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Polychem GP44 User Manual

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GP44 Semi-Automatic Strapping Machine
OPERATION -1-
GP44
Semi-Automatic Strapping
Operation and Maintenance Manual
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Polychem GP44 Specifications

General IconGeneral
BrandPolychem
ModelGP44
CategoryPackaging equipment
LanguageEnglish

Summary

Revision History

Introduction

Serial Number Location

Details the locations of the machine's serial number identifiers.

Safety Instructions

Specifications

Simple Machine Description

Arch Unit Assembly Procedure

Part Identification and Function

Magnetic Operation Control Box (GP44)

Strap Feed Complete Light

Indicator for strap feeding.

Manual Strap Switch

Starts operation in manual mode.

Auto/Manual Select Switch

Selects operating mode.

Reset Switch

Resets machine to home position.

Control Box Features

Circuit Power Switch

Controls main power and has an indicator light.

Emergency Stop Switch

Immediately halts all machine operations.

Set-Up Procedures

Uncrating the Machine

Steps for safely removing the machine from its shipping crate.

Installing the Machine

Procedure for positioning and placing the machine.

Power Requirements

Details electrical power needs and safety precautions.

Testing and Operating the Machine

Initial Machine Set-Up

Preparation after installation.

Loading of Strap

Procedure for loading strapping material.

Preparing for Operation

Final steps before cycling.

How to Load Strap

Adjusting Strap Tension

Sequence of Operation

Feed Strap

Describes the process of feeding the strap into the machine.

Grip Lead End of Strap

Details how the strap is gripped for tensioning.

Initial Retraction/Tension

Explains the initial strap tensioning phase.

Sequence of Operation (Continued)

Controlled Tension

Describes the process of applying controlled tension to the strap.

Release Tension, Cut and Weld

Explains the final steps of releasing tension, cutting, and welding.

Auto Feed Cycle

Details the automatic strap feeding process.

Troubleshooting

Troubleshooting Scope

Defines the scope and organization of troubleshooting procedures.

Troubleshooting Procedure

Strap Feed Issues

Addresses problems related to strap feeding and solutions.

Gripper Issues

Resolves problems associated with the machine's grippers.

Hard Feed / Escaping Track

Troubleshoots issues where strap feed is difficult or escapes.

Short Feed Issues

Addresses problems causing short or incomplete strap feeding.

Grip Lead End of Strap Issues

Initial Retraction Issues

Controlled Tension Issues

Release Tension, Cut & Weld Issues

Electrical System Overview

General Maintenance

Daily Cleaning and Inspection

Routine tasks for maintaining machine cleanliness and performance.

General Maintenance (Continued)

Periodic Maintenance, Teardown & Cleaning

Scheduled maintenance tasks for high-cycle intervals.

Preventive Maintenance

Tool Kit

Strap Feed Solenoid Adjustment (Closed Top Plunger)

Step 1: Set Solenoid Height

Procedure for setting the solenoid height for proper operation.

Step 2: Verify Gap

Procedure for verifying the gap between roller bearing and strap.

Strap Feed Solenoid Adjustment (Open Top Plunger)

Step 1: Adjust Spring for Pressure

Procedure for adjusting spring for correct feed pressure.

Step 2: Verify Gap

Procedure for verifying the gap between roller bearing and strap.

Heater Temperature Adjustment

Heater Blade Position Adjustment

Height of Heater Plate

Procedure for setting the correct clearance of the heater plate.

Adjustment to Right and Left

Procedure for aligning the heater plate horizontally.

Cam Shaft Position Settings

Home and Initial Retraction Positions

Explanation of how home and retraction positions are determined.

High Tension Position

Explanation of how the high tension position is achieved.

Setting Cam Shaft Positions

Setting Home and Initial Retraction Positions

Details how the S2 sensor sets stopping positions.

Electromagnetic Brake Adjustment

Brake Function and Issues

Describes brake function on motors and potential issues.

Brake Clearance Adjustment

Procedure for adjusting the clearance between brake components.

Gripper Information

General Information

Provides general notes and details about gripper operation.

Power (AC115V)

Control Circuit Diagram

PLC Inputs

PLC Outputs

Spare Parts Revision History

Spare Parts Catalogue Introduction

Scope of Spare Parts Catalogue

Defines the purpose and usage of the spare parts catalogue.

Caution on Spare Parts

Warning regarding the use of original Polychem spare parts only.

Validity of Catalogue

States that catalogue contents apply to GP44 machines.

Ordering Spare Parts

Information required when ordering spare parts for identification.

Figures in Catalogue

Notes on how figures relate to current machine configurations.

Updates and Contact

Information on how to obtain updates or further details.

Part List: Front of Machine (Fig. GP44-08)

Part List: Rear of Machine (Fig. GP44-09)

Part List: Reel Brake (Fig. A-1-002)

Part List: Pool Box (Fig. A-7-2-H)

Part List: Arch A (Fig. A-9P-1)

Part List: Cam Shaft (Fig. HEAD-12P-1)

Part List: Panel (Fig. PANEL-14)