Signode BXT2 User manual

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BXT 2
BXT 2-19
Maintenance
Manual

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Content:
1. Preface ..................................................................................................................................................................3
2. Basic Innovations...................................................................................................................................................3
3. Tool Design............................................................................................................................................................4
3.1. Housing/electrical components: ....................................................................................................................4
3.2. Welding unit..................................................................................................................................................5
3.3. Rocker lever and reset..................................................................................................................................6
3.4. Rocker and toothed plate..............................................................................................................................6
3.5. Tensioning gear............................................................................................................................................7
3.6. Side cover with strap guides.........................................................................................................................7
4. Wear parts .............................................................................................................................................................7
5. Diagnostic aids ......................................................................................................................................................8
5.1. Cycle counter................................................................................................................................................8
5.2. Problem reports.............................................................................................................................................8
5.3. Service Interface.........................................................................................................................................11
6. Tool reset.............................................................................................................................................................14
7. Disassembling .....................................................................................................................................................15
7.1. Housing/electrical components ...................................................................................................................15
7.2. Welding unit................................................................................................................................................16
7.3. Rocker lever and reset................................................................................................................................17
7.4. Tensioning gear..........................................................................................................................................18
8. Assembly.............................................................................................................................................................18
9. Adjustments.........................................................................................................................................................19
9.1. Adjustment of the welding reset..................................................................................................................19
10. Lubricating chart..............................................................................................................................................20
11. Wiring ..............................................................................................................................................................21
12. Error Code List ................................................................................................................................................23
12.1. User Errors..................................................................................................................................................23
12.2. Device Error control system........................................................................................................................24
12.3. Device error battery.....................................................................................................................................25
12.4. Device Error Drive.......................................................................................................................................26
13. Wiring diagramm: ............................................................................................................................................28
14. Explosion drawing ...........................................................................................................................................29
15. Product information .........................................................................................................................................33
16. Contact............................................................................................................................................................33

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1. Preface
The objective of this maintenance manual is to familiarize a skilled technician with the tools particular
features and enable him to repair and maintain it independently.
Current issues of the operating instructions and the concerning product information sheets are essential
elements of this manual and have to be checked as well.
2. Basic Innovations
Following new technical features have been implemented in this tool generation:
Innovation
Advantage
Lithium-Ion battery technologie •Increased energie density
•negligible self discharging
•
no memory effect
Brushles DC Motor
•Higher Efficiency
•Wear-free
Automatic welding •Constant high sealing quality
•Ergonomic benefits
•
Increased productivity
Rocker with floating tooth plate
•Improved characteristics in tensioning
Revised Tension release pawl •
Improved handling

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3. Tool Design
3.1.Housing/electrical components:
The housing is carried out in 3 pieces. All processes are controlled and monitored by the Printed circuit
board (pos. 198). The PCB interacts via the signal cable (pos. 202) with the motor power electronics (pos.
212). The power electronics is required to run the brushless motor. You can find a schematic wiring
diagram in chapter 13.

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3.2.Welding unit
The unit is lowering automatically when the welding process is started. Depending on the direction of
motor rotation (freewheels) this is taking place as follows:
1. The cam ring (pos 109) is turning towards the switching cam (pos. 140, 143).
2. This forces the switching cam to go up and to push the welding unit downwards.
3. The eccentric axe (pos.155) is driving the welding shoe via needle bearing (pos.157)
The position of the cam ring needs to be controlled by the PCB. The required information about its
current position (reference point) is provided by the micro switch (pos. 103).
1. 2.
3.

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3.3.Rocker lever and reset
The Blocking Pawl (pos. 65) prevents the tension gear from turning backwards during tensioning. After
strapping has taken place, the rocker lever (pos.89) is pulled, the pawl and therewith the tension is
released. The reset cam (pos. 72) brings the welding unit back to its initial position.
The Micro switch (Part of pos. 103) scans the position of the rocker lever. When the lever is pulled, the
PCB does not allow initiating any function.
3.4.Rocker and toothed plate
The tooth plate (Pos. 53) is not tightened onto the rocker.
This principle has the advantage that regardless the strap
thickness the contact pressure is always consistent. The
gap between tooth plate and the tension wheel (Pos. 46) is
ensured by a bedstop on the cam disk, (Pos.44) notice the
arrow.
0-0.1mm
44
53
46

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3.5.Tensioning gear
There is a free wheel integrated into the bevel gear pinion (Pos. 132). Provided the appropriate turning
direction the free wheel delivers the torque to the 2 stage planetary gear and the tension wheel. To
loose the tension the ring gear (Pos.19) is released by the pawl axle (Pos. 59). See also chapter 3.3).
3.6.Side cover with strap guides
The strap guide (Pos. 179) is integrated into the
side cover. To set up the required strap width
the shims (Pos. 177, 178, 181) have to be
added or removed.
4. Wear parts
Tension wheel, toothed plate and knife are wear parts. In order to reduce costs for the enduser these
parts can easily be replaced by themselves. The operating instructions provide the necessary information
in chapter 7.1 – 7.3.

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5. Diagnostic aids
Service technicians are supported in fault finding by the tools firmware. Faults in operating sequence or
system errors are reported by acoustic signals or via the segment display by failure codes. Additionaly a
service interface allows detailed diagnosis with the help of your computer.
5.1.Cycle counter
To readout the number of strapping’s the tool has already accomplished, proceed as follows:
1. Press and hold the “F” button on the panel
2. Pull the Rocker lever
The number of cycles is indicated in the segment display:
- - 1 6 8 3 5 - - = 16‘835 Cycles
5.2.Problem reports
The reporting of events is structured as follows:
You will find a complete list with the failure codes and remedy in chapter 12 “Error codes”.
Event
Function counter (F-Numbers)
The function counter are counting
certain events during the tool
operation for service purpose. The
user is not affected. Counter
readings are displayed in the
service interface
User Errors (A-Numbers)
The A-Numbers identifie errors in
operating sequence. They are not
an indication of a tool related
defect (except defective switch).
The tool calls the users attention
to faulty operation.
Device Errors (E-Numbers)
These errors are normally not
caused by faulty operation. One or
more parameters are beyond their
valid range. When they occur
repeatedly, the tool needs
repairing.
Storage in the service interface
under „FUNCTION COUNTER“
Storage in the service interface
under „USER ABORTS“
Storage in the service interface
under „ERRORS“
Userinteraction Userinteraction

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Example of the event readout using the service interface:
As per description above, tool faults are displayed as E-numbers. Following diagram shall help to simplify
the fault finding:
E10
E11
Replace
battery
Replace
battery
E23
E34
Replace printed circuit board (Pos. 198)
Abort, the tool is in
standby mode again
Stop, the tool shuts down
Release
keypad
Replace
keypad
E12
Pull Rocker
lever
Replace
Microswitch
(Pos.103)
E13

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Clean mech.
components
E21
E22 E37
Replace power electronics (Pos. 212)
E35
Replace the
battery
E33
Let the tool
cool down
E30
Check wiring
PCB to power
electronics.
E31 E32 E25 E26
Plugg battery
properly
Replace
battery
Check wirings
power electronic
to contact plate
E20
Replace printed circuit board (Pos198.)
E24
E36E38
Check wirings
Motor to Power
electronics
Replace the
motor
Replace
battery
Check wirings
power electronic
to contact plate
Plugg battery
properly
Replace
battery
Check wirings
power electronic
to contact plate
Check wiring
PCB to power
electronics.
Abort, the tool is in standby mode again Abort, the tool shuts down

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5.3.Service Interface
As optional accessory a data cable (Art. Nr: 1821.163.153). for detailed fault diagnosis is available. Using
this data cable allows to readout the most important tool parameters on your computer and helps
debugging. Hyperterminal is required as user interface. Hyper terminal is already installed on every XP-
Computer. For other operating systems without Hyper terminal get into contact with Orgapack.
To set up Hyperterminal:
1. Start Programm Path: All Programmes\ accessories\Communication\Hyper Terminal
2. Type in a name for the
connection on which the set up
will be saved. E.g. Debugger.
Confirm by clicking „OK“ .
3. The window „Connect to“ will open. Chose Comm port,
COM1 in most cases. Confirm by clicking„OK“.

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4. Window „COM1 Properties“ will open. Make settings as
enclosed in the illustration. Confirm by clicking „OK“.
5. „Debugger“ Hyper Terminal will open. Cut the connection by clicking on Icon (5).
6. File/Properties/ASCII-Setup . Check the box „Echo typed characters locally.
7. Save the settings (File/Save) and close Hyper Terminal.
5
6

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Establish connection:
1. Plug the data cable to the serial interface(RS 232) of your computer.
Should your PC or Laptop not be equiped with a serial interface, you
have to purchase a virtual serial interface and connect via USB. Please
follow the instructions of the interface manufacturer.
2. Remove the battery from the tool. Remove the screws of the
motorhousing, untighten it and plug the data cable to data plug socket.
3. Start Hyper Terminal (saved configuration)
4. Insert the battery in the tool. The start screen will now be displayed (See
illustration). All Program steps (e.g. when tension button is pressed) can
now be monitored.
Potential failures in operating sequence are
displayed in plain text.
5. Following options are available by pressing key
2-4:
•2 Device History
•3 adjustable Cycle counter B e.g. to
reset after maintenance work.
•4 Reset of Device History,
recommended after maintenance work.
By pressing key 1 the start screen is displayed
again.
6. Remove the battery before unplugging the tool.
Plug socket
for data cable

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6. Tool reset
In some rare cases, it may occur that it is not possible to bring the welding unit back to its initial position
Also the rocker lever is blocked.
Important!
Reason for this behavior may be:
Never try to lift the rocker lever with force.
•Interrupt of power supply during welding process (disconnection of battery?!)
•Pulling the rocker lever with force during welding process (to protect the motor, it switches off
due to over-current consumption).
•Microswitch (Pos. 103) is defective reparation is necessary.
•PCB or wirings are faulty reparation is necessary.
To debug the 2 possibilities given on top, the tool is equipped with a reset feature, as also stated in
chapter 6.3 in the operating instructions:
1. Switch to fully automatic mode.
2. Press and hold the welding button, thereafter press the tension button.
The tool will now run the welding function and so turn the cam ring away from its inappropriate position.
But probably the motors torque may not be sufficient to do so. Do not try to execute this process more
than 3 times within a short period. Otherwise the motor may get damaged.
If you have not been successful so far, and the rocker lever is still blocked, proceed as follows:
1. Insert an Allen key (3mm) through the hole in front of the base plate and apply on cylinder head
screw. Pos. 164.
2. Turn 10 revolutions counterclockwise. Moderate effort may be needed to do so.
3. Pull rocker lever welding shoe must swing up.
1.
2.

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7. Disassembling
Please consider the explosion drawing which is printed on the last pages of the operating instructions.
Purpose of this manual is only to draw the technician’s attention to the most relevant issues.
7.1.Housing/electrical components
Important!
The connectors and cables have to be treated carefully. Never pull on the wiring to
disconnect the connectors.
1. Remove the screws
of the motor cover
(Pos. 191) and pull it
slightly backwards.
6. Remove side cover
(Pos. 175), 4 x Screw M4
(Pos. 41). Loosen the
screws of the housing, 7
x Pos.197.
Disassemble the housing
(notice the picture). Pay
attention to the wiring,
the housing cannot yet
be removed completely.
5. Disconnect the motor from the
power electronics
2. Disconnect
the intermediate
cable (Pos. 201)
4. Disconnect and remove the
intermediate cable (Pos. 201).
3. Disconnect the signal cable
(Pos. 202) from the PCB. If the
harness is secured with a cable
tie, cut tit.
Remove the motor cover.

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7.2.Welding unit
1. Remove cable
tensioning (Pos. 103)
2. Remove set screw
and compression
spring (Pos. 86 & 169).
3. Loosen centering screws (2x
Pos. 101) and remove them
completely.
4. The whole
welding unit can
now be pulled
backwards.
7. Disconnect the
Intermediate cable
(Pos. 201). Remove the
left part of the housing
8. Disconnect the
motor hall sensor
wirings

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Important!: The motor is fixed to the motor support with precote®-coated screws. Should it become
necessary to replace the motor the screws have to be warmed with a hot air fan to 80°C maximum.
7.3.Rocker lever and reset
5. Remove washer (Pos.163). To do so, retain
the excentric axe (Pos.155) with a 5mm
wrench on its back side and loosen the screw
(Pos. 164).
6. Pull out the toothed belt wheel (Pos. 127).
Remove screw (Pos.102) and retaining rings
(Pos. 74). The cover of the motor support (Pos.
126) can now be removed.
1. Remove retaining rings (Pos. 66 & 74).
Loosen the blocking pawl with a screw
driver and pull it off the lever. Remove the
bolt (Pos.64).

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7.4.Tensioning gear
8. Assembly
To assembly the tool, simply proceed in the opposite way. Please consider the explosion drawing which
is printed on the last pages of the operating and safety instructions. All positions which are marked with
* have to be secured. Most screwings are TufLok ® coated and secured. Do not use these screws several
times. Replace them with new original screws or secure them with loctite.
Moving parts need to be lubricated. Please consider
chapter 10.
Information about how to assemble the wiring and the
housing can be found in chapter 11.
1. Remove retaining ring (Pos. 136). The bevel
wheel complete is now free to be pulled out.
2. Remove the tension wheel, the planetary
wheels and the cam disk (Pos. 44-46 & 18) from
flange complete (Pos.32).
3. Loosen the screw connection
(5xPos.41) and remove retaining ring
(Pos 40). All other gear parts can now
easily be removed.
Screw with TufLok ®-
coating

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9. Adjustments
9.1.Adjustment of the welding reset
To avoid play in the reseting parts of the welding unit these parts can be adjusted by the set screw (pos.
73). This screw is adjusted when the tool is assembled in the factory. Normally readjustments are not
necessary. When parts of this unit are replaced, it may become reasonable to check this setting. To do so
proceed as follows:
1. Unscrew (Pos 73) until it is flush with the reset cam (Pos.72).
2. Push onto the switching cam (pos. 140) until the welding unit springs completely downwards.
3. Screw in the set screw until the switching cam starts to lift itself. Unscrew for a quarter revolution.
4. Check the setting with a feeler gauge (0.05 - 0.1mm).
0.05-0.1mm
Must contact each other (Pos.96 & 126)

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10. Lubricating chart
Recommended Lubrication:
Description: Lubricant: Interval:
1
Planetary gear tensioning
Klüber Microlube GBU-Y 131
100‘000 Cycles
2
Planetary gear welding unit
Klüber Microlube GBU-Y 131
100‘000 Cycles
3
Freewheels (Pos. 127/ 132) Important! No grease!
Universal oil e.g. WD 40
100‘000 Cycles
4
Bevel gear
Klüber Microlube GBU-Y 131
50‘000 Cycles
5 Cam disk, reseting cam, switching cam Klüber Microlube GBU-Y 131 50‘000 Cycles
6
Tooth plate, Set screw
Klüberpaste 46 MR 401
50‘000 Cycles
7 All other moving parts. Pressure resistant lubricant
spray, e.g. Würth HHS 2000
50‘000 Cycles
8 Ball guides at welding shoe, knife guide, excentric
axle
Pressure resistant lubricant
spray, e.g. Würth HHS 2000
25‘000 Zyklen
2
1
3
4
5
5
6
7
8