Signode BXT3-13 User manual

V 07.17
Battery-operated hand tool for plastic strapping
BXT3-13
BXT3-16
BXT3-19
Service manual

2von 37 V 07.17
Service Manual BXT3-13/16/19ENGLISH
Validity:
●BXT3-13 from series no A/17020001
●BXT3-16 from series no B/17020001
●BXT3-19 from series no C/17020001
Manufacturer
Signode
c/o Signode Industrial Group GmbH
Orgapack Packaging Technology
Silbernstrasse 14
Postfach 595
8953 Dietikon 1, SWITZERLAND
www.sigpse.com
Changes:
Version Date Visa Description
V 03.17 16.03.2017 ak/hp DRAFT
V 07.17 30.06.2017 ak/hp 1. Version

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Table of contents
1 General information 4
1.1 Safety 4
1.2 Target group 4
1.3 Changes 4
2 Periodic maintenance 5
2.1 Implementation 5
2.2 Maintenance requirements table 6
2.3 Maintenance table 7
2.4 Clean the tool 8
2.5 Lubrication plan 8
3 Problemidentication 9
3.1 Diagnosis of mechanical or electro-mechanical faults 9
3.2 Diagnosis of electronic faults 12
3.3 Error lists 13
3.4 Service interface (PT-Studio) 17
4 Preventive maintenance work (wear parts) 20
4.1 Replacing tension wheel, tooth plate and knife 20
5 Corrective maintenance work 21
5.1 Electronics components 21
5.2 Housing parts 22
5.3 Wiring components and switches 23
5.4 Mechanical components 24
5.5 Motor 26
5.6 Rocker lever 27
5.7 Wrap spring clutch unit 27
5.8 Tensioning system 28
5.9 Gear 29
5.10 Blocking of the welding mechanism 30
5.11 Wiring 31
6 Electric diagram 33
7 Firmware-update 34
8 Product information 37
9 Contact 37

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1 General information
The purpose of this service manual is to get experienced technicians familiar with the technical features of the tool,
in order to be independent in carrying out maintenance and repair work.
The current operating instructions and the document «Parts lists & Exploded drawings» of the tool as
well as the respective product information sheets are an integral component of this manual and must be
consulted in all cases.
Meaning of warning symbols. representation convections
DANGER
This text describes an extremely dangerous situation in which failure to observe the safety instruc-
tions will result in death or serious injury.
WARNING
This text describes a dangerous situation in which failure to observe the safety instructions can
result in death or serious injury.
CAUTION
This text describes a dangerous situation in which failure to observe the safety instructions can
result in minor injury.
ATTENTION
This text describes a situation that may lead to property damage or adverse operating results.
This text describes useful supplementing information.
►This symbol indicates handling steps.
– This symbol indicates results from the handling steps.
●This symbol indicates lists.
1.1 Safety
This manual must be read and understood by all persons who carry out repair and service work on the respective
strapping devices.
Use only original parts for repair and service work. Disregarding this may lead to damage to the device or
in the worst case, to personal injury.
1.2 Target group
This manual is intended for those technicians that are already familiar with the repair and service work of strapping
devices. The manual can also be used for training purposes for new employees.
1.3 Changes
The production lines and the technical design of the strapping devices are permanently optimised.
In case the respective changes have an inuence on the device performance, service or spare parts, a product
information shall be prepared.
A current version of the operating instructions and the document «Parts lists & Exploded drawings“ as well as the
respective product informations are a fundamental component of this manual and must also be observed.
!

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2 Periodic maintenance
In order to ensure the highest-possible availability and to avoid subsequent damage caused by insufcient lubricati-
on, periodic maintenance must be carried out in the device according to the following instructions.
The maintenance intervals are orientated according to the degree of usage (see maintenance requirements table
2.2) and the number of strapping cycles carried out. However, we recommend performing a service at least every
two years.
In addition, the details in the operating instructions (section 6.1) apply with regard to smaller maintenance work by
the customer.
2.1 Implementation
2.1.1 Cleaning
● Cleaning the tensioning and sealing area of the device from strap particles (with compressed air).
● Removal of excess contamination on other components of the device.
2.1.2 Visual check
● Is there any visible damage to the housing, base plates and other components that is relevant for its func-
tioning?
● Are all screws and other components that could be removed present and tight, and are they the original
part?
● Does the strap width setting match with the strap in use?
Refer to operating instructions (chapter 5.3).
● Are all original wear parts with correct article number installed?
Refer to operating instructions (chapters 6.4, 6.5 and 6.6).
2.1.3 Function test
● Inserting the rechargeable battery: The backlight should illuminate briey
● Check the user interface function: Are all buttons functional? Select MAN Mode
● Pull up the rocker lever and hold it: Rocker opening and strap guide display okay?
● Actuate the tensioning and sealing button: With the lever pulled up, only one beeping tone sounds
per each button?
● Insert and tension the strap: Is the strap tension range matching the strap size?
● Weld the strap: End of cooling time display? (green backlight and buz-
zer)
● Remove the device from the strap Did any issues occur?
● Check the welding: Weld quality and strap cutting are okay?
2.1.4 Maintenance
● If an error has occurred during the function test, rst continue with rectication according to chapter 3.
● Carrying out maintenance according to chapters 2.2, 2.3, 2.4 and 2.5.
2.1.5 Read out the cycle counter
►Touch the operating panel, the backlight lights up.
►Press the «Welding time“ button (1) and hold it for two
seconds.
►Raise the rocker lever. Now the number of cycles (2) is
displayed at the top of the display.
12

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Light applications Average applications Heavy applications
Number of strappings - 1 to 100/day 100 to 500/day > 500/day
Environment – Indoors
– Clean surroundings – Room temperature –No contact with uids – dry – No abrasive substances present – No corrosion vapours
– Indoors – Industrial environment – Low temperature (<5°C) or strong
uctuation
– Increased humidity – No abrasive substances present – No corrosion vapours
– Outdoors, covered – Industrial environment –Low temperature (<5°C) or strong uctuation – Abrasive substances – High humidity
Typical sectors – General logistics
– Paper industry – Cardboard box
– Food – Panel wood –
– Construction industry (brick production, cement
factories, etc.)
– Sawmills
Recommended accessories
– If required, hanging bracket – If required, hanging bracket
– If required, second rechargeable
battery.
– If required, hanging bracket – If required, second rechargeable battery – If required, optional protection plate set – If required, optional protection cover set
Special measures: – None –Avoid strong temperature uctuations.
For example, when using in a refrige- rated warehouse, leave the device in the cold area, and remove the rechar- geable battery for charging at ambient temperatures.
–Avoid strong temperature uctuations. For example,
when using in a refrigerated warehouse, leave the device in the cold area, and remove the rechargea- ble battery for charging at ambient temperatures.
– In wet areas, remove the battery from the tool as
soon as it is no longer needed.
– Dry the tool before the next use if it will be exposed
to moisture at the next use.
Maintenance recommen- dations (see also chapter 2.3)
– Cleaning the tool as required (com-
pressed air).
– Lubricate the welding unit with grea-
se every six months (see operating instructions, chap. 6.3.)
– Every 2 years, service by a specialist
unit.
– Cleaning the tool as required (com-
pressed air).
– Lubricate the welding unit with grea-
se every six months (see operating instructions, chap. 6.3.).
– Annual service by specialist unit.
– Cleaning the device as required (Caution! Abrasive
dusts should not be blown into the tool using com- pressed air).
– Lubricate the welding unit monthly with grease (see
operating instructions, chap. 6.3).
– Six-monthly service by specialist unit.
2.2 Maintenance requirements table The workload and need for maintenance of the tool may vary strongly depending on the operating environment. The required service work also differs accordingly. The table below should provide a reference for categorising.

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2.3 Maintenance table
Description Parts list
pos.
Action Light
applications (Cycles*)
Avarage applications (Cycles*)
Heavy applications (Cycles*)
Remarks
Tensioning wheel
46 Replace As required Wear part (see operating instructions)
Tooth plate 53 Replace As required Wear part (see operating instructions) Knife 166 Replace As required Wear part (see operating instructions) Shaft 180 Check 120‘000 100‘000 80‘000 Only for tool BXT3-19 Welding shoe 158 Check 120‘000 100‘000 80‘000 Check the toothing, ball guides and contact surface of the needle bearing for wear.
Replace if necessary.
Swivel bearing 153 Check 120‘000 100‘000 80‘000 Check the ball and knife guide for wear. Replace if necessary. Sleeve 80 Check 120‘000 100‘000 80‘000 Check the toothing, turn or replace if necessary. Toothed belt 162 Check
Replace
120‘000 240‘000
100‘000 200‘000
80‘000 160‘000
–
Needle bushing 157 Replace as
preventive measure
120‘000 100‘000 80‘000 –
Belt pulley cpl. 127 Replace as
preventive measure
120‘000 100‘000 80‘000 A defective or contaminated idle-run may damage the motor axle.
Bevel pinion cpl. 132 Replace as
preventive measure
120‘000 100‘000 80‘000 A defective or contaminated idle-run may damage the motor axle.
Pressure springs
81, 83, 170 Replace as
preventive measure
240‘000 200‘000 160‘000 –
* For the read out of the cycle counter, see chap. 2.1.5.

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2.4 Clean the tool
ATTENTION!
Do not use water or other solvent to clean.
See operating instructions, chap. 6.2.
2.5 Lubrication plan
Re-lubricate the device, see operating instructions (Manual), chap. 6.2 and 6.3.
Description Recommended lubricants Interval*
1Drive train, planetary gear Klüber Microlube GBU-Y 131 80,000 cycles
2Switchover gear (Attention: exclusive free wheel!) Klüber Microlube GBU-Y 131 80,000 cycles
3Freewheel (Attention: no grease!) Universal oil, e.g. WD 40 80,000 cycles
4Angular gear Klüber Microlube GBU-Y 131 80,000 cycles
5Cam disk, resetting lever, coupling shaft Klüber Microlube GBU-Y 131 80,000 cycles
6Tooth plate, threaded rod Klüberpaste 46 MR 401 80,000 cycles
7All moving parts such as axles, joints, strap guides, etc. High-pressure resistant adhesive
lubricant oil, e.g. Würth HHS 2000
80,000 cycles
8Ball guides on the welding shoe, eccentric shaft, knife
guide
High-pressure resistant adhesive
lubricant oil, e.g. Würth HHS 2000
25,000 cycles (see
manual, chap. 6.3)
* see also maintenance table 2.3.
!
8
7
7
8
6
5
1
7
7
2
5
3
5
54
4
3

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3 Problemidentication
Unexpected start-up in case of problem resolution, possible injuries.
Before any work on the tool, remove the rechargeable battery.
3.1 Diagnosis of mechanical or electro-mechanical faults
3.1.1 Tensioning process
Symptom Possible cause Rectication
The strap is not
tensioned or is only
tensioned with low
force although the
feed wheel is rotating.
This is creating strap
particles and dust.
1. The tensioning wheel is contaminated or worn.
2. The tensioning wheel has been installed in the oppo-
site direction of the arrow.
3. The tool is held too close to the front edge of the
package or the package item has a round cross-secti-
on.
4. The strap used is less than the specied minimum
strap thickness.
5. The rocker has hairline cracks.
– Clean or replace the tensioning wheel
(chapter 4.1.1)
– Turn the tensioning wheel according to
the printed arrow (chapter 4.1.1)
– Move the device back from the edge of
the packed product. Check suitability of
package shape and size.
– Select a strap thickness according
to the specications in the operating
instructions. See operating instructions
(chap. 7).
– Replace the rocker # 50 (chapter 5.8).
The strap is not tensi-
oned. The feed wheel
does not turn although
the motor is running.
1. The spring clutch does not engage.
2. The freewheel pressed into the bevel gear # 132 has
a malfunction.
– Check the sleeve # 77 for smooth run-
ning. (See also chapter 5.7.1)
–Check the bearing pins # 61 for tight t.
(See also chapter 5.7.1)
– Replace the bevel wheel with pinion
# 12 (chapter 5.9.1).
The strap tension
releases again after
tensioning. The feed
wheel rotates back-
wards.
1. The freewheel # 13 pressed into the base plate has
a malfunction.
– Replace the freewheel.
– Replace the bevel wheel with pinion
# 12 (chapter 5.9.1).
Instead of starting the
tensioning process,
only a beeping tone
sounds.
1. The battery was inserted after inserting the strap.
2. The signal “Rocker lever closed” is missing.
– Actuate the rocker lever
– The micro switch # 103 is defective or
is not inserted.
– The micro switch # 103 is not actuated
for mechanical reasons, e.g. the rocker
lever jams.
The tool ends the
tensioning process
although the strap has
not been completely
tensioned. In SEMI
or AUTO mode, the
tool also completes a
welding cycle.
1. The strap used is unsuitable for hand-held devices.
It causes too high friction when placed on top of ano-
ther.
2. There is a problem in the drive train.
3. The current measurement on the PCB supplies
incorrect values.
4. The motor is defective.
– Change to strap types suitable for
hand strapping.
– Check the tensioning drive
– (chapter 5.9.2).
–
– Replace the PCB.
– Replace motor.
The positions # in these tables refer to the positions in the document „Parts Lists & Explosions Drawings“.

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3.1.2 Welding and cutting procedure
Symptom Possible cause Rectication
The sealing surface
has not been welded
through completely.
1. The welding time has been set too low
2. The strap width setting does not correspond with the
strap in use.
3. The toothed plate # 9 has a tight t
4. The ball guide of the swivel bearing # 153 or the
welding shoe # 158 are worn.
5. The base plate is bent.
– Increase the welding time. See opera-
ting instructions (chap. 4.5).
– See the operating instructions (chap.
5.3).
– Remove contamination, replace the
toothed plate and / or bolts if
necessary
– Replace the swivel bearing and / or
welding shoe
– Replace the base plate.
The welding time must
be set extraordinarily
high for sufcient wel-
ding. Unusual noises
during sealing
1. The sliding surfaces of the welding shoe are worn. – The sealing shoe and, if necessary, the
needle sleeve must be replaced. En-
sure to lubricate sufciently to prevent
wear.
The strap is not cutting
the strap although the
knife has not been
worn yet.
1. The welding time is too short
2. The spring above the knife is not present or not
functional
3. The strap thickness is outside the device specica-
tion
4. The knife may be too coarse for very thin and narrow
strap.
– Increase the welding time. See opera-
ting instructions (chap. 4.5).
– Check spring # 168.
– Check the strap dimensions. See ope-
rating instructions (chap. 5.3).
–Slightly grind the knife with ne emery
cloth.
The strap tears during
the sealing procedure.
1. The welding time is set too long. The bottom strap,
being under tension, is getting affected
2. The strap tension is set too high for the strap used.
– Reduce the welding time.
– Reduce the tension level
Part of the weld joint is
tearing at opening of
the tool
1. At the strapping site lubricants could be in use that
have contaminated the strap. During the sealing proce-
dure, the lubricant is affecting the welding.
– Query the application.
Instead of the sealing
noise, only a quiet
rustling of the motor
can be perceived.
Then an E53 error
code appears. Typical-
ly, this does not occur
for every strapping.
1. The sleeve freewheel installed in the belt wheel has
malfunctions and does not transfer the torque correctly.
It is probably contaminated with grease or other foreign
objects.
– Replace the belt wheel # 126. Atten-
tion! No grease may enter the free-
wheel. Lubricate only with light oil.

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Symptom Possible cause Rectication
The tool cannot be
removed or only poorly
from the strap after the
welding procedure.
The rocker lever can-
not be fully lifted.
1. The cam disk # 109 stands in a position that pre-
vents the welding unit from swivelling back.
2. The strap tension is not released. The toothed ring
# 19 cannot be turned back.
– Attention! Do not attempt to pull the
lever with brute force.
– Perform a tool reset.
See chapter 5.10.2
– Check # 19 and 57 for smooth running.
– Toothed ring # 19 only lubricate with
light oil. If necessary, remove grease or
foreign parts.
3.1.3 Remove the tool from the packaged goods

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3.2 Diagnosis of electronic faults
The tool errors can be divided into the following categories:
3.2.1 Operating error
The operator presses a button that is not intended at this moment of operation. Depending on the response of the
mechanics to an operating error, these may be further differentiated.
● If the manipulation does not have any direct inuence on the mechanics, the error may only be indicated e.g. by
a beeping tone (and the current status of the tool controls will be maintained).
●If however it is to be expected that the mechanical components change to another mode (e.g. Tensioning -> In-
sert strap) when detecting an operating error, this is indicated by a beep tone and the tool control mode changes
accordingly.
Signalling example (A1):
●short beep tone (0.4s)
●write Axx in “Application Error Code” object (no display)
3.2.2 Processing error
In the process ow, an event is detected that does not belong to the “normal” process (e.g. at a performance limit).
A change is accordingly carried out into an alternative tool control mode
Signalling example (A2):
●2x short beep tones (0.2s, 0.2s Pause, 0.2s)
●write Axx in “Application Error Code” object (no display)
3.2.3 Temporary system error
This category of error is detected by the control unit and can be deleted by the operator by, for example, starting
a new strapping cycle. In doing so, the current cycle process is cancelled and as a result, is incorrect. If the error
recurs, the device should still be checked by the service centre.
Signalling example (E1):
●beep tone (pulsating / medium)
●orange backlight
●(Application) Error Code Exx in Display (medium)
●Axx (is stored in History)
3.2.4 Static system error
These errors detected by the control unit cannot be deleted by the operator. Accordingly, the battery must be remo-
ved, the error rectied and the device must be reset by reinserting the battery (possibly recharged).
Signalling example (E2):
●pulsating beep tone, long (5s)
●backlight red (or orange)
●Application) Error Code Exx in Display
●Axx (wird in History gespeichert)

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3.3 Error lists
The following summary shows the errors to be detected by the strapping device
3.3.1 Tension process error
No. Process error System response Signalling Rectication
A10 Tension button pressed without releasing
the tension
No tensioning (A1) Short beeping
tone
Insert strap
A13 Rocker lever, tension button or welding
button pressed during the tensioning
process [AUTO]
Cancel tensioning
process
(A1) Short beeping
tone
A14 Permissible number of cycles exceeded
[MAN]
No (more) tensioning (A1) Short beeping
tone
Weld or insert the
strap
A15 Tensioning process timeout Cancel tensioning
process
(A2) 2x short beeping
tone
Tension again
A16 Mechanical components limit switch (S4 =
0) during the tensioning process
Cancel tensioning
process State open
tensioning process
(A1) Short beeping
tone
A18 Limit performance [MAN, SEMI] Cancel tensioning
process
(A2) 2x short beeping
tone
Tension again
A19 Tension button activated with active cam
switch
No tensioning (A1) Short beeping
tone
Insert the strap (actu-
ate rocker)
3.3.2 Process error welding / cooling
No. Process error System response Signalling Rectication
A20 Welding button (S5) activated without
welding release
No welding (A1) Short beeping
tone
Insert and tension
the strap
A24 Tensioning button (S1) activated during
the welding process
No tensioning (A1) Short beeping
tone
A25 Tensioning button (S1) activated during
the cooling process
No tensioning (A1) Short beeping
tone
3.3.3 Processing error “Insert strap”
No. Processing error System response Signalling Rectication
A11 Tensioning button (S1) activated while the
mechanical components are disassem-
bled
No tensioning (A1) Short beeping
tone
A21 Welding button (S5) activated while the
mechanical components are disassem-
bled
No welding (A1) Short beeping
tone
3.3.4 Processing error battery
No. Processing error System response Signalling Rectication
n.a. Battery temperature too low (derating) Tensioning level will be
reduced
Symbols &
ash, force display
ashes
Increases auto-
matically at higher
battery temperature

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3.3.5 System error
No. System error System response Signalling Rectication
E11 Invalid rechargeable battery type
Unknown rechargeable battery inserted,
invalid
– Incorrect rechargeable battery type
inserted
– Incorrect control print
– Control unit defective
No device function E2) Error Code, red
backlight,
symbol ashes,
pulsating beep tone,
long
– Insert the correct
rechargeable
battery
– Change the cont-
rol print
E20 Rechargeable battery high temperature
limit, temperature limit protection of the
rechargeable battery
– Rechargeable battery temperature >
60°C
No device function E2) Error Code, back-
light red,
symbol &
ashes, pulsating beep
tone, long
– Let the rechar-
geable battery
cool down
– Replace the
rechargeable
battery
E23 Rechargeable battery undervoltage,
undervoltage limit of the rechargeable
battery in operation reached
– Rechargeable battery empty
– Rechargeable battery too cold
Cancel current process
(with controlled positio-
ning)
Tensioning / welding
invalid!
No device function
(E2) Error Code, red
backlight,
symbol ashes,
pulsating beep tone,
long
– Charge the
rechargeable
battery
– Replace the
rechargeable
battery.
E24 Rechargeable battery coding error, coding
resistance cannot be detected (short-cir-
cuit / open)
– Rechargeable battery not inserted
correctly
– Coding resistance in the rechargeable
battery faulty
– Wiring to the rechargeable battery
adapter defective
– Control unit defective
No device function (E2) Error Code, red
backlight,
symbol ashes,
pulsating beep tone,
long
– Insert the rechar
geable battery
correctly
– Replace the
rechargeable
battery
E25 Rechargeable battery temperature
measurement invalid, temperature sensor
(NTC) cannot be detected correctly
(short-circuit / open)
– Rechargeable battery not inserted
correctly
– Temperature sensor in the rechargeab-
le battery faulty
– Wiring to the rechargeable battery
adapter defective
– Control unit defective
No device function (E2) Error Code, back-
light red,
symbol &
ashes, pulsating beep
tone, long
– Insert the rechar
geable battery
correctly
– Replace the
rechargeable
battery
E27 Idle run voltage level not reached
– Rechargeable battery empty
No device function (E2) Error Code, red
backlight,
symbol ashes,
pulsating beep tone,
long
– Let the rechar-
geable battery
cool down
– Replace the
rechargeable
battery
3.3.6 System error hardware
No. System error System response Signalling Rectication
E32 Internal electronics error
ESCON Internal Hardware Error (Error
Register Bit6) - control unit defective
No device function ((E2) Error Code, red
backlight,
symbol ashes,
pulsating beep tone,
long
– Replace the
control unit.
E33 Electronics high temperature limit
ESCON Thermal Overload Error (Error
Register Bit3) - control unit too hot - cont-
rol unit defective
No device function (E2) Error Code, red
backlight,
symbol ashes,
pulsating beep tone,
long
– Let the control unit
cool down.
– Replace the
control unit.

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E34 Supply undervoltage
ESCON Vcc Undervoltage Error (Error
Register Bit1) - Supply only via USB
- Very low batter charge - control unit
defective
No device function (E2) Error Code, red
backlight,
symbol ashes,
pulsating beep tone,
long
– Let the rechar-
geable battery
cool down
– Replace the
rechargeable
battery
– Replace the
control unit.
E35 Supply overvoltage
ESCON Vcc Overvoltage Error (Error
Register Bit0)
Cancel current process (E1) Error Code, oran-
ge backlight,
symbol ashes,
pulsating beep tone,
average
In case of repetition
– Replace the
control unit
E36 5 V Supply undervoltage ESCON +5V
VDC Undervoltage Error (Error Register
Bit2)
– Motor Hall sensors / Encoder defective
– Control unit defective
No device function (E2) Error Code, red
backlight,
symbol & pul-
sating beep tone, long
– Motor / replace
wiring
– Replace the
control unit
E37 End stage overvoltage
ESCON Overcurrent Error (Error Register
Bit4)
– Wiring to the motor defective
– Motor defective
– Control unit defective
Cancel current process (E1) Error Code, oran-
ge backlight,
symbol & pul-
sating beep tone,
average
In case of repetition
– Motor / replace
wiring
– Replace the
control unit
E38 Hall sensors error
ESCON Hall sensor errors (Error Register
Bit10, 11, 12)
– Wiring to the hall sensors defective
– Motor hall sensors defective
– Control unit defective
No device function (E2) Error Code, red
backlight,
symbol pulsating
beep tone, long
– Motor / replace
wiring
– Replace the
control unit
E39 Encoder error
ESCON Encoder errors (Error Register
Bit16, 17)
– Wiring to the encoder defective
– Motor encoder defective
– Control unit defective
No device function (E2) Error Code, red
backlight,
symbol pulsating
beep tone, long
– Motor / replace
wiring
– Replace the
control unit
E40 Internal drive software error ESCON
Internal Software Errors (Error Register
Bit25, 27)
Cancel current process (E1) Error Code, oran-
ge backlight, pulsating
beep tone, average
In case of repetition
– Replace the
control unit
E41 Internal software error
Internal Application Error (Error Register
Bit26?)
Cancel current process (E1) Error Code, oran-
ge backlight, pulsating
beep tone, average
In case of repetition
– Replace the
control unit
E42 Display does not detect incorrect display
identication
– Incorrect display print
– Incorrect control print
No device function (E2) Output not pos-
sible! Pulsating beep
tone, long
– Install correctly
Display Print
– Install correctly
Control Print
E43 Display communication error faulty com-
munication with display
– Poor Flexprint display
– Display defective
– Control unit defective
No device function (E2) Output not pos-
sible! Pulsating beep
tone, average
– Replace Flexprint
display
– Replace display
– Replace the
control unit

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3.3.7 System error process
No. System error System response Signalling Rectication
E50 Cancel welding Open the rocker (S4:0) Cancel welding process. (E2) Error Code, oran-
ge backlight,
symbol pulsating
beep tone, average
Incorrect welding.
– Repeat strapping
– Replace rocker
switch wiring
E51 Cancel cooling: Rocker switch open
(S4:0)
Cancel cooling process. (E2) Error Code, oran-
ge backlight,
symbol pulsating
beep tone, average
Incorrect welding.
– Repeat strapping
– Replace rocker
switch wiring
E53 Timeout lower welding mechanism (S3
!= 1)
– Mechanical components jammed
– Cam switch / wiring defective
Cancel welding process. (E2) Error Code, red
backlight,
symbol pulsating
beep tone, long
Incorrect welding.
– Repeat strapping
– Clean mechanical
components
– Replace cam
switch / wiring
E54 Timeout welding process (End position
not found)
- Mechanical components jammed
Cancel welding process. (E2) Error Code, red
backlight,
symbol pulsating
beep tone, long
Incorrect welding.
– Repeat strapping
– Clean mechanical
components
E55 Performance limitation [AUTO] Cancel tensioning pro-
cess.
(E1) Error Code, oran-
ge backlight,
symbol &
pulsating beep tone,
average
– Repeat auto
tensioning.
E56 Timeout tensioning process [AUTO] Cancel tensioning pro-
cess.
(E1) Error Code, oran-
ge backlight, pulsating
beep tone, average
– Repeat auto
tensioning.
E57 Strap torn or slipped Cancel tensioning
process
idle state, BE = 0
(E1) Error Code, oran-
ge backlight, pulsating
beep tone, average.
Symbol ashes
– Reduce tensioning
force
– Insert the strap
again.
– Clean or replace
the tensioning
wheel

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3.4 Service interface (PT-Studio)
●With the Packaging Technology Studio (PT-Studio), the service technician is provided with a tool that helps to
identify problems with the periphery system of the electronics, the electronics themselves and the motor.
The scope of the diagnostics includes the following points:
●Motor
●Hall effect sensors (BXT3-13)
●Encoder (BXT3-16 and BXT3-19)
●LCD display
●Switches and connections
●Buzzer
3.4.1 Starting PT-Studio and connecting to the device
The program does not have to be installed. Execute the File “Packaging Technology Studio” to start.
►Then remove both screws # 246 of the LCD operating unit. Lift the operating unit to release it and only lift it so
far that the Micro USB connector can be accessed.
►Insert the battery in the tool and then connect to a computer using a USB connecting cable (USB 2.0 connector
A - USB 2.0 connector Micro-B).

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To establish the connection of PT Studio to the tool, click on the icon “Search controller”.
With the rst connection, PT Studio requests the rmware le loaded on the tool. This is stored in the “Packaging
Technology Studio“ folder.
● Using Explorer, highlight the respective le, while observing the version (displayed in red), and conrm with OK.
The connection is being made. Now PT Studio communicates with the device and data is transferred.
3.4.2 Diagnostics
Double click on the “Diagnostics” icon to start the diagnostics.
►Follow the instructions in English.

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3.4.3 Operating data
In the tool “Operating Data”, there is a tab “Operating History” with a detailed list of the last 250 strapping actions.
● The history can be exported as csv le by a right-click in the list box.
In the tab “Operating Actual”, you can nd the current Status Information.
3.4.4 Parameters
The current parameter settings are represented in the tool “Parameter”. Those marked with “RW” settings can be
changed via PT Studio.
3.4.5 Data recorder
PT Studio is equipped with a “Data Recorder” for more detailed diagnostics. This tool offers the function of a
4-channel oscilloscope.

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4 Preventive maintenance work (wear parts)
WARNING
Unexpected startup during maintenance work, injuries possible.
Always remove the battery before performing cleaning or preventive and corrective maintenance
work.
4.1 Replacing tension wheel, tooth plate and knife
4.1.1 Replacing the tension wheel
Dismantling
►Remove battery from tool. Remove four cylinder scr-
ews Torx (4), strap guide rear (5) and side cover (3).
►Carefully pull out tension wheel (1).
►Remove ball bearing (2) from tension wheel.
WARNING
Wear eye protection when cleaning
with compressed air!
►Clean tension wheel (1) with compressed air.
► In the case of heavy soiling of the toothing: Carefully
clean tension wheel with enclosed wire brush (6).
►Check tension wheel for worn teeth. If teeth are worn,
replace tension wheel.
Attention
The tension wheel must not be cleaned
while it is rotating. Risk of tooth breakage!
Fitting
►Fitting is performed in reverse order. Observe the direction of rotation of the tension wheel, see arrow.
►Lightly lubricate the inner teeth of the tension wheel with Klüber grease GBU Y 131 (Microlube).
►Tighten cylinder screws Torx (4) with a torque of 1.0 Nm.
4.1.2 Replacing the toth plate
Dismantling
►Remove battery from tool.
►Remove counter-sunk screw Torx (1).
►Lift rocker lever towards the handle, remove tooth plate
(2).
WARNING
Wear eye protection when cleaning
with compressed air!
►Clean tooth plate (2) with compressed air.
► In the case of heavy soiling of the teeth: Carefully cle-
an tooth plate with enclosed wire brush (3).
►Check tooth plate for worn teeth. If several teeth are
worn, replace tooth plate.
Fitting
►Fitting is performed in reverse order. Secure counter-sunk screw (1) with Loctite 222.
►The tooth plate (2 ) must sit freely movable in the rocker.
►Tighten counter-sunk screw Torx (1) with a torque of 1.0 Nm.
!1 2 3 4 5
6
BXT3-19
1
2
3