07/07/07

HELIOS H-45

KEEP IT WELL

IMPORTANT!

OPERATION MANUAL

&

BATTERY-POWERED MANUAL TOOL FOR PLASTIC STRAPPING

SPARE PARTS LIST

07/07/07

PART I

CONTENTS

1. Safety Instructions…………………………………….1

2. Functional Unit ……………………………………… 3

3. Technical Data………………………………………. 4

4. Operation Elements ……………………………………4

5. Operation ………………………………………………5~8

6. Wiring Diagram ………………………………………9

07/07/07

Do not put your fingers into the tension wheel area.

Do not use water or steam to clean the tool.

and hand protection (cut-proof gloves).

Before starting preventive or corrective maintenance, remove battery from the tool.

When operating the tool, wear eye, face

ambient temperature is 50 . Keep dry at all times.℃● Do not open batteries and store them only in dry and frostproof rooms. The maximum

● Never charge a damaged battery. Replace by a new one immediately.

● Do not store batteries together with metal objects.

● Do not dispose of used batteries in the household refuse, water or by burning them.

Become familiar with your tool and keep fingers away from areas that can pinch or cut.

Tool must not be used by persons not properly trained in their use. Before tensioning strap, read and understand the tool operating instructions. Failure to follow the operating instructions or improper load positioning could result in strap breakage.

Before using the tool, read the operating instructions carefully.

Operation

Danger of Shortcircuit：

Environment protection：Operation with Battery

1. Safety Instructions

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07/07/07

Never modify any tool. Modification can result in severe bodily injury.Check tool regularly for broken or worn parts. Do not operate a tool with broken or worn parts.

Do not stand in line with the strap while it is tensioned.

When cutting the strap, hold the upper portion and stand safely away from the strap.Caution: The lower strap will snap forward.

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

in this manual for your tool. Using strap not recommended for this tool can result in strap ● Use the correct strap quality, strap width, strap gauge and strap tensile strength recommended

● Positioning yourself in-line with the strap, during tensioning and sealing, can result in severe ● Place the strap correctly around a properly positioned load.● If the load corners are sharp, use edge protectors.

● Both tool and strap flying violently towards your face.

during tensioning, which could result in the following： or sharp corners on the load can result in a sudden loss of strap tension or in strap breakage Improper operation of the tool, excessive tensioning, using strap not recommended for this tool

Tool HazardsA well maintained tool is a safe tool!

breakage during tensioning.

The strap could break!

Note as follows：

● A sudden loss of balance causing you to fall.

Strap Breakage Hazard

Do not put hands or other parts of the body between the strap and the package during the strapping process.

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07/07/07

4 Sealing & Cutting Unit

H45-100001 Tensioning Unit

H45-300003 Linkage Unit

H45-200002 Gripper Unit

H45-40000

6 Battery UnitH45-60000

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2. Functional Unit

5 Body Frame UnitH45-50000

07/07/07

(Fig. a)

In order to assure optimal welding, the pressure of the welding gripper to the straps to be welded must be within a certain range. Depending on the thickness of the strap, this pressure

Disregarding this regulation will cause considerable trouble.

When adjusting the welding perssure, the shim must be inserted

is adjusted by means of the adjusting the quantity of shim(s). Please see the following chart.

(2) Adjusting the Welding Pressure

Steel Insert 0.4~0.6 mm

0.7~0.8 mm

0.9~1.05 mmShimH45-40270 1

0

2

strap thickness

into "steel insert".

H45-40260 H45-40270

smooth strapquantity for shim(s)

Finally just tighten the Battery Fastener to the battery as (Fig. a) shows.

and you would need to do it again after recharging the battery.

Putting on the Battery

would see the LED lights on GREEN shortly. That means the battery is installed correctly.

sides of the battery to take off the battery.

Removing the Empty Battery

Please loosen the Battery Fastener (H45-60261) and push the unlatching buttons on both If the LED lights on RED while tensioning or welding, that means the battery is exhausted.

Warning! The last welding on the package might not have sufficient seal efficiency

Please loosen the Battery Fastener (H45-60261) first. Then putting on the battery and you

(1) Installation

5. Operation

2

1

3

quantity for shim(s)H45-40270

emboss strap

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07/07/07

(a) Preselecting of Strap Tension and Tensioning Speed

increases, turning counterclockwise

Pull up the handle lever firmly with your right hand.Insert the two straps well aligned on each other into

The strapping is fed around the package as illustrated.

Warning! The plastic strap which will be welded

The welding time can be adjusted at the right adjusting knob.Depending on the size and quality of the strap, different welding times are required.

Turning clockwise increases, turning counterclockwise decreases the welding time.

Release the handle lever.the strap guide using your left hand.

(5) Inserting the Strap

Dirty plastic straps can't be welded correct!must be free from oil, grease and other dirt.

tensioning strength of the strap, the strapwill tear while the tensioning.

Do not adjust the tensioning force too high.If the tensioning force is higher than the

Tensioning force can be preselected with the left adjusting knob. Turning clockwise

decreases the tensioning force.

(3) Adjustments

(b) Adjusting the Sealing Time

(4) Feeding the Strap Around the Package

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Adjusting knob tensioning forceAdjusting knob sealing time

When P.P. straps or straps with thinner thickness around 0.55mm to 0.7mmare still being damaged by H45-10090 (tension wheel) during strapping whilethe tension is at the lowest level (make a counterclockwise turn on the tension knob to the end), simply use an allen key wrench to make a counterclockwise turn on the trimmer of P. C. board. You need to take off the protection cover first and you will then see the VR underneath the

On the other hand, if tension is not enough while it is at the highest level (make a clockwise turn on the tension knob to the end), simple make a clockwise turn on the trimmer of P.C. board for even higher tension.

the protection cover. After making all the adjustments, tension will become lower. When the tension becomes as low as you desired, just put the protection cover back on.

Protection cover

07/07/07

During welding, the LED lights green.

(LED lights yellow).

(7) Removing the Tool

(8) Seal - Control

be examined visually.

and off the strapping.

Make a seal, peel it apart and examine it as follows：

Pull up the handle lever, pull the tool right / backwards

A regular control of the seal is necessary. The seal can

After expiration of the adjusted welding time, the cooling down time begins

When the LED lights green again, the sealing procedure is finished.

strap tension is reached, the tool will do sealing

and press down again and again. Until the desired tension is reached.

Sealing the Straps

The plastic strap is welded and cut off from the strap coil at the same time.

Press down the rocker switch and then release it,

by itself, at this time, we can release the rocker switch.

-Semi

Press the black switch to sealing the straps.

Press down the rocker switch until the desired

(6) Tensioning and Sealing the Straps

-Auto

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07/07/07

Warning! Straps with insufficient seal strength must

Adjust the welding time.be removed from the package!

Minot quantities of fused plastic may overflow on

the strap.

The fused plastic overflows on both sides of the straps. If the welding time is too long the straps are overheated.

The seal efficiency is affected.

Welding Time Too Long

The plastic strap is not welded over the whole width of

The seal efficiency is insufficient.

Adjust the welding time.

Welding Time Too Short

Warning! Straps with insufficient seal strength must be removed from the package!

sides.

Correct Seal The seal must be completely welded over the whole width of the strap on a length.

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07/07/07

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6. Wiring Diagram

1

A

2 3

BC

MAC

HIN

E M

OD

EL

DE

1

F

PAG

E

2 3

A

4

BC

DE

F

4

07/07/07

shape

HN

RR

BWW

ER

TW

PW

SW

PN

NTE

FLG

WN

shape

TMS

CAP

HSS

THS

FMS

HB

PMS

classification

HBS

KYA

FTP

TTP

DS

φ6×φ15~φ16×1.0~1.5tφ8×φ14~φ16×1.3~1.5t

φ8×φ12~φ16×0.4~0.8tφ6×φ13~φ4×0.8~1.5t

PWB

PWA

φ8×φ20~φ23×2.0tφ6×φ16~φ19×2.0t

PWC

HBW

KYC

KYB

SP

MB

TAL

HFL

KT

BK

BR

one way

single cover

classification

SR

FHS

PART II

CONTENTS

1. Tensioning Unit …………………………………………………..1

2. Gripper Unit ………………………………………………………4

3. Linkage Unit……………………………………………………..6

4. Sealing & Cutting Unit ………………………………………………..8

5. Body Frame Unit ……………………………………………….11

6. Battery Unit……………………………………………………….13

1 TENSIONING UNIT H45-10001H45-10002

REF.NO. PART NO. DESCRIPTION Q'TY REMARKS

H45-10001 Tensioning Unit (For 12mm) 1H45-10002 Tensioning Unit (For 16mm) 1H45-10003 Tensioning Unit (For 9mm) 1

1 H45-10010 End Cover 12 H45-10020 Torsion Spring 13 H45-10030 Strap Stop (For 16mm) 1

H45-10031 Strap Stop (For 9mm, 12mm) 14 H45-10040 Tensioning Body 15 H45-10050 Swivel Shaft 16 H45-10060 Holder 17 H45-10070 Gripper (For 16mm) 1

H45-10071 Gripper (For 9mm, 12mm) 18 H45-10080 Holder (For 16mm) 1

H45-10081 Holder (For 9mm, 12mm) 19 H45-10090 Tensioning Wheel 1

10 H45-10100 Dowel 311 H45-10110 Parallel Pin 312 H45-10120 Idler Gear 313 H45-10130 Washer 114 H45-10140 Tensioning Wheel Shaft 115 H45-10150 Parallel Pin 316 H45-10160 Idler Gear 317 H45-10170 Cover 118 H45-10180 Bearing 119 H45-10190 Tension Gear 120 H45-10200 Spur Wheel 121 H45-10210 M1 Motor Support 122 H45-10220 M1 Motor Pinion 123 H45-10230 Motor (M1) 124 H45-10240 Screw 125 H45-10250 Washer 226 H45-10260 Tube 127 H45-10270 Set Ball 128 H45-10280 Strap Stop (For 12mm, 16mm) 1

H45-10281 Strap Stop (For 9mm) 129 H45-10290 M1 Motor Ass'y 1

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1 TENSIONING UNIT H45-10001H45-10002

REF.NO. PART NO. DESCRIPTION Q'TY REMARKS

30 H45-10300 Cover 131 BK0808Z Needle Bearing, 0808Z 132 BR6806 Bearing, 6806 133 BR6806Z Bearing, 6806Z 234 BR6808Z Bearing, 6808Z 135 FHS0410N FHS, M4×10 (N) 336 FHS0514N FHS, M5×14 (N) 337 FHS0308N FHS, M3×8 (N) 238 HBS0410N HBS, M4×10 (N) 239 HBS0430HN HBS, M4×30 (H)(N) 240 HBS0516N HBS, M5×16 (N) 141 HN05 HN, M5 142 KT-477N Needle Bearing, 477N 343 KT-5810N Needle Bearing, 5810N 344 HBS0412N HBS, M4×12 (N) 245 SB04 Ball, Ø4 146 MB0815 Metal Bush, 0815 247 FHS0306N FHS, M3×6 (N) 248 SP0306 Spring Pin, 3×6 549 SP0432 Spring Pin, 4×32 1

51 SW04 SW, M4 652 SW05 SW, M5 2

60 H45-10600 Tensioning Wheel Shaft Ass'y 161 H45-10700 Tensioning Body Ass'y (For 16mm) 1

H45-10701 Tensioning Body Ass'y (For 9mm, 12mm) 1

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2 GRIPPER UNIT H45-20000REF.NO. PART NO. DESCRIPTION Q'TY REMARKS

3 H45-20030 Spring 24 H45-20040 Eccentric Shaft 15 H45-20050 Inner Raceway 16 H45-20060 M2 Motor Gear 17 H45-20071 Switch Rocker 18 H45-20080 M2 Motor 1

10 H45-20100 Eccentric Shaft Gear 111 H45-10250 Washer 112 H45-20120 M2 Motor Ass'y 113 H45-20110 Spring Slide Ass'y 1

23 HBS0320N HBS, M3×20 (N) 124 HN05 HN, M5 125 HSS0305 HSS, M3×5 426 MB0805 Metal Bush, 0805 127 MB1709 Metal Bush, 1709 128 PMS0218 PMS, M2×18 229 PW05B PW, M5 (B) Ø13 130 SP0310 Spring Pin, 3×10 1

32 SW02 SW, M2 233 SW03 SW, M3 1

35 SW05 SW, M5 1

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3 LINKAGE UNIT H45-30000REF.NO. PART NO. DESCRIPTION Q'TY REMARKS

1 H45-30010 Pressure Roller 12 H45-30020 Front Toggle Link 13 H45-30030 Lever 14 H45-30040 Torsion Spring 15 H45-30050 Stanchion 16 H45-30060 Collar 17 H45-30070 Spur Wheel 18 H45-30080 Collar 19 H45-30090 Handle Arm 1

10 H45-30100 Collar 111 H45-30110 Arm 112 H45-30120 Coupler 113 H45-30130 Coupler Shaft 114 H45-30140 Handle Lever 115 H45-30150 Connector 116 H45-30160 Handle Shaft 117 H45-30170 Washer 418 H45-30180 Shaft 119 H45-30190 Spur Wheel Ass'y 1

21 H45-10250 Washer 422 HBS0420N HBS, M4×20 (N) 123 H45-30230 Collar 224 PMS0312 PMS, M3×12 125 HFL0615 Bearing, 6×10×15 126 NTE04 NTE, M4 227 HSS0305 HSS, M3×5 128 HSS0508G HSS, M5×8 (G) 229 KYA020210 Key, 2×2×10 230 MB0810 Metal Bush, 0810 131 PW03 PW, M3 232 SW03 SW, M3 133 MB0812 Metal Bush, 0812 234 MB0606 Metal Bush, 0606 235 FMS0420 FMS, M4×20 136 SW04 SW, M4 2

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4 SEALING & CUTTING UNIT H45-40001H45-40002

REF.NO. PART NO. DESCRIPTION Q'TY REMARKS

H45-40001 Sealing & Cutting Unit (For 12mm) 1H45-40002 Sealing & Cutting Unit (For 16mm) 1H45-40003 Sealing & Cutting Unit (For 9mm) 1

1 H45-40011 Bearing Support 12 H45-40020 Rocker 13 H45-40030 Welding Excentric 14 H45-40040 Pinion 15 H45-40051 M3 Motor Support 16 H45-40060 M3 Motor Pinion 17 H45-40070 Thrust Piece 18 H45-40080 Coupler 19 H45-40090 Cutter 1

10 H45-40100 Pressure Spring 111 H45-40110 Driver 212 H45-40120 Driver Pin 113 H45-40130 Bolt 114 H45-40140 Thrust Piece 115 H45-40150 Ball Cage 116 H45-40160 Welding Gripper 117 H45-40170 Seesaw Lever (In Side) 118 H45-40180 Guide Case 119 H45-40190 Seesaw Lever (Out Side) 120 H45-40200 Parallel Pin 1

22 H45-40220 Pressure Spring 223 H45-40230 Guide Pin (For 16mm) 1

H45-40231 Guide Pin (For 9mm, 12mm) 124 H45-40240 Guide Pin (For 12mm, 16mm) 1

H45-40231 Guide Pin (For 9mm) 125 H45-40250 Welding Stop Gripper 126 H45-40260 Steel Insert 127 H45-40270 Shim

Strap Thickness 0.4~0.6mm 2Strap Thickness 0.7~0.8mm 1Strap Thickness 0.9~1.05mm 0

28 H45-40280 Shaft 1

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4 SEALING & CUTTING UNIT H45-40001H45-40002

REF.NO. PART NO. DESCRIPTION Q'TY REMARKS

29 H45-40290 M3 Motor Ass'y 130 H45-40300 Welding Excentric Ass'y 131 H45-10230 M1/M3 Motor 132 T7-5-20210 Grommet 233 H44-10710 Lock Pin, 4×8 134 H45-40330 Cover 235 H45-40340 Cover 1

40 HBS0545HN HBS, M5×45 (H)(N) 141 BR627ZZ Bearing, 627ZZ 242 TMS0408 TMS, M4×8 143 HBS0408N HBS, M4×8 (N) 244 HBS0416N HBS, M4×16 (N) 245 HBS0420N HBS, M4×20 (N) 146 HBS0425N HBS, M4×25 (N) 347 SR05 Snap Ring, S-5 748 SB04 Ball, Ø4 649 SP0318 Spring Pin 3×18 150 SW04 SW, M4 851 TAL1012 Needle Bearing, 1012 252 SW05 SW, M5 1

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5 BODY FRAME UNIT H45-50000REF.NO. PART NO. DESCRIPTION Q'TY REMARKS

1 H45-50010 Body Frame 12 H45-50021 Cover Front 13 H45-50030 Cover Rear 14 H45-50040 Plate 15 H45-50050 Battery Lock Pin 16 H45-50060 Cover 17 H45-50070 Stiff Suspension Bracket (Option) 18 H45-50080 Stiff Suspension Bracket Set (Option) 19 H45-50090 Bottom Base Wearing Protection Plate 1

(Option)10 H45-50100 Bottom Base Wearing Protection 1

Plate Set (Option)11 FHS0310N FHS, M3×10 (N) 212 FHS0408N FHS, M4×8 (N) 6

14 FTP0410BN FTP, M4×10 (B)(N) 415 HBS0416N HBS, M4×16 (N) 216 TTP0420BN TTP, M4×20 (B)(N) 317 HBS0440HN HBS, M4×40 (H)(N) 218 PW04 PW, M4 219 SW04 SW, M4 720 H45-50160 Washer(M4×∮8×0.8t) 121 HBS0410N HBS, M4×10 (N) 122 HBS0410N HBS, M4×10 (N) 123 PW05 PW, M5 124 HBS0516N HBS, M5×16 (N) (Option) 425 SW05 SW,M5 (Option) 426 FHS0410N FHS, M4×10 (N) 627 H45-50110 Turnable Suspension Bracket (Option) 128 H45-50140 Block 129 H45-50150 Turnable Suspension Bracket Set 1

(Option)30 HSS0410GN HSS, M4×10 (G)(N) 131 AD-2-20181 Washer 132 T7-5-20210 Grommet 133 LA-40010 Label 134 LA-50008 Label 1

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6 BATTERY UNIT H45-60000H45-60001

REF.NO. PART NO. DESCRIPTION Q'TY REMARKS

H45-60000 Battery Unit (For 230V/220V/240V) 1H45-60001 Battery Unit (For 110V) 1

10 H45-60100 Connecting Plate 111 H45-60110 Battery 112 H45-60120 Charger (For 110V) 1

H45-60121 Charger (For 220V/230V/240V) 113 H45-60130 Tension Switch (Auto) 114 H45-60141 Control Box (PCB) 115 H45-60150 Knob 216 H45-60160 Sealing Switch (Semi) 117 H45-60171 Lock 118 H45-60181 Cam 119 H45-60190 Spring 1

21 HBS0412N HBS, M4×12 (N) 122 HN05 HN, M5 123 TTP0305 TTP, M3×5 224 PMS0430 PMS, M4×30 225 PW03 PW, M3 226 PW05 PW, M5 127 SW04 SW, M4 328 H45-20090 Micro Switch 329 H45-60210 Position Wires Ass'y 130 H45-60220 Start/Sealing Wires Ass'y 131 H45-60230 LED Wire 132 H45-60240 Electric Control Group 133 H45-60261 Battery Fastener 134 SW05 SW, M5 1

06/2009

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組合B00b01b02b03B04B05B06b07b08b09~10b11b12b13b14