Signode TENSION-WELD VXL-2000-Z, TENSION-WELD VXM-2000-Z Operation, Parts And Safety Manual

VXL-2000-Z and VXM-2000-Z

TENSION-WELD®

STRAPPING TOOLS

READ THESE INSTRUCTIONS CAREFULLY.

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SEVERE 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, MAINTENANCE & PARTS REPLACEMENT.

! Take good care of the tool. Inspect and clean it daily, lubricate it weekly and adjust when

necessary. Replace any worn or broken parts.

! ALWAYS disconnect the pneumatic connection to the tool when performing part removal

and replacement procedures. NEVER connect a pneumatic source to a disassembled tool unless otherwise specified.

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.

Signode tools and machines are designed and warranted to work together with Signode strapping and seals. Use of non-Signode strap, seals and/or manufactured or specified replacement parts may result in strap breakage or joint separation while applying strapping to a load or during normal shipping and handling. This could result in severe personal injury.

SAFETY PROCEDURES FOR TOOL OPERATION

1. Before using this tool, read its Operation and Safety instructions.

! Do not exceed the operating air pressures stated elsewhere in the manual.

! Use Signode's approved filter-regulator-lubricator unit (P-008559).

! Never operate a pneumatic tool with a bottled air or gas source.

! For tension adjustments, follow instructions in this manual. For all other adjustments,

repairs or cleaning of the tool, disconnect air supply.

! 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. Insure 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.

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.

TABLE OF CONTENTS

General Safety Instructions 2

Specifications 4

Air Line Piping Installation 5

Operating Instructions 8

Adjustments 10

Parts Removal and Replacement 12

Air Logic and Diagram 20

Air Motor Identification 21

Parts List, Air Motors 22

Parts List, Tool 28

Troubleshooting 30

Maintenance 34

Tool Options 35

EU Declaration of Conformity 39

Maximum operating air pressure is 90 psig (6.2 bar).

Strap could possibly break at less than 90 psig (6.2 bar) depending on strap size and type of package.

VXL-2000-Z VXM-2000-Z Part No. 306540NT Part No. 306541NT

SPECIFICATIONS

MODEL

TYPE WIDTH THICKNESS

VXL-2000-Z {302}, {304}, 306 Dymax

{502}, {504}, 506, 508 Dymax

{714}, {716}, 718 Contrax {814}, {816}, 818 Contrax

{1716}, 1718 Tenax {1816}, 1818, 1822 Tenax

VXM-2000-Z {304}, 306 Dymax

{504}, 506, 508 Dymax

{716}, 718 Contrax {816}, 818 Contrax

{1716}, 1718 Tenax {1816}, 1818, 1822 Tenax

NOTE: Strap sizes shown in brackets { } indicates strap sizes that (due to tension capabilities) may require use of the VXL model only or the use of Tension Control Kit (Signode Part No. 422540 shown on page 33). Successful use of these strap sizes depends upon air pressure, tool condition and package characteristics.

STRAP

7/16"(10.5mm)

1/2"(12.7mm)

7/16"(10.5mm)

1/2"(12.7mm)

7/16"(10.5mm)

1/2"(12.7mm)

7/16"(10.5mm)

1/2"(12.7mm)

7/16"(10.5mm)

1/2"(12.7mm)

7/16"(10.5mm)

1/2"(12.7mm)

0.017" to 0.029" (.43-.73mm)

0.015" to 0.030" (.38-.76mm)

0.019" to 0.030" (.48-.76mm)

0.017" to 0.026" (.43-.66mm)

0.021" to 0.024" (.53-.60mm)

0.017" to 0.028" (.43-.71mm)

0.023" to 0.029" (.58-.73mm)

0.020" to 0.030" (.50-.76mm)

0.025" to 0.030" (.63-.76mm)

0.022" to 0.026" (.55-.66mm)

0.021" to 0.024" (.53-.60mm)

0.017" to 0.028" (.43-.71mm)

PNEUMATIC INFORMATION

AIR PRESSURE REQUIREMENTS

The VXL/VXM tools are designed to operate at air pressures ranging between 70 and 90 psig (4.8 -

6.2 Bar). Operating these tools outside this pressure range could result in strap breakage due to

over tensioning or poor quality welds.

AIR PRESSURE VS. PERFORMANCE

The air pressure supplied to the VXL/VXM tools must be a minimum of 70 psig (4.8 Bar) If the air supply pressure can be adjusted within a range from 70 psi to 90 psi (4.8 - 6.2 Bar) the tool's performance can be fine tuned to a particular application or operation preferences. Raising the VXL/VXM air supply pressure to the tool will directly alter the rate at which the tool will take-up the strap slack and the strap tension. Increasing or decreasing the VXL/VXM air supply within the suggested 70 to 90 psig (4.8-6.2 Bar) range will not seriously affect the actual welding portion of the strap cycle.

After an initial "Break-In" period, the air motor may become more powerful. If the tool's performance is effected by this increase in performnace, reduce the air pressure at the regulator as required (but not below 70 psig).

AIR SUPPLY INSTALLATION

If compressor has a good dryer unit, use black pickled pipe. When a dryer unit is not installed, use galvanized or copper pipe. To perform reliably, a pneumatic tool requires a continuous source of clean, water-free air at adequate pressure.

Never operate this tool using a bottled air or gas source.

Bottled air/gas sources do not provide consistant operating pressure.

A filter-regulator-lubricator unit (Signode P/N 008559) must be installed as close to the air tool as possible, preferably within 10 feet. It should be placed in a convenient location where it can easily be drained, adjusted, and filled with oil. The air hose (Signode P/N 008558) must have at least a 3/8" I.D. A quickconnect press-on socket (Signode P/N 008569) is installed on the stress spring end of the hose for convenient hookup to the air tool.

PNEUMATIC INFORMATION, Continued

Filter and lubricator bowls are made of polycarbonate material. Do not install where bowls may be exposed to materials incompatible with polycarbonate. Certain oils, solvents, and chemicals or their fumes can weaken these bowls and possibly cause them to burst. Clean only with warm water. A cut-off valve placed ahead of the filter will be useful when cleaning the filter or replenishing the lubricator.

MOISTURE

Moisture is always present in air lines due to condensation within the lines as the air cools. Steps must be taken to remove this moisture and to keep it from the air tool. This is because water tends to wash away lubricants and cause corrosion, sticking and failure of internal parts.

The main line should be pitched so the far end terminates in a water leg. Branch lines are taken from the top of the main, never off the bottom. Every branch should have a water leg at its lowest point, with a drain cock which is drained daily.

If these precautions are taken and water is still present, an after cooler and a moisture separator are required between the compressor and the air receiver tank. A large air line separator can be installed in the air tool line, but precautions must be taken to insure that it will be drained daily, before the air tool is operated.

Water in air lines is a constant threat to the proper operation of air tools. Even near freezing operating conditions, a good refrigerant type dryer is essential. A good dryer will remove 95% or more of water right at the compressor. The remaining moisture is removed at the water leg in the piping system or in the filter (Signode Part No. 008559).

NOTE: Additional information is available in the Signode publication, "Air Supply Manual" (E-

186038). If you have any questions, contact your local Signode Representative.

LUBRICATION

The air motor must be properly lubricated. This is achieved by keeping the air line lubricator filled with oil and correctly adjusted. Without proper lubrication, the motor will become sticky and the tool will give low and erratic tension and be difficult to release from the strap.

Install the lubricator as close to the air tool as possible. The arrow on the lubricator's top surface must point in the direction of air flow. For proper operation, oil must drop through the lubricator sight glass at a rate of 1 to 4 drops per minute. This rate is checked while the air tool is running free. Only 20% of this oil is actually delivered to the tool. The remaining oil drops back into the oil reservoir. The unit is factory set and should require no adjustment. If an adjustment is required, the adjusting screw on top of the lubricator may be turned as marked to reduce or increase the flow of oil.

The correct grade of oil must be used in the lubricator; too heavy an oil will not provide sufficient lubrication and will cause sticking and sluggish operation of the air tool. Recommended oils are any good grade of rust and oxidation inhibiting oil with a viscosity of 80-120 S.U.S. at 100 degrees Fahrenheit. (0.15 to 0.25 cm

/sec. at 38 degrees Celsius), such as:

Non Fluid Oil Co., grade #LS-1236 Signode oil - Part No. 008556

If necessary, use SAE #5 or SAE #10 non-detergent, cut 1 to 1 with kerosene.

NOTE: Some oils contain anti-wear additives which may disable the air motor. Be certain to use recommended oil.

Several drops of lubricator oil added to the inlet of the air motor or into the air line each day will help insure good operation. A noticeable reduction of air motor performance can usually be corrected by squirting a few drops of oil into the air line.

STRAP TENSION

Strap tension is controlled by air pressure. Adjust the pressure regulator, within a range of 70 - 90 psig (4.8-6.2 bar), to provide the desired tension. Once the regulator is set the tension will be uniform on all straps, provided the operator allows the air motor to stall. The air pressure gauge must be accurate. Confirm calibration by comparing it to a master gauge.

The VXL-2000Z tool is factory tested to ensure that at least 90 lbs. (400N) of tension is drawn at 90 psig (6.2 bar) and the VXM-2000Z tool is factory tested to ensure that at least 140 lbs. (621 N) of tension is drawn at 90 psig (6.2 bar).

Review the instructions on page 10 of this manual for information on how to adjust strap tension.

Strap breakage hazard.

Strap can break if inlet air pressure to tool exceeds 90 psig (6.2 bar).

Strap breakage can result in severe personal injury. Maximum operating air pressure is 90 psig (6.2 bar).

AIR CONSUMPTION - Air consumption in cubic feet per minute (cfm) for the VXL/M can be calculated as follows: cfm = (a) x (b) x (0.17)

a = Number of straps applied per minute. b = Number of seconds motor is on per strap during tensioning, from start to deceleration

to stall including stall time while making joint.

0.17 = VXL/M efficiency ratio.

Example Calculation: Peak strapping load is 4 straps/min. so a = 4

Air motor is on 5 seconds/strap, so b = 5 VXL/M efficiency ratio is 0.17

(a)x(b)x(0.17) 4x5x0.28=5.6 cubic meters/hr. (5.6M

6 4x5x0.17=3.4 cubic ft/min.

/hr.)

Air pressure is assumed to be 90 psig (6.2 Bar) with recommended size and length of air hose. Volume of air is at room temperature and sea level pressure, or so-called "free air" conditions. For more detailed information about air supply systems refer to Signode manual Part No. 186038.

COLD WEATHER OPERATION

If a tool does not operate satisfactorily in freezing temperatures, certain steps can correct the problem. The following steps can be taken to improve cold weather operation of the tool:

a. An air line dryer adjacent to the compressor.

b. Use lubricant recommended by Signode. Signode has tested the use of anti-freezes, none

work well in air tools; the tool will gum up when anti-freezes are introduced and will not function properly. The best lubricant for freezing weather is the 1 to 1 oil and kerosene combination.

c. If possible, run the air supply line to a indoor located Filter-Regulator-Lubricator or relocate the

F-L-R to a warmer operating area.

OPERATING INSTRUCTIONS

Wear safety glasses.

Stand to one side of the strap when tensioning. Make sure all bystanders are clear before proceeding.

1. With the dispenser placed behind you, bring the strap over the top and around the package, pulling out excess slack. Press the operating lever with your right hand and, with your left hand, insert the overlapped straps under the feedwheel and welding mechanism. Leave only a short tail ahead of the feedwheel and make sure straps are aligned behind the tool. Do not make a joint over a void area of the package.

3. When the motor stalls, indicating completion of tension, continue to hold the motor lever fully closed against the motor housing and pull back the weld handle with your left hand. The handle should be pulled quickly without hesitation. When the weld lever is pulled back it traps the motor lever in the ON position.

all the way back

2. Recheck the strap alignment at the rear of the tool and realign if necessary. Release the operating lever and, while standing to one side of the strap line, squeeze the motor control lever to tension the strap.

4. The internal weld timer is energized. The strap is welded and the supply end of the strap is cut-off. Pull the cut strap away during welding. The tool will continue through the weld cycle and stop with the motor lever being held in place. When the timer times out, the weld action stops. Allow the tool to remain stationary for at least 3 seconds to ensure that the weld is fully cooled.

Failure to wait 3 seconds can result in an improperly formed joint which may lead to joint separation.

5. Push the weld handle to the forward

position with your left hand. The motor lever will return to the OFF position as the weld handle is moved forward.

6. Press the operating lever and swing the tool off the strap, rear of tool first. Inspect the joint to make sure the straps have been properly welded.

SEALING OPERATION

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:

1. Insure that the tools 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.

TOP VIEW

SIDE VIEW

The welded area should extend the full length and width of the gripper impression.

TOOL ADJUSTMENTS

WELD TIME

Weld time has been factory adjusted to provide acceptable weld strength when using Tenax (polyester) or Contrax (polypropylene) type strap. When using Dymax (nylon) strap the weld time must be increased.

Weld time may need to be adjusted due to air supply differences, tool wear, etc. Adjustments are made by turning the small slotted screw, located beneath the weld housing at the rear of the tool, using a small screwdriver.

STRAP TENSION

Strap tension can be accurately controlled by turning the adjustment screw in 1/4 increment turns counter-clockwise using a 3/32 hex wrench (P/N 422587) to reduce strap tension and clockwise to increase strap tension. Operating air pressure must be set between 85 and 90 psi (5.7-6.2 Bar). With accurately controlled air pressure the tension will be uniform on all straps, provided the operator allows the air motor to stall.

STRAP GUIDES

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

NOTE: Turning the adjustment screw clockwise increases weld time and counterclockwise decreases the weld time.

1. Adjust the screw in 1/8 to 1/4 turn increments only.

2. Apply a strap and make a weld.

3. Compare the weld made with the illustrations shown on page 9 of this manual. 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.

The VXL/VXM tool is manufactured with a strap guide for 7/16" (10.5mm) strap. When using 1/2" (12.7mm) strapping material, the standard strap guide must be replaced with the 1/2" (12.7mm) strap guide for proper strap alignment. One 1/2" (12.7mm) strap guide is packaged with each VXL/VXM tool.

To remove a strap guide from the tool, remove the screw from the bottom of the tensioner foot. Once the screw has been removed the strap guide can be lifted over the alignment pin and out of the tool.

Replace the new strap guide in the same manner in which the old guide was removed.

CUTTER ADJUSTMENTS

When the strap cutter begins to wear or strapping seems difficult to cut off the strap cutter may need adjustment. Contact the Signode tool repair center or your Signode representative for information on accessing the adjustment screw.

Before attempting to adjust the cutter, first place a single layer of strapping in the tool and pull the weld handle to the full back position.

Adjust the cutter blade position by turning the adjustment screw inward (clockwise) or out (counter-clockwise) using 1/8 turn increments. Adjust the cutter blade so that the cutting edge of the blade places a slight impression into the single layer of strap.

Remove the single layer of strap. Run one or more tool cycles and continue to adjust the cutter as necessary until proper strap cut-off has been obtained.

NOTE: Do not over tighten cutter mechanism as lower strap damage or poor strap cut-off will occur.

FEEDWHEEL TO GRIPPER PLUG

2. Release the tensioner foot to pinch the shims between the feedwheel and the gripper plug. Holding the shims with one hand, jog the air motor on and off to rotate the feedwheel at least one full revolution. If properly adjusted the tool should lightly tug at the shims while rotating. Clearance between the feedwheel and gripper plug at this point should fall between .002"-.004" (.05.10mm).

3. If the feedwheel needs to be adjusted, use a 3/32" hex wrench to rotate the adjustment screw located in the tensioner foot.

The feedwheel to gripper plug clearance may require readjustment if the feedwheel, tensioner foot or gripper plug has been replaced. The feedwheel clearance should also be inspected during routine tool maintenance procedures. Adjust the feedwheel clearance as follows:

1. Open the tensioner foot and place 1 to 2 layers of .002", 1/2" wide (.05 x 12mm) shim stock between the feedwheel and the gripper plug.

NOTE: Using a single .004" (.10mm) shim is not recommended because a single thicker shim may not conform to the feedwheel shape, resulting in inaccurate clearance measurements.

Turn the adjustment screw clockwise for greater clearance and counter-clockwise for less clearance. Turn the adjustment screw only in 1/8 turn increments. After each 1/8 turn, repeat the adjustment testing as described in step 2.

4. Once the proper clearance has been found the tool can be returned to service.

NOTE: Never turn out the adjustment screw more than 1/8 turn at a time without testing or completely removing the adjustment screw. These actions will severely damage both the feedwheel and gripper plug.

PARTS REMOVAL & REPLACEMENT

FEEDWHEEL AND GRIPPER PLUG

1. Place the tool on its side and remove the two socket head cap screws (75) from the weld housing (24).

2. Pull upward on the weld housing and raise it slightly.

3. Insert a thin rod or screwdriver and disengage the torsion spring (23) from the tab on the weld housing (24).

4. Pull the weld housing off the tool.

5. Lift the feedwheel (22) from the feedwheel shaft (21).

6. Lift the torsion spring (23) and the tensioner foot (16) off the support pin (25). This allows the gripper plug (17) to be replaced if necessary. Turn the tensioner foot over, remove the flat head cap screw (19) and with a small punch, drive the roll pin (20) upward to remove the gripper plug and strap guide, (18).

7. Replace the feedwheel if necessary, making sure the hollow face of the feedwheel faces inward.

8. Lubricate the support pin and the end of the feedwheel shaft with Mo-Lith No. 2 lubricant to allow the tensioner foot to pivot freely.

9. Reassemble the parts in reverse order if further parts removal and replacement are not needed.

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Signode TENSION-WELD VXL-2000-Z, TENSION-WELD VXM-2000-Z Operation, Parts And Safety Manual

Specifications and Main Features

Frequently Asked Questions

User Manual