Samuel Strapping Systems P-625 Guide

Columbus, OH Etobicoke, ON Fountain Inn, SC Longview, TX Paris, France Scarborough, ON Woodridge, IL
Detroit, MI Fort Mill, SC Kilnhurst, U.K. Mississauga, ON Rock Hill, SC Winchester, TN
A Samuel Manu-Tech Company
SAFETY, OPERATION,
MAINTENANCE AND
PARTS MANUAL
P-625
P-725
P-625 & P-725
SEMI-AUTOMATIC STRAPPING MACHINE
and P-625E & P-725E Electric Tension versions
9-16-08 S/N 02040170 AND HIGHER

2
SAFETY INSTRUCTIONS
THIS MANUAL GIVES YOU INFORMATION ON SAFETY
INSTRUCTIONS, SPECIFICATIONS, OPERATION AND MAINTENANCE
OF STRAPPING MACHINES.
BEFORE OPERATING OR SERVICING THE MACHINE, PLEASE
REVIEW THE ENTIRE MANUAL AND FOLLOW THE SAFETY
INSTRUCTIONS CAREFULLY.
OPERATION
1. Do not operate the machine with the tabletops or covers removed.
2. Make sure the proper voltage is being used to operate the machine.
3. Never put any part of your body near, under or into a moving machine.
4. Do not operate the machine with any safety devices removed or disabled.
5. Follow instructions provided in this manual.
6. Only trained people should operate this machine.
7. Do not attempt to strap any part of your body.
8. Do not overload the machine by exceeding the performance limitations specified in
this manual.
MAINTENANCE
1.Shut off and lock out all electrical power before performing any maintenance
procedure.
2. Use the correct tools and parts to repair the machine.
3. Only trained people should service the machine.
4. Follow instructions provided in this manual.
ADDITIONAL CONSIDERATIONS
1.Do not touch the heater and the surrounding area. The heater operates at
approximately 6081F. (3201C). Allow sufficient time for the heater to cool down.
2.The machine should be placed on a level floor and the surrounding area should be
kept free of debris and discarded strap.
3.If you are unsure about the operation or the maintenance of the machine, contact
your nearest Samuel Strapping Systems office.
This symbol: is used throughout this manual and in conjunction with one of three
words: CAUTION, WARNING or DANGER. It is used to alert operators and
maintenance personnel to a condition that requires special to extreme care to avoid
personal injury.

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TABLE OF CONTENT
PAGE #
INTRODUCTION 5
MAJOR COMPONENTS 5
EXTERIOR MACHINE 6
STRAPPING HEAD 8
INSTALLATION 9
PREASSEMBLY OF MACHINE 10
THREADING STRAP THRU MACHINE 11
OPERATORS CONTROLS 11
STRAPPING CYCLE 13
PRINCIPAL OF OPERATION 14
SERVICE ADJUSTMENTS AND CLEARANCES 20
MAINTENANCE 22
TROUBLESHOOTING 23
PARTS LIST AND EXPLODED VIEWS 23
ELECTRICAL SCHEMATIC - Standard 52
ELECTRICAL SCHEMATIC - Elect. Tension Option 53

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5
INTRODUCTION
This manual contains safety, operating
and maintenance instruction for the P-
625 and P-725 Semi-automatic Power
Strapping Machines. These models are
designed to strap packages with
Polypropylene Strap 1/4” to 5/8” (6mm
to 15mm) wide. The strap ends are
joined by means of ‘Hot-Knife’ welding
process.
MAJOR COMPONENTS
In figures 1 through 4, the major
components of the machine and the
strapping head are shown in detail. A
detailed description of additional
systems and specific components are
as follows:
STRAP DISPENSER:
The dispenser supplies strapping
material to the strapping head. It is
located inside the cabinet on the lower
left-hand side. A friction brake is
provided to limit over-run of strap.
1. GRIP – The grip holds the lead end of
the strap beneath the anvil while the
remainder of the strap is being
tensioned around the package.
2. STRAP FEED AND TENSION – Both
feed and tension are achieved by two
sets of gear rollers powered by an
electric motor by means of a drive-
belt and slip-clutch system.
An operator controlled adjustable
timer controls the duration of strap
feed. When the set time for feed is
up, the timer stops feeding strap. If
additional feed is required beyond
that determined by the timer setting,
jog feed will be facilitated by pushing
the ‘Jog Feed’ button on the
operator’s control panel.
3. WELDING AND CUT-OFF – Welding
of the strap ends and cutting of the
strap supply are facilitated in this
process.
4. PACKAGE RELEASE – After a
short weld-cool period (necessary to
avoid welded ends from popping
open) the package is released.
(Note:) The previously mentioned
functions of 1, 3 and 4 are driven by a
cam shaft coupled to the drive system
by means of electromagnetic clutch
which turns one full revolution per cycle.
HOT KNIFE. The ‘Hot Knife’ is centrally
located at the front of the strapping
head. Movement of the knife is
controlled by a cam.
ELECTRICAL SYSTEM. An all new
electrical system using solid state
technology supplies continual power
supply to the electrical components
within the machine. Using simple to
insert circuit boards provides for safe
and fast maintenance free operation.
OPERATOR CONTROLS. The
Electrical Control panel consists of the
‘Main Power ON-OFF Switch,’ ‘Feed
Length Timer,’ ‘Reset Switch’ and ‘Feed
Length Switch’ (Jog Feed) and Electric
Tension Control (on P-625E & P-725E
versions).

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7

8

9
INSTALLATION
Installation requires that the machine be
uncrated in its proper position and secured in
place with the casters locked. Operation may
begin once strap of the proper size is loaded
and the power cord plugged into the appropriate
electrical outlet.. See pre-assembly instructions
on the following page for additional set-up
instructions.
One set of tools and spare parts is packed with
each machine for use in making adjustments
and for replacement of parts as needed. Please
compare your supplied tools with the following
list:
TOOL PARTS
1 Phillips screwdriver (4”)
2 8mm/10mm open end wrench
1 5mm Allen wrench
1 4mm Allen wrench
1 3mm Allen wrench
1 2.5mm Allen wrench
SPARE PARTS
1 4-08000-140 Brake rubber (P-625 only)
1 2201109130 Brake spring (P-625 only)
1 4-01000-150 Retainer, top cover holder
1 104G001 Microswitch, heavy (LS-1)
1 2201210020 Tension spring, short
1 2201011022 Tension spring, long

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PREASSEMBLY OF P-625 & P-725 MACHINES
The P-625 and P725 Strapping machines are
normally pre-assembled and tested prior to
shipping, however if your P-625 is received with
the legs disassembled, the following procedure
should be followed. Open the top cover of the
P-625 and place the machine on a steady
working surface. Remove the temporary
wooden legs from the machine and install the
round machine legs by putting the leg
assemblies into the base of the machine with the
screw facing up and locking the down with the
M12 nuts and washers. Attach the casters to
the legs by screwing them into the base of the
legs. Once the legs have been installed, the
dispenser assembly can be mounted to
machine. On the Gear Box, remove the
setscrew in the Vent Plug.
FIGURE 8. P-625 LEG ASSEMBLY
The dispensers are designed to accept strap
core diameters of 8” (200mm), 9” (230mm), and
11” (280mm). Refer to Figure 10 to make the
adjustments.
1. For an 8” core diameter, position the holes
of the Reel Claw (item 6) to the #1 and #3
positions for all three Claws and screw the
claw in place with two M6x20 Screws.
2. For a 9” core diameter, position the holes of
the Reel Claw (item 6) to the #2 and #4
positions for all three Claws and screw the
claw in place with two M6x20 Screws.
3. For an 11” core diameter, position the holes
of the Reel Claw (item 6) to the #3 and #5
positions for all three Claws and screw the
claw in place with two M6x20 Screws.
LOADING STRAP INTO THE MACHINE
On the P-725 machine, open the Dispenser
access panel and remove the dispenser
assembly as shown on Figure 10.
1. Turn the Reel Nut Handwheel to disengage
the handwheel from the shaft.
2. Remove the Outer Flange from the shaft
and set aside.
3. Place a coil of strap on the Inner Flange
with the strap pay-off going clockwise as
shown on Figure 11. Allow the plastic wrap
to poke through the shaft. (Note: do not
remove the protective plastic wrap from the
strap coil)
4. Replace the Outer Flange and reinstall the
Reel Nut Handwheel.
5. Remove the protective plastic wrap from
the strap coil at this time.
6. Place the dispenser assembly back into the
rear-end of the machine. Make sure the
assembly is positioned correctly with the
Handwheel facing to the right and the ends
of the shaft resting in the machine brackets.
7. When the dispenser is installed correctly,
close the rear panel door.
On the P-625machine the same procedure is
followed as in the P-725 machine except, the
Inner Flange and Shaft assembly are not
removed from the machine and the strap coil is
loaded directly onto the machine.

11
THREADING STRAP THRU MACHINE
The threading process involves routing the strap
from the dispenser and up through the strapping
head. Refer to Figure 11 for threading the P-725
Machine and Figure 11A for threading the P-625
Machine.
On the P-725 Machines:
1. Open the right-hand door and pull about 3
feet (1M) of strap from the coil.
2. Thread the strap through the lopper (B), pass
it under roller (C) and allow it to exit the
cabinet. On the P-725, close the right-hand
door.
3. Pull up on the strap, then insert the lead-end
between the guide roller (D).
4. Continue to push the strap through the head
until it can be seen at point (E).
On the P-625 Machine:
Follow the same procedure except reach in from
the front or right of the machine and pull about 3
feet of strap from the coil.
OPERATORS CONTROLS
The P-625 and P-725 controls are identical,
however, the mechanical and electrical tension
versions are different as follows:
MECHANICAL TENSION VERSION
CONTROL PANEL. The control panel is located
on the left-hand side of the front panel of the
machine. (See Figure 12)
FIGURE 12. CONTROL PANEL
POWER SWITCH. An Illuminated push button
glows when power is turned on. All electrical
circuits and the electric motor are then
energized. Pushing the “POWER” switch once
more cuts off all power supply to the machine.
STRAP FEED LENGTH TIMER. The length of
the pre-fed strap can be adjusted to
automatically feed from 1” (25mm) to
approximately 25 feet (7620mm) using the
LENGTH timer.
RESET SWITCH. When pushed, the strapping
head cycles to the home position.
FEED LENGTH SWITCH. When pushed,
additional strap is fed out into the strap channel.
Strap feed will continue as long as the button is
depressed.
COOLING TIME - MOTOR SHUT DOWN TIME.
The cooling time and motor shut down can be
set by turning the pots shown on the circuit
board.(FIGURE 13) Turn the pot CW to increase
and CCW to decrease the time settings.
CAUTION: Be sure to shut power OFF before
making any changes on the board.
FIGURE 13. CIRCUIT BOARD MECH TENS.

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OPERATORS CONTROLS cont’d
ELECTRIC TENSION VERSION
CONTROL PANEL. The control panel is located
on the left-hand side of the front panel of the
machine. (See Figure 12A)
FIGURE 12A. CONTROL PANEL
POWER SWITCH.
An Illuminated push button glows “Green” when
power is turned on. All electrical circuits and the
electric motor are then energized. Pushing the
“POWER” switch once more cuts off all power
supply to the machine.
STRAP FEED LENGTH TIMER. The length of
the pre-fed strap can be adjusted to
automatically feed from 1” (25mm) to
approximately 25 feet (7620mm) using the
LENGTH timer.
TENSION CONTROL. The amount of tension
applied to the package can be controlled by
turning the control CW for more tension and
CCW for less tension.
RESET SWITCH. When pushed, the strapping
head cycles to the home position.
FEED LENGTH SWITCH. When pushed,
additional strap is fed out into the strap channel.
Strap feed will continue as long as the button is
depressed.
MOTOR SHUT DOWN DIP-SWITCH.
The dip-switch setting allows the user to adjust
the time the machine sits idol before the motor
shuts down. Set the dip switches as shown on
Figure 13A. CAUTION: Be sure to shut power
OFF before making any dip switch changes.
FIGURE 13A. COOLING DIP-SWITCH
TENSION TIME AND MINIMUM TENSION
The tension time and minimum tension settings
can be adjusted on the Circuit Board by adjusting
the two pots as shown on FIGURE 13B. The
minimum tension (W1) pot controls the lower
limit of the tension setting by rotating the pot CW
for more tension and CCW for greater tension.
The tension time (W2) adjusts the time tension is
applied. Turn W2 CW for more time and CCW
for less time.
FIGURE 13B. CIRCUIT BOARD ELECT TENS
COOL TIME SETTING
One additional control on the Electrical Tension
machine is located on the right side of the
electrical enclosure. This is a pot that adjusts
the cool delay for the machine. Turn the Pot CW
for more cool delay, CCW for less cool delay.
The cool delay allows the welded joint to properly
set before the strap is released. This adjustment
is used if an adequate joint is not achieved by
adjusting the Hot Knife temperature control.

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STRAPPING CYCLE
The machine is now ready for strapping a
package. To operate the machine, proceed as
follows:
1. Push the power switch to the “ON” position
and allow the hot knife 5 seconds to reach
operating temperature.
2. Place a package on the tabletop, directly
above the sealing head. Allow the package
to contact the package stop to the right.
3. Grasp the end of the strap on the left side
and bring it over the package and insert the
end into the strap channel on the right side of
the package. As the lead-end of the strap
closes LS1, the strap will tension, weld and
release the package automatically.
CAUTION: Be sure to keep fingers
from beneath the strap.
4. Remove the strapped package and note the
length of the strap fed out for the next cycle.
If the strap is too short or too long, adjust the
timer as needed.
5. Note the condition of the weld and the
tension of the strap on the package. If the
condition of the weld or the level of tension is
unsatisfactory, adjust the hot knife
temperature or the tension level as needed.
Refer to the OPERATING ADJUSTMENTS
section.
OPERATING ADJUSTMENTS
The following adjustments may need to be
performed if changes in the package size,
tension requirements or change in strap size is
needed.
ADJUSTING TENSION
On Mechanical Tension machines, if tension
adjustment is required, proceed as follows:
Turn the knurled knob located at the rear of the
machine, clockwise to increase tension,
counterclockwise to decrease tension.
On Electric Tension machines, adjust the tension
by turning the tension control knob in the front
panel.
ADJUSTING HOT-KNIFE TEMPERATURE
If the weld does not hold on the package, easily
comes apart, or appears to be overheated, an
adjustment to the weld temperature may be
required. The hot-knife rheostat control is found
under the tabletop in a box mounted next to the
strapping head. Make corrections in small
increments according to the following conditions.
RAISING HOT-KNIFE TEMPERATURE - If the
weld appears to have insufficient heat to melt the
strap, turn the hot-knife rheostat in a clockwise
direction.
LOWERING HOT-KNIFE TEMPERATURE - if
the condition of the weld appears to be over
heated, turn the rheostat counterclockwise.
STRAP GUIDE ADJUSTMENT FOR VARIOUS
WIDTHS OF STRAP.
The machine is designed to handle strap widths
of 1/4” to 5/8” (6mm to 16mm).
To adjust the Exit Guide for the proper strap,
loosen screws (# 5) mounting the adjustable exit
guide (# 2) and slide the adjustable guide as
wide as possible. Do not loosen or move the
lower guide (# 1).
Thread the strap through the machine and have
the end extend approximately 6” past the head.
With the edge of the strap against the lower exit
guide (#1), slide the adjustable guide against the
strap then back the guide off approximately
0.004” (1mm). Lock the adjustable guide (# 2) in
place with the screws (# 5). Check that the strap
is not pinched and that it can easily pass through
the guide.
To adjust the Entry Guide loosen the screws (#
8 ) and place a scrap piece of strap between the
upper (# 6) and lower (# 7) guides. Move this
assembly so that the scrap piece of strap is in
line with the strap exiting the head. Once
alignment is made, retighten the mounting
screws (# 8).
Apply a few straps on a package. Strap should
feed out of the head easily and the weld should
not be misaligned. If misalignment occurs,
readjust the entry guide.

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PRINCIPAL OF OPERATION
GENERAL
The strapping cycle can be divided into three
distinct operations:
a. Grip and tension
b. Weld, cut, and release
c. Feed
The following descriptions refer to Figures 15
through Figure 20. Note that both the
mechanical and the control functions of the micro
switches are described.
1. NEUTRAL POSITION. When the strap is
initially threaded through the machine, it
enters the head under the strap guide and
over roller ‘D’, between two sets of feed and
tension rollers and on through a slot in the
end gripper. It then passes beneath the
anvil, over the welding clamp and holding
gripper and out into the strap channel on the
left-hand side of the tabletop where the
operator has access to it.

15
2. ENCIRCLING PACKAGE; TRIPPING LS1.
Grip and tension is initiated by the operator
who encircles the package with the strap and
inserts the strap end into the slot of the
upper strap guide on the right-hand end of
the machine. In doing so, the strap is guided
between the gripper portion of the end
gripper and anvil then into a slot in the anvil
where it makes contact with the start switch
detector lever. As the lever moves to the
left, it trips the cycle start switch, LS1.

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PRINCIPAL OF OPERATION cont.
3. TENSION. When LS1 is closed, the
electromagnetic clutch energizes and the
camshaft rotates approximately 45 degrees.
This small amount of shaft rotation is
controlled by LS3, mounted at the right-hand
end of the camshaft. When LS3 closes it de-
energizes the electromagnetic clutch and the
end gripper will have been moved upward to
contain the upper strap beneath the anvil.
The tension lever pivots and closes the tension
rollers. The tension rollers close against the
strap, drawing it back through the head, thus
tensioning it around the package. When full
tension has been drawn, the electronic tension
detector reacts at the same time the
electromagnetic clutch energizes again.

17
4. HOLDING GRIPPERS RISES; HOT-KNIFE
MOVES INWARD. Momentarily, the
electronic tension detector energizes the
control circuit to energize the electromagnetic
clutch and turn the cam shaft. As the
camshaft turns, the holding gripper rises to
contain the other end of the strap beneath
the anvil. The tension lever is lowered to
release tension and the welding clamp
begins to rise.
It’s important to note that all tension to
the strap must be released before the
strap is cut, otherwise the strap-end
could be damaged and feeding reliability
will be affected.
The hot-knife moves in between the two
layers of strap.
NOTE: TENSION ROLLERS ARE
RELEASED AND STRAP IS AT
REST.

18
PRINCIPAL OF OPERATION cont.
5. STRAP IS CUT; WELD IS MADE. The
welding clamp cuts the strap during it’s
upward movement then pushes the upper
surface of the lower strap against the lower
surface of the hot-knife. It then pushes the
hot-knife against the lower surface of the
upper strap.

19
6. WELD IS RELEASED; HEAD RETURNS TO
HOME POSITION.
The hot-knife retracts and the welding clamp
pushes the two molten surfaces together,
welding the strap.
After this short delay, to ensure that the strap
has fused properly, the camshaft again turns
and the holding gripper, the welding clamp
and the end gripper retract to the neutral
position.
The anvil then retracts and the welded strap
is released to the lower side of the package
The camshaft returns to the home position
and closes LS3 and LS5. The
electromagnetic clutch is de-energized by
LS3 while LS5 energizes SOL1. As the
solenoid pulls down on the tensioning lever,
the feed rollers close against the strap,
pushing it through the head and out into the
strap channel. The feed timer de-energizes
and SOL1 is released.
Strap feed stops and the machine is ready
for the next cycle.
NOTE: SOL1 ENERGIZES TO CLOSE
FEED ROLLERS AND FEED STRAP
AFTER THE CAM SHAFT REACHES
HOME POSITION

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SERVICE ADJUSTMENTS AND CLEARANCES
ANVIL: To insure that the anvil operates
smoothly, a minimum clearance between the
anvil and the left and right guides must be
maintained. To adjust, proceed as follows:
1. Make sure the right-hand guide is securely
mounted.
2. Loosen the two left-hand guide mounting
screws.
3. Insert a shim, 0.002” (.050mm) thick. x .118”
(3mm) wide x 5” (130mm) long between the
shoulder of the anvil and the left guide.
4. Push the left guide against the anvil and
tighten the left guide mount screws.
5. Remove the shim and check to make sure
the anvil moves smoothly.
SWITCH CAM: The switch cam is a two level
cam. The inner cam actuates LS5. The outer
cam actuates LS3.
To make sure the cams are set properly,
proceed as follows:
1. Make sure the machine is in the neutral or
home position.
2. If the micro-switches need adjusting, loosen
the mounting screws and set LS5 as shown
on Figure 22. When properly set, tighten the
mounting screws.
3. Position LS3 as shown in Figure 23. When
set, tighten the mounting screws. As the
cam rotates clockwise, the transition from B
to A starts the cooling time.
WELDING CLAMP AND END GRIPPER: To
adjust the clearance between the welding clamp
and the end gripper, refer to Figure 24 and
proceed as follows:
1. Remove the anvil.
2. Loosen the two socket head cap screws that
secure the “L” shaped adjustment bracket to
the casting.
3. Push the block left or right to adjust the
clearance.
4. When set, securely tighten the two mounting
screws.