xcs550 - packaging brands

Certificate of Conformity

XCS550

We certify that the abovementioned product meets the requirements stipulated by:2006/42/EC Machinery Directive

The above mentioned product meets the following standards and guidelines:EN 415-8:2008

For more information on Optimax® Strapping Machines and the Optimax® Packaging Equipment range and to find your preferred or appointed distributor please call0333 005 9603 or email [email protected]

©Packaging Brands LtdXCS550 Operating Instructions 11.2016Re-order code: LIT-MAN038

No part of this publication may be reproduced or transmitted in any form or by any means without the express written authorisation of Packaging Brands Ltd.Optimax® is a registered trademark of Packaging Brands Ltd.

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Semi-Automatic Strapping Machine

Operating Instructions

XCS550

OPTIMAX XCS550 OPERATING MANUAL_Layout 1 23/11/2016 11:13

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DescriptionFeaturing compact design, low-maintenance control head, electronic tension control,table height adjustment and lockable swivel castors make the XCS550 the perfect semi-auto strapping machine.

Features> Compatible with 5-16mm polypropylene machine strapping on 200mm and 280mm internal diameter strapping cores

> Height adjustable table> Lockable swivel castors> External manual strap tension adjustment> Hinged stainless steel top plate> Quiet, compact control head with sensor-controlled heater blade and direct-drive mechanism

Specifications> Dimensions (W x D x H): 850 x 560 x 780-950mm> Nett weight: 75kg> Power supply: 240V 50Hz> Power consumption: 0.25kW> Min/max strap tension: 15-45kg> Strap width: 9mm - 16mm> Strap reel diameter: 200mm, 280mm> Cycle time: 3 seconds @ 50Hz> Optimum ambience

temperature: +5°C to +40°Chumidity: not exceeding 50% @ +40°C

> Noise emission: 78dB(A)

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SSafety instructions Before operation a. Read the instruction manual b. Verify that the mains supply voltage is correct for the strapping machine and is properly earthed c. This strapping machine can only be used with polypropylene (PP) strap; do not use polyester (PET) or polyethylene (PE) cord strap d. Before operation ensure the area around the strapping machine is clear and safe.

During operation a. Wear appropriate personal protective strapping machine (PPE) while operating this strapping machine b. Do not attempt to strap any package exceeding 100kg c. Do not attempt to strap a package less than 80mm wide or 20mm high d. Immediately suspend operation if smoke or unusual sounds are observed

After operation a. Remove all dust and dirt from the strapping machine, paying particular attention to the inside of the arch b. Turn off the power supply when the strapping machine is not in use

General safety remarks Basic safety precautions a. The strapping machine is only to be operated when in good running order and in following the instructions provided in the operator manual, in accordance with its designated use b. Operators must be properly trained in strapping machine operation procedures and operator safety

Safety warning symbols

Maintenance a. Always disconnect mains power supply before removing either of the top covers b. Always use the correct tools and parts to service and repair the machine c. Be aware that the heater assembly may still be extremely hot and cause burns if touched

Location a. The strapping machine must always be located in a low-humidity environment b. Do not expose the strapping machine to extremes of temperature c. Position the strapping machine on an even floor, to prevent distortion that may cause malfunction

Other a. Keep the operator manual with the strapping machine at all times b. Do not modify the strapping machine or its circuitry including safety interlocks, unless specifically authorised to do so by the manufacturer c. Do not operate the machine with any covers removed d. Only use the machine within the parameters of its stated performance.

Risk of electric shock Hot surface, do not touch

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General safety remarks (cont.) c. To minimise environmental impact, all consumables and replaced parts must be disposed of appropriately inaccordance with local/national regulations d. In addition to the operator instructions, the user is to be instructed in all generally applicable legal or mandatory regulations relevant to safety and the environment e. Long hair, jewellery and loose clothing may all be a safety hazard and must be secured prior to operation f. Use personal protective strapping machine (PPE) where applicable or required by law g. Carefully observe all safety instruction and warning labels attached to the strapping machine; keep these clean and legible and replace them if damaged or missing h. Personnel undergoing training on the use of the strapping machine must be supervised at all times by experienced, fully trained personnel i. Avoid unsafe operation of the strapping machine, including operating it in such a way as might affect its stability

Safety devices a. Only operate the strapping machine with all safety devices in place and fully functional, including protective panels, interlock switches and emergency shutoff devices b. All safety devices must be regularly checked for functionality and replaced as necessary c. All safety guards and machine panels removed during maintenance or repair must be securely and fully reinstated, using all original fixings

Electrical a. The heating unit operates at very high temperatures required to melt polypropylene strapping and to prevent burns, care must be taken to avoid skin contact with the area immediately around the heater unit (adjacent to the strap outfeed on the table) b. The heating unit may continue to present a risk of burns even after the machine has been switched off, and contact should be avoided for three minutes following disconnection from the power supply c. In the event of electrical malfunction immediately disconnect the strapping machine from the mains power supply d. Ensure that the style and rating of replacement fuses matches the original e. Any electrical work carried out on the strapping machine must be conducted by a qualified electrician or under the close supervision of a qualified electrician, observing good electrical engineering practice, following safety regulations and local/national wiring standards f. Inspect internal electrical connections at regular intervals; tighten any loose connections; check for scorch marks, replacing damaged wiring and correct the cause of scorching g. If working with live electrics > ensure a second person is on hand to disconnect the power in the event of an emergency > where appropriate secure the area with physical barriers and warning signs > always use insulated tools h. When working with high voltage assemblies, turn off the power supply, discharge the power cable and any energy-storing components such as capacitors i. Before moving the strapping machine, remember to disconnect the power supply and remove the plug from the mains socket, stowing the cable securely on the strapping machine j. Following movement of the strapping machine, ensure that any fixings or components loosened or removed are properly and securely reinstated k. Ensure that the strapping machine is properly connected to a suitably earthed supply l. If the power cable and/or plug require replacement, ensure that the electrical connections are wired correctly and securely; if in doubt, consult a qualified electrician

Environmental a. To minimise environmental impact, all consumables and replaced parts must be disposed of appropriately in accordance with local/national regulations b. Electrical components must be correctly disposed of in accordance with local/national regulations

Operating Instructions – Start-up®


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Machine overview

1. Main power switch2. Ready lamp, lamp will light up after turn on the Main power

switch, and flash when machine error3. Feed length knob, strap feed length4. Selector switch, strap feed and reset5. Tension adjustment knob, strap tension adjustment6. Table top7. Strap reel8. Castor, two lockable, two free9. Adjustable legs10. Frame11. Door

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Strap loading and threading1. Turn reel nut handle (A) left and remove it.2. Remove the outer flange (B) and install the strap reel.3. Make sure that the sense of rotation is counterclockwise (a) when unrolling.4. Put the outer flange back on and tighten reel nut handle (A) to the right.5. Remove all adhesive strips or other adhesive material.6. Unroll about 1.5 m of strap and make sure that it is not twisted.7. Thread the strap over (C) to roller (D) in direction of the arrow.8. Turn left button SA1 (strap feed) to the left until obtaining the length you need.

Operating the machine1. Turn main switch QS1 to ON. The heating element reaches the working temperature at approximately 3 minutes.2. Place a package on the table top (The package must cover the Slide Table).3. Properly adjust the strap tension potentiometer R4 according to various package.4. Place the strap around the package to be strapped and insert the strap into the strapping head until it stops.5. The strapping and welding sequence should complete.6. At end of strapping sequence the strap end is fed automatically, and potentiometer R3 is to adjust the strap length

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TroubleshootingStrap doesn’t joint after sealinga. Check if heater has too much carbonized debris resided on both sides. Too much debris will cause

heater incapable of melting straps. Clean the surfaces of heater from carbonized debris.b. The temperature of heater is whether too high or too low. When the temperature is too high, there

might be not enough cooling time for cooling down. When the temperature is too low, heater will be unableto melt the straps.

c. Increase welding cooling time behind the control box so to produce longer cooling time.d. Return spring for heater arm is either broken, coming off or worn which makes heater unable to enter the correct melting position.e. If you find the jointed surface is smaller than the standard size, check if the position of the strap guide (B) is according to your requested strapping width. Or you can adjust guide front (TB-197) and front plate (TB-208) as illustrated in the following drawing for positioning PP straps equal to each other.

Insufficient strapping tensiona. Turn VR T5-4-10231 clockwise to increase the tension.b. The package is too small (smaller than 80mm).c. The bearing (BR635ZZ) for rear bar (TA-074) is broken or the tip of rear bar (TA-074) is worn which

makes rear bar unable to hold the straps after tensioning. This produces bad quality tension.d. Replace PC Board.e. Turn tension adjustment nut (TB-133) clockwise for an increase in the tension pressure as i llustrated in the drawing to the left.

For 5-6mm PP Strap

For 9mm PP StrapFor 12mm PP Strap

For 12mm PP StrapFor 15.5mm PP Strap

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Strap width

1. Adjust Guide Front for inserting strap. The inlet for strap should be 0.5mm – 1.0 mm wider than strap in use.

2. Adjust the position of Strap Guide B according to the strap width.3. Loosen the 5 screws outside the Strap Guide B and adjust its position

according to the scale indicated.

Adjustments Maintenance (cont.) Six-monthly maintenance (or every 18,000 strapping cycles) 1. Check heater plate, replacing or readjusting it as required. Ensure the heater plate is cool before carrying out this maintenance! 2. Check strap cutter in seal head, replacing it as required. 3. Check connection between wiring loom and printed circuit board is sound. 4. Carry out test strapping cycles, noting and correcting any malfunctions.

Annual maintenance (or every 36,000 strapping cycles)1. Check deflection roller and replace if showing visible changes.2. Check bearings for loud noises and replace as required.3. Carry out test strapping cycles, noting and correcting any malfunctions.4. Apply light oil in the positions shown in the illustration shown left.

Light Oil

The most common settings for the temperature are 3 or 4, but any position can be selected between 1 and 6.

Optimum temperature will vary depending on the ambient temperature of the machine location and the quality of the strap.

Gradually increase or decrease the temperature setting until an optimum seal is obtained, but bear in mind that both too high and to Low temperatures will give a poor seal.

Daily maintenanceUse high-pressure air to remove dust and debris from the cutter and strap guideareas indicated in the following illustrations. Remove all plastic residue from insidethe machine.

MaintenanceHigh reliability and long service life of this machine depend on regular lubrication, cleaning and maintenance.

Lubrication Only non-resinous SAE 30 lubricant should be used. Care should be taken to avoid spread of lubricant to components having contact with the strap, such as tension rollers and strap guides.

Weekly maintenance Thoroughly clean and lubricate the front bar, press bar and rear bar areas shown in crosshatches on the above illustration.

Monthly maintenance (or every 3,000 strapping cycles) 1. Clean both sides of the heater plate and polish with fine sandpaper if necessary. Ensure the heater plate is cool before carrying out this maintenance! 2. Check seal head cam rollers for easy movement and ensure seal head returns automatically to home position under spring tension. 3. Clean all debris away from the tension roller.

Strap tensionThe machine is already well set for enough high tension. However, according todifferent strap characteristics (such as smoother surface or different thickness),some adjustments for higher tension might be necessary.When insufficient strapping tension occurs while R4 (tension adjustment knob) ison MAX position, please turn Nut A clockwise.This can solve the problem of insufficient strapping tension at high tension andstrap slipping between B & C due to this.

Sealing temperatureThe control panel for the sealing temperature is located underneath the hingedstainless steel table top. To access it, remove the two screws at the front of thetable top and lift it towards the back.

Air Air


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SPackaging products from Optimax®

Semi and Fully Automatic Strapping Machines

Heat Shrink Chambers

Air Pillow Void Fill SystemsCardboard Shredders

Semi-Automatic Case TapersPallet Stretch Wrap TurntablesThese units provide a cost effective means of significantly increasing your pallet stretch wrapping output. They also reduce operator fatigue caused by repetitive manual palletstretch wrapping.

The Optimax® range of strapping machinery is one of themost comprehensive available to the packaging professional. All models feature the very latest strapping technology designed to offer the user the most effective strapping solution for their application.

Optimax® heat shrink chambers are available in a range ofchamber capacities to suit a wide variety of product sizes. Utilising the latest shrink chamber technology, these units offer the packaging professional high quality, on demand heat sealing.

Impulse Heat SealersThe Optimax® range of high quality impulse heat sealers offerthe ultimate in sealing performance and productivity. From desktop to heavy duty industrial models available, there is anOptimax® heat sealing solution for any application.

Optimax® case tapers offer integrated carton sealing within an existing packaging line or stand-alone system. These machines aremanufactured to the highest standards, suitable for continuous industrial use with minimal set-up and consistent sealing results.

The range of Optimax® carton shredders provide an eco-friendlymeans of creating useful loosefill on demand from your wastecardboard. With models suitable for light to heavy use, Optimax®cardboard shredders are an excellent way of producing free, eco-friendly loosefill on demand from your waste cardboard packaging, while reducing your carbon footprint and landfill costs.

An efficient means of creating void fill material on demand.Prior to use, air pillow film rolls require minimal storage spaceand are less prone to settling or movement during transit thanmany conventional void fill materials. Deflation of pillows afteruse minimises waste volume.

ENVIRONMENTALLYRESPONSIBLEALTERNATIVE

ENVIRONMENTALLYRESPONSIBLEALTERNATIVE

All Optimax products come with a 12 months parts or return to base warranty as standard.Extended warranty options are also available; please ask yourauthorised Optimax® distributor for more details.

Optimax® WarrantyFor more information on the range of Optimax®

packaging equipment please contact your authorised Optimax® distributor.


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SThe Optimax® brand is a global standard that encapsulates the very best packaging equipment, innovation, engineering and consumables available to the packaging professional.Optimax® offers a comprehensive technical advice service and trainingprogramme to ensure you maximise the full operating potential of your Optimax® packaging equipment.

Our highly trained technical team and European network of authorised distributors can offer training either on-site or at an Optimax® training centre.

® The Optimax® aftersales service offers complete peace of mind via our technicalservice centre, highly trained technicians andcomprehensive parts and spares operation.

Please contact your authorised Optimax® distributor for more information on theOptimax® range of training and aftersales maintenance and service packages.

To ensure your Optimax® packaging equipment is maintained to the highest operating standards, the Optimax® technicalservice centre provides full technical supportand service for our distinctive and evolving product range.

In addition to our large stock holding of spare parts, wehave many years of experience in packaging equipmentservice and repair, which help to minimise the downtime inyour packaging operation.


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