALL"BEARING"/"9x24x7MM"
190004"
7 "
3"605"700"006"
1 "
BEARING"FLANGE"
205673"
8 "
3"600"905"148"
1 "
DEEP-GROOVE"BALL"BEARING"/"DIN"625-7x19x6"
190005"
9 "
2"600"202"013"
1 "
SPACER"RING"
X"
10 "
2"600"202"014"
1 "
SPACER"RING"
X"
11 "
2"916"011"012"
1 "
PLAIN"WASHER"/"DIN"125-A5,3-ST"
190192"
12 "
2"911"061"150"
1 "
HEX"SCREW"/"DIN"933-M5x8-8.8"
X"
14 "
3"606"316"000"
3 "
CYLINDRICAL"GEAR"/"Z=12"
189990"
15 "
3"600"913"000"
6 "
NEEDLE-ROLLER"ASSEMBLY"/"INA"K3x5x7"
189781"
26 "
3"606"300"002"
1 "
PINION"/"Z=23"
X"
27 "
3"600"101"001"
1 "
STOP"DISC"
X"
28 "
3"606"334"091"
1 "
RING"GEAR"
X"
29 "
3"606"337"071"
1 "
PLANETARY-GEAR""CARRIER "
X"
30 "
3"606"316"001"
3 "
CYLINDRICAL"GEAR"/"Z=16"
X"
31 "
3"600"113"010"
1 "
FRICTION"WASHER"
X"
33 "
3"603"201"000"
3 "
NEEDLE"ROLLER"
205974"
34 "
3"603"201"044"
2 "
NEEDLE"ROLLER"
X"
36 "
3"600"900"016"
1 "
DEEP-GROOVE"BALL"BEARING"
X"
38 "
3"606"337"208"
1 "
PLANETARY-GEAR""CARRIER "
X"
40 "
2"600"210"024"
1 "
O-RING"/"32x2"MM"
X"
41 "
3"600"905"145"
1 "
DEEP-GROOVE"BALL"BEARING"
X"
42 "
3"600"910"018"
1 "
FREEWHEELING"
X"
43 "
1"900"210"113"
1 "
O-RING"/"15x2,5"MM"
X"
44 "
2"916"650"011"
1 "
SPRING"RETAINING"RING"/"DIN"471"20x1,2"
X"
45 "
3"606"337"105"
1 "
PLANETARY-GEAR""CARRIER "
X"
46 "
3"603"344"055"
1 "
THREADED"RING"
X"
48 "
3"606"316"053"
3 "
CYLINDRICAL"GEAR"/"Z=14"
X"
49 "
3"600"903"001"
3 "
NEEDLE-ROLLER""ASSEMBLY "
X"
50 "
3"600"101"024"
2 "
FRICTION"WASHER"
X"
53 "
3"604"710"070"
1 "
BOLT"
189637"
55 "
1"900"210"306"
1 "
O-RING"/"10x2"MM"
X"
56 "
3"605"190"192"
1 "
VALVE"HOUSING"
X"
57 "
3"601"010"002"
1 "
SILENCER"
189729"
58 "
3"600"210"126"
1 "
O-RING"/"6x2,5"MM"
189651"
60 "
3"600"002"000"
1 "
STRAINER"
189915"
62 "
3"603"458"018"
1 "
FITTING"
189670"
65 "
3"600"210"036"
1 "
O-RING"/"16x1,25"MM"
189663"
66 "
3"604"710"051"
1 "
STRAIGHT"PIN"
X"
68 "
1"903"230"528"
1 "
BALL"/"DIN"5401-9,5MM-III-ST"
189649"
69 "
3"604"616"018"
1 "
COMPRESSION"SPRING"
189650"
78 "
2"917"700"040"
1 "
GROOVED"PIN"/"DIN"1475-2x18-ST"
189734"
82 "
3"604"643"011"
1 "
COMPRESSION"SPRING"
189636"
83 "
1"603"231"013"
1 "
PUSH-BUTTON"
189635"
84 "
3"600"210"105"
1 "
O-RING"/"1,8x1,2"MM"
189647"
86 "
3"603"435"032"
1 "
ADJUSTING"SCREW"
189652"
87 "
3"600"210"015"
1 "
O-RING"/"4x1"MM"
189648"
90 "
3"600"105"002"
1 "
SILENCER"
X"
95 "
3"601"106"047"
1 "
NAMEPLATE"
X"
99 "
3"601"110"331"
1 "
MANUFACTURER'S"""NAMEPLATE "
X"
804 "
3"607"030"249"
1 "
ASSEMBLY"OF"SERVICE"PARTS"
X"
$

No.
ITEM
QTY
DESCRIPTION
JDE PART #
53"
3"604"710"071"
1
BOLT"
X"
55"
1"900"210"306"
1
O-RING"/"10x2"MM"
X"
56"
3"605"190"194"
1
VALVE"HOUSING"
X"
57"
3"601"010"002"
1
SILENCER"
189729"
58"
3"600"210"126"
1
O-RING"/"6x2,5"MM"
189651"
59"
3"605"700"172"
1
FLANGE"
X"
60"
3"600"002"000"
1
STRAINER"
189951"
62"
3"603"458"020"
1
FITTING"
X"
63"
3"603"201"068"
1
NEEDLE"ROLLER"
X"
65"
3"600"210"036"
1
O-RING"/"16x1,25"MM"
189663"
66"
3"603"201"000"
1
NEEDLE"ROLLER"
205974"
67"
3"600"409"009"
1
SLEEVE"
X"
68"
1"903"230"528"
1
BALL"/"DIN"5401-9,5MM-III-ST"
189649"
69"
3"604"616"008"
1
COMPRESSION"SPRING"
X"
82"
3"604"651"018"
1
EXTENSION"SPRING"
X"
84"
3"600"210"105"
1
O-RING"/"1,8x1,2"MM"
189647"
86"
3"603"435"032"
1
ADJUSTING"SCREW"
189652"
87"
3"600"210"015"
1
O-RING"/"4x1"MM"
189648"
90"
3"600"105"002"
1
SILENCER"
X"
95"
3"601"106"047"
1
NAMEPLATE"
X"
TENSION MOTOR WITH CHOKE COLLAR
SPARE$PARTS$LIST$401-0299$

I
Polychem Corporation declares under own responsibility that the under mentioned machinery, to
which this declarations refers, is in conformity with 2006/42/CE Directive and successive
modifications, as well as with standards EN12100-1 / EN12100-2
POLYCHEM CORPORATION
6277 HEISLEY ROAD
MENTOR, OHIO 44060
Tel.: [phone] Fax: [phone] www.polychem.com
Manufactured in Italy
MODEL:
Series SP3100
MACHINE TYPE