Signode Tension-Weld BTS-16, Tension-Weld BTS-19, Tension-Weld BTS-25, Tension-Weld BTS-32 Operation, Parts And Safety Manual

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BTS-16/19/25/32

ENSION-WELD® STRAPPING TOOL

NOTE: Fully charge battery before first use of tool.

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READ THESE INSTRUCTIONS CAREFULLY. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN S

EVERE PERSONAL INJURY.

GENERAL SAFETY CONSIDERATIONS

1. STRAP BREAKAGE HAZARD Improper operation of the tool or sharp corners on the load can result in strap breakage during tensioning, which could result in the following:

! A sudden loss of balance causing you to fall.

! Both tool and strap flying violently towards your face.

Failure to place the strap properly around the load or an unstable or shifted load could result in a sudden loss of strap tension during tensioning. This could result in a sudden loss of balance causing you to fall.

Read the tool's operating instructions. If the load corners are sharp use edge protectors. Place the strap correctly around a properly positioned load.

! Positioning yourself in-line with the strap, during tensioning and sealing, can result in severe

personal injury from flying strap or tool. When tensioning or sealing, position yourself to one side of the strap and keep all bystanders away.

! Using strap not recommended for this tensioner can result in strap breakage during tensioning.

Use the correct Signode products for your application.

2. TRAINING This tool must not be used by persons not properly trained in its use. Be certain that you receive proper training from your employer. If you have any questions contact your Signode Representative.

3. EYE INJURY HAZARD Failure to wear safety glasses with side shields can result in severe eye injury or blindness. Always wear safety glasses with side shields which conform to ANSI Standard Z87.1 or EN 166.

4. FALL HAZARD Maintaining improper footing and/or balance when operating the tool can cause you to fall. Do not use the tool when you are in an awkward position.

5. CUT HAZARD Handling strap or sharp parts could result in cut hands or fingers. Wear protective gloves.

6. TOOL CARE Take good care of the tool. Inspect and clean it daily, lubricate it weekly and adjust when necessary. Replace any worn or broken parts.

7. WORK AREA Keep work areas uncluttered and well lighted.

Several types of strap can be used with this tool. Use the correct Signode products for your application. If you need help contact your Signode Representative.

CUTTING TENSIONED STRAP

Use only cutters designed for cutting strap; never use claw hammers, crowbars, chisels, axes or similar tools. Such tools will cause the strap to fly apart with hazardous force. Before using any Signode product, read its Operation and Safety Manual.

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SAFETY PROCEDURES FOR ELECTRIC TOOLS

. GUARD AGAINST ELECTRIC SHOCK

2. CONSIDER WORK AREA ENVIRONMENT

!!!! T

ry not to operate tool in damp or wet locations.

!!!! Prevent body contact with grounded surfaces, such as pipes, radiators, ranges, refrigerator

enclosures.

!!!! When tool is used outdoors, use only extension cords intended for outdoors and so marked. !!!! Wear rubber gloves and non-skid footwear when working outdoors. !!!! Do not expose power tools directly to rain. !!!! Never operate tool in presence of gases or flammable liquids.

3. Never allow visitors to contact tool or extension cords. All visitors should be kept away from work area.

4. DO NOT ABUSE TOOL

!!!! K

eep handle dry, clean and free from oil and grease.

!!!! Never carry tool by cord or yank it to disconnect from receptacle. !!!! Always keep cord from heat, oil and sharp edges. !!!! Always store idle tool in dry, high or locked-up place. !!!! Always disconnect tool when not in use or before servicing. !!!! To avoid unintentional starting, never carry plugged-in tool with finger on switch. Be sure switch

is off when plugging in.

5. MAINTAIN TOOL WITH CARE Check Damaged Parts. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other condition that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced by an authorized service center unless otherwise indicated elsewhere in this instruction manual. Have defective switches replaced by authorized service center. Do not use tool if switch does not turn it on and off.

!!!! W

hen servicing double insulated tool, use identical replacement parts.

!!!! Keep tool clean for better and safer performance. !!!! Inspect tool cord periodically and, if damaged, have repaired by authorized service facility. !!!! Inspect extension cord periodically and replace if damaged.

SAFETY PROCEDURES FOR TOOL OPERATION

Before using this tool, read its Operation and Safety instructions. This tool is a Tension Weld® type sealer. A properly made joint will appear as shown in the illustration. If the joint does not appear as shown, then the operator must proceed as follows:

A. Ensure that the tools operating instructions are being followed before applying another strap.

B. Cut the strap off and apply another.

If the joint still does not appear as shown, then inspect the tool for worn and/or damaged parts. Replace tool parts as needed. NEVER HANDLE OR SHIP ANY LOAD WITH IMPROPERLY FORMED JOINTS. Misformed joints may not secure the load and could cause serious injury. Tuck strap end back into the dispenser when not in use.

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TABLE OF CONTENTS

Page

General Safety Instructions 2

Specifications 4

Major Components 5

Battery Information 5

Operating Instructions 7

Weld Time Adjustments 9

Parts List 10

Troubleshooting 12

Tool Maintenance 13

SPECIFICATIONS

MODEL

(110 Volt)

BTS-16

(426500)

BTS-19

(426501)

BTS-25

(426502)

BTS-32

(427140)

MODEL

(220 Volt)

BTS-16

(429516)

BTS-19

(429519)

BTS-25

(429525)

BTS-32

(429532)

STRAP

TYPE WIDTH THICKNESS

16mm

(.629")

19mm

(.748")

High

Strength

Tenax

25mm

(1.000")

32mm

(1.250")

0.030" to 0.044" (0.76-1.11mm)

0.045" to 0.055" (1.14-1.40mm)

0.040" to 0.050" (1.00-1.30mm)

RECOMMENDED

TENSIONER

Signode PT-16

Signode PT-19

Signode PT-25

Signode PT-32

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MAJOR COMPONENTS

ATTERY INFORMATION

Before attempting to us this tool make sure the batteries are properly charged. A discharged battery may result in a poor weld or no weld condition.

1. The battery pack accepts only about 80% of its maximum capacity with its first few charge cycles. However, after the first few charge cycles, the battery will charge to full capacity.

2. The charger was designed to fast charge the battery only when the battery temperature is

between 40/F (4/C) and 105/F (41 OC).

3. A substantial drop in operating time per charge may mean that the battery pack is nearing the end of its life and should be replaced.

4. If you anticipate long periods (i.e. a month or more) of non-use of your tool, it is best to run your tool down until it is fully discharged before storing your battery pack. After a long period of storage, the capacity at first recharge will be lower. Normal capacity will be restored in two or three charge/discharge cycles. Remember to unplug charger during storage period.

5. If battery does not charge properly:

A. Check for voltage at outlet by plugging in some other electrical device.

B. Check to see if outlet is connected to a light switch which turns power "off"when lights are turned

off.

C. Check battery pack terminals for dirt. Clean with cotton swab and alcohol if necessary.

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BATTERY INFORMATION, Continued

NDICATORS, SYMBOLS AND MEANING

If the indicator lights are "OFF", the charger is not receiving power from power supply outlet. If the green indicator light is "ON", the charger is plugged in but the battery pack is not inserted, o the battery pack is fully charged and is being trickle charged

If the green indicator light is "BLINKING", the battery pack is being fast-charged. Fastcharging will automatically stop when the battery pack is fully charged.

If the red indicator light is "ON", the battery pack is too hot or cold for fast-charging. The charger wi I switch to trickle charge, until a suitable temperature is reached, at which time the charger will switch automatically to fast-charging.

If the red indicator light is "BLINKING", the battery pack cannot accept a charge or the contacts o the charger or battery pack are contaminated. Clean the contacts of the charger or battery pack only as directed in these operating instructions or those supplied with your tool or battery pack.

Plug charger cord into your standard power outlet. Before inserting battery pack, remove protective cap, then insert battery pack into charger. The charger's green indicator light will begin to "BLINK". This indicates that the battery is receiving a fast charge. Fast-charging will automatically stop when the battery pack is fully charged.

When the indicator light stops "BLINKING" (and becomes a steady green light) fast charging is complete. The battery pack may be used even though the light may still be blinking. The light may require more time to stop blinking depending on temperature. When you begin the charging process of the battery pack, a steady red light could also mean the battery pack is too hot or too cold.

The purpose of the green light is to indicate that the battery pack is fast-charging. It does not indicate the exact point of full charge. The light will stop blinking in less time if the battery pack was not completely discharged.

When charging several batteries in sequence, the charge time may slightly increase. When the battery pack is fully charged, unplug the charger (unless you're charging another battery pack) and slip the battery pack back into the tool.

To prevent fire or injury when batteries are not in tool or charger, always place protective cap onto end of battery pack.

INSTALLING A BATTERY

1. Release the latch that secures the battery cover. Open the battery cover.

2. Insert the battery into the BTS. Firmly push the battery in until fully seated.

3. Close and latch the cover.

NOTE: Do not operate tool with battery cover open. Occasionally inspect the battery compartment for moisture. Inspect the battery cover gasket for wear, replace if needed.

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OPERATING INSTRUCTIONS

Wear safety glasses. Stand to one side of the strap when tensioning.

ke sure all bystanders are clear before proceeding.

PLEASE NOTE: Do not operate tool without strap, as damage to the tool may occur.

1. Using a Signode PT manual strap tensioner tool, encircle the package with strap and tension the strap as required.

Refer to the Signode PT tool’s operation, parts and safety manual for proper use of the tool.

2. Squeeze the operator handle of the BTS to open the upper welding gripper.

3. While holding the operator handle, align the BTS with the tensioner as shown, slide the nose of the BTS tool over the upper and lower straps.

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OPERATING INSTRUCTIONS, Continued

. Push the BTS tool all the forward so that the straps

are fully seated into the base of the tool as shown.

5. Release the operator handle to secure the strap in the tool. Press the weld button on the top of the tool.

The BTS will then weld the strap together. As the straps are welded together the BTS will also cut off the top strap.

While operating, the weld button will glow the color Red. Once the welding process has been completed the weld button will continue to glow Red indicating the wait period before removing the tool.

NOTE: If the weld button immediately flashes Red and the tool does not function the battery cell needs to be charged.

6. Once the weld button begins to flash Green in color, squeeze the operator handle to open the tool and remove the tool from the strap.

Continue to remove the strap tensioner from the strap.

Inspect the strap joint for proper formation using the information found on the next page of this manual

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STRAP JOINT INSPECTION

his tool is a Tension Weld® type sealer. A properly made joint will appear as shown in the illustration. If the joint does not appear as shown, then the operator must proceed as follows:

1. Ensure that the tool operating instructions are being followed before applying another

strap.

2. Cut the strap off and apply another.

A good weld will show some material displacement along the edges. The welded area should extend the full length and width of the gripper impression.

WELD TIME ADJUSTMENT

Weld time duration has been factory adjusted to provide acceptable weld strength when using High Strength Tenax (polyester) type strap. Weld time may need to be adjusted due to the application, environment, tool wear, etc. Adjustments are made by turning the adjustment screw, located inside the battery compartment. Turn the screw clockwise to increase weld time and counterclockwise to decrease weld time.

Establishing the correct weld time is a matter of trial and error and should be conducted as follows.

1. Remove the tool battery to access the adjustment screw. Adjust the screw in 1/8 to 1/4 turn increments only.

2. Reinstall the battery, apply a strap and make a weld.

3. Compare the weld made with the illustration shown above. A good weld will displace some material along the outer edges of the joint.

4. If you are unable to produce an acceptable joint or if you have any questions as to whether your tool is producing good weld strength, contact your Signode Sales Representative.

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PARTS LIST

Qty Part No. Description

Key

1 1 426583 Frame (16/19/25)

427139 Frame (32) 2 1 426586 Frame Cover 3 1 426508 Vibrator Arm 4

1 426577 Weld Gripper (16/19/25)

1 427138 Weld Gripper (32) 5 1 427074 Piston Pin 6

1 426511 Pivot Pin (16/19/25)

1 427134 Pivot Pin (32) 7 2 423997 Bearing INA HK0808 8 1 423994 Bearing INA NK 16/16 9 2 423889 Bearing 10 1 426576 Eccentric Shaft 0.9mm 11 2 426901 Cutter Guide 12 1 426512 Cutter Insert Holder 13

1 426581 Cutter Insert (16/19/25)

1 427136 Cutter Insert (32) 14 1 426884 Cutter Pin

5 1 427075 Handle Pin

1 16 3 427076 Garlock 0610DU Bushing 17 1 426596 Handle 18 1 426588 Motor Cover 19 1 426592 Belt Cover 20 1 426590 Cover 21 1 426594 Battery Cover 22

1 427087 14.4 V Battery Cell 23 1 427079 Base (16mm)

1 426906 Base (19mm)

1 426907 Base (25mm)

1 427141 Base (32mm) 24 1 426575 Piston

5 2 426897 Lift Arm

2 26* 1 426578 Gates Pulley 16 Teeth 27* 1 426579 Gates Pulley 28 Teeth 28 1 427085 Electrical Assy

1 427089 PC Board

1 427084 Battery Connector

1 427077 Lighted Switch

1 427078 Mabuchi Motor 29 1 427081 Wear Pad 30 1 423943 Spring 31 9 423288 M5 X 12 SHCS 32 4 170304 M5 X 16 SHCS 33 2 166063 M5 X 20 SHCS 34 1 010031 M5 X 25 SHCS 35 3 280848 M6 X 12 SHCS 36 2 262456 M3 X 6 SHCS (16/19/25)

2 428492 M3 X 4 SHCS (32) 37 2 427104 M3 X 8 SPHMS 38 2 259935 M3 X 12 SHCS 39 4 420216 M4 X 10 SHCS 40 2 274451 3 X 10 Dowel Pin (16/19/25)

2 299975 3 X 8 Dowel Pin (32) 41 2 181261 5 X 10 Dowel Pin 42 2 423493 5 X 16 Dowel Pin 43 1 162404 6 X 28 Dowel Pin 44 1 428229 M4 x 14 SLHSS 45 4 427080 Lee Spring LC-047D-16M 45A 4 428264 Lee Spring LC-032BB-19M 45B 4 428265 Lee Spring LC-49D-17M

Qty Part No. Description

Key

46 1 427082 Lee Spring LC-020B-8M 4

7 2 427083 Lee Spring LC-035C-15M

48 1 427086 O-Ring SAE -157

1 426580 Gates Belt

49 50 2 162383 M4 X 8 SHCS

1 1 423591 M4 X 5 SHCS

1 426665 Draw Latch

52 53 1 427096 Nord-Lock M4

4 1 427099 Door Catch

5 55 1 427098 Button Keeper 56 1 022789 O-Ring SAE-16 57 1 427103 O-Ring SAE-130 60 1 003132 Warning Sign 61 1 024727 Information Sign 62 1 286383 Information Sign 63 1 436396 Nameplate (BTS-16)

1 436397 Nameplate (BTS-19) 1 436398 Nameplate (BTS-25)

1 510455 Nameplate (BTS-32) 64 1 510450 Information Sign 65 1 252230 M4 Hex Locknut 66 1 427091 Battery Charger (110V)

1 429510 Battery Charger (220V) 67 1 428224 Bumper 68 1 428138 Push Button Cover

! When ordering parts please indicate tool

model, part number and description.

! Recommended spare parts are underlined

and should be stocked.

! Common hardware parts can be obtained at

any local hardware supply.

* Includes mounting screws.

NOTE:

When installing the electrical assembly (Key 28), fill the wire channel with hot-melt glue as indicated below to secure the wire harness.

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TROUBLE SHOOTING

he following items are the most common types of tool malfunctions. For symptoms or remedies not shown, contact your Signode service representative for additional information and details. The following tool conditions are shown in this manual:

#1 - A poor weld identified by an incomplete area of weld. #2 - Incomplete or no weld. #3 - Strap is over welded. #4 - The cut-off has become difficult.

#1 CONDITION: A poor weld identified by an incomplete area of weld.

CAUSE REMEDY

Welding is achieved by a combination of vibration and downward pressure of the upper gripper. Either a restriction of motion or a reduction of downward pressure will cause a poor weld.

#2 CONDITION: Incomplete or no weld.

CAUSE REMEDY

1. Improperly set weld time adjustment.

2. Worn teeth on upper or lower weld pads.

3. Low battery voltage.

Dismantle and clean the weld mechanism by brushing away the strap residue or washing the entire unit in a solvent. When a solvent is used it is imperative the assembly be blown dry to remove all solvent. Check for dry or worn bearings. Replace or lubricate as required. If the tool has been used extensively, examine the teeth on the upper and lower weld pads for wear. Replace if worn.

1. Adjust weld time as required per instruction in this manual.

2. Replace as required.

3. Recharge battery as required.

#3 CONDITION: Strap is over welded.

CAUSE REMEDY

Improper weld timing adjustment. Decrease weld timing as needed.

#4 CONDITION: The cut-off has become difficult.

CAUSE REMEDY

1. Strap residue jamming cutter mechanism.

2. Cutter blade worn or damaged adjustability.

1. Clean parts as required.

2. Replace as required.

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TOOL MAINTENANCE

ENERAL

1. Clean the teeth on the upper welding gripper and welding base with the special brush provided.

2. Periodically clean the tool with compressed air.

3. Disassemble, clean and lubricate the welding and cutting mechanisms.

CUTTER INSERT SERVICE

The cutter insert of the BTS has two serrated cutting edges. Over time the cutter blade insert may become worn. Use the instructions below to reverse the insert to use the other cutting edge. If the blade has been previously reversed, it should be replaced with a new part. These instructions can also be used for installing a new cutter insert.

! Remove the battery cell from

the tool.

! Remove the four M5x12 socket

head cap screws which secure the front cover to the tool.

! Remove the cutter holder from

the tool. The small compression spring should remain with the cutter holder as it is removed.

! Remove the two M3x6 socket

head cap screws which secure the cutter insert. Rotate the cutter insert 180B and reinstall (or replace if new).

! Clean any debris from the tool and apply a light coating of grease to the cutter holder.

! Reinstall the cutter holder into the tool. Continue to reinstall the from cover.

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EU Declaration of Conformity

he Supply of Machinery (safety) Regulations

92 (S.I. 1992/3073)

It is hereby declared that the undermentioned machinery has been designed and constructed to comply with the health and safety requirements defined in EC Directive 89/392/EEC

Machine Supplier: Signode, Division of ITW Ltd.

Queensway, Fforestfach Swansea SA5 4ED

Machine Description: BTS Series

Machine Type: Electric Combination Hand Strapping tool.

Provisions with which machine complies:

89/392/EEC, 91/368/EEC

Harmonized EuroNorms with which machine complies:

EN 292:1, EN 292:2, EN 294, EN 349

Technical Standards with which machine complies:

Signature: Date: 12 July 2007

(Peter Oseland)

Page 16

SIGNODE

NEW TOOL WARRANTY

Signode Engineered Products Warrants that a new Signode strapping tool will operate per functional specifications for a period of sixty (60) days after the date of shipment to the owner's place of business. Normal wearing parts, as outlined in the Operation, Parts & Safety manual, are covered by a thirty (30) day warranty unless, in Signode's judgment, these parts have been subjected to abnormal or extreme usage. Signode's sole liability hereunder will be to repair or replace, without charge, F.O.B. Signode's Glenview, Illinois plant, any tool which proves to not operate per functional specifications within the stated period. Signode reserves the right to replace any tool which proves not to operate per functional specifications with a new or like-new tool of the same model if in Signode's judgment such replacement is appropriate. Any new replacement tool provided to an owner will carry a full sixty (60) day warranty. Any warranty repaired tool or like-new replacement tool will carry a warranty for the balance of the time remaining on the initial sixty (60) day warranty. This warranty will be extended to compensate for the time the tool is in Signode's possession for warranty repairs.

This warranty is void as to any tool which has been: (I) subjected to mis-use, misapplication, accident, damage, or repaired with other than genuine Signode replacement parts, (II) improperly maintained, or adjusted, or damaged in transit or handling; (III) used with improperly filtered, unlubricated air or improper strapping material, (IV) in Signode's opinion, altered or repaired in a way that affects or detracts from the performance of the tool.

SIGNODE MAKES NO WARRANTY, EXPRESSED OR IMPLIED, RELATING TO MERCHANTABILITY, FITNESS OR OTHERWISE EXCEPT AS STATED ABOVE AND SIGNODE'S LIABILITY AS ASSUMED ABOVE IS IN LIEU OF ALL OTHERS ARISING OUT OF OR IN CONNECTION WITH THE USE AND PERFORMANCE OF THE TOOL. IT IS EXPRESSLY UNDERSTOOD THAT SIGNODE SHALL IN NO EVENT BE LIABLE FOR ANY INDIRECT OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, DAMAGES WHICH MAY ARISE FROM LOSS OF ANTICIPATED PROFITS OR PRODUCTION, SPOILAGE OF MATERIALS, INCREASED COSTS OF OPERATION OR OTHERWISE.

Considerable effort has be made to ensure that this product conforms to our high quality standards.

owever, should you experience any difficulties, please contact your Sales Representative providing

H samples and the manufacturing code specified on the tool.

Thank you for your help.

SIGNODE ENGINEERED PRODUCTS

Hand Tool Division

3620 W. Lake Avenue, Glenview, Illinois 60025