OPERATION MANUAL
SATURN SA-3350
AUTOMATIC ARCH STRAPPING MACHINE
SERIAL NUMBER
Please refer to the serial number in all correspondence with Highlight or any Highlight
Distributor. This identifies your machine and will help in our ability to quickly and
efficiently respond to your needs.
Version 1.2 – March 2013
TABLE OF CONTENTS
1. General System Information
1. System Specifications ……………………………………………………………………... I-1
2. Dimensional Drawing …………………………………………………………………… I-2
3. System Descriptions…..……………………..…………………………….………………. I-3
4. Limited Warranty …………………………………………………………………..……. I-4
2. Installation Instructions
1. Machine Placement ………...…………………………………………………………….. II-1
2. Machine Set-Up…..……………………..………………………………………………… II-2
3. Operation Instructions
1. Safety Precautions…………...…………………………………………………………….. III-1
2. Pre-Operation Adjustments…………………………………………………………….... III-3
3. Operator Panel…..……………………………...………………………………………...... III-11
4. Strap Threading Procedure & Diagram ..……………………………………………… III-13
5. Machine Operations……………………………………………………………………… III-14
4. Maintenance
1. Preventive Maintenance…………...……………………………………………………… IV-1
5. Troubleshooting
1. Troubleshooting Guide……………………………………………………………………. V-1
6. Electrical References
1. Electrical Schematic………………………………………………………….…………… VI-1
7. Mechanical References
1.Mechanical Parts List and Prints…………………………………………………….……. VII-1
8. Notes
1
Chapter
I.
Chapter 1
HIGHLIGHT INDUSTRIES, INC.
Saturn® SA-3350 Arch Strapping Machine Operation Manual
General System
Information
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
SYSTEM SPECIFICATIONS
Highlight’s Saturn SA-33550 arch strapping machine is the simplest and most user
friendly arch strapping system, capable of cycle speeds of up to 30 straps per minute.
The model SA-3350 was specifically designed to eliminate common problems with
strapping machines and provide trouble free use for operators at an economical price.
The machine takes just minutes to learn to use: align the product to the center of the
arch and trigger the start button. The machine will tension, heat seal and secure your
products by applying an adjustable force from 5 pounds to 120 pounds using
economical 3/8” (9mm), ½” (12mm), or 5/8” (15mm) wide polypropylene strapping.
The SA-3350 is designed to operate semi-automatically with the push-activated start
button or by remote foot switch for hands-free use. Also, a built-in sensor in the table
top allows completely automatic operation for ease of performing rapid successive
straps on long products or to execute quick four-sided strapping on boxes for extra
security. Value added features included in the design are: safe internally enclosed strap
coil with easy loading via slide out door, easy access strap threading, automatic strap
reset, auto strap loop eject when a cycle is accidentally triggered, anti-jam protection,
electronic tension control, and flip-open table tops for easy cleaning & maintenance.
Machine Size
o
o
o
o
22” L (front to back) x 43.5” W x 58” H
Shipping weight – 400 lbs on a pallet
Strap Roll Inner Diameter: 8” & 9” Adjustable
Strap Width: 3/8”, ½”, 5/8” Adjustable (metric equivalents: 9mm, 12mm,
15mm)
Operation Space
o
24” L (front to back) x 70” W x 70” H
Electrical Data
o
120 VAC; Single Phase, 4 Amps, 60 Hz
Production Capacity
o
o
o
o
o
Operating Rate: Up to 30 straps per minute, 5 - 120 lbs tension capacity
Minimum Load Size: 3” L x 3” W x 0.5”H
Minimum Load Weight: N/A (operator must hold down light weight
packages)
Maximum Load Size: 33” W x 23” H
Maximum Load Weight: 45 lbs
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
I-1
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
DIMENSIONAL DRAWING
SATURN SA-3350 STRAPPER
w/ 33”W x 23”H ARCH
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
I-2
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
SYSTEM DESCRIPTIONS
Arch Assembly
Cabinet
Assembly
Strapping Head
Assembly
Pool Feed Unit
Strap Dispenser
& Brake Unit
(strap)
Strap Pool
Chamber
Holding Gripper
Welding Press
End Gripper
Seal Plate
Strap Guide
Feed Rollers &
Guides
Tension Rollers
Cam (6)
Brake
Timing Arch Track Holding
Gearmotor Opening
Gripper
Cam
Cam (1)
Seal
Plate
Cam (2)
Welding End
Press
Gripper
Cam (2) Cam (5)
Heater
Cam (4)
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
Home
Cam
Cam (6)
One-Way Roller
Backfeed
Position
Cam
I-3
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
LIMITED WARRANTY
Highlight Industries, Inc. warrants our Saturn Strappers, will be of merchantable
quality, free from defects in material and workmanship as determined at the date of
shipment, by generally recognized, applicable and accepted practices and procedures in
the industry, for a period of six (6) months from the Highlight invoice date, under
normal use and service.
When the Purchaser gives Highlight written notice of any alleged defect within the
applicable warranty period, Highlight will, at its option repair or replace the same free
of charge F.O.B. its manufacturing plant, installation not included. Equipment replaced
under the warranty shall have the same warranty as new equipment but does not extend
the warranty of the original equipment.
Satisfaction of this warranty, consistent with other provisions herein, will be limited to
the replacement or repair or modification of, or issuance of a credit for, the equipment
involved, at Highlight’s option.
Highlight neither assumes nor authorizes any person to assume for it any other
obligation in connection with the sale of Highlight’s equipment.
This warranty shall not apply to any equipment which has been repaired or altered by
un-authorized personnel in any way so as to, in the judgment of Highlight, affect
serviceability, or which has been subjected to misuse, negligence, accident, or to
equipment made by Highlight which has been operated in a manner contrary to
Highlight’s instructions.
In no event regardless of the cause, shall Highlight be liable for penalties or penalty
clauses of any description or any damages resulting from loss of profits, use of products
or for any incidental indirect or consequential damages, even if advised of the possibility
of such damages. This limitation of Highlight’s liability will apply regardless of the form
of action, whether in contract or tort, including negligence. Any action against Highlight
must be brought within twelve (12) months after cause of action accrues.
“THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES WHETHER
EXPRESSED, IMPLIED OR STATUTORY INCLUDING IMPLIED WARRANTIES OF
MERCHANTABILITY OF FITNESS AND EXTENDS ONLY TO THE BUYER OR
CUSTOMER PURCHASING FROM HIGHLIGHT OR AN AUTHORIZED HIGHLIGHT
DISTRIBUTOR.”
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
I-4
2
Chapter
II.
Chapter 2
HIGHLIGHT INDUSTRIES, INC.
Saturn® SA-3350 Arch Strapping Machine Operation Manual
Installation
Instructions
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
MACHINE PLACEMENT
Inspections
Before installation, inspect the entire machine for visual damage. If found, please report
this damage to the truck line. Highlight Industries has taken every precaution during the
packaging and loading of this equipment. However, it is YOUR RESPONSIBILITY to
inspect for damage before installation.
Positioning of the Machine
Place your Saturn® Strapping System in an area with sufficient operational space.
Make sure that there is sufficient room to load/unload the machine and that you do not
stretch the wiring cable. Remember, you will need to provide electrical service to a 120
VAC, 10 Amp-outlet. DO NOT USE EXTENSION CORDS!!
Floor Weight Bearing/Stress Tolerance
The floor must be able to bear the weight of the machine, plus the weight of the
maximum load, which is 45 lbs, plus a safety factor. The floor must also be able to
tolerate the stress of the machine’s operation.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
II-1
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
MACHINE SET-UP
It is very important to read all instructions before undertaking any of these steps. The
following steps should help achieving a safe and quick machine set-up.
1. Your Saturn ® SA-3350 Strapping Machine comes pre-assembled and ready for
operation. Set up the machine where it will not be subject to moisture or damage
to its power cord.
2. Lock the caster brakes before using the machine to prevent it from shifting out of
positions while in use.
3. Connect the machine to a 120V 15 Amp power socket. Do not use an extension
cord unless the cord is rated for 15 Amps.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
II-2
3
Chapter
III.
Chapter 3
HIGHLIGHT INDUSTRIES, INC.
Saturn® SA-3350 Arch Strapping Machine Operation Manual
Operation
Instructions
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
SAFETY PRECAUTIONS

Read the Operation Manual before operating the machine.

Do NOT attempt to service the machinery unless you are qualified and understand
the Operations Manual.

Do NOT use extension cords to operate the system.

Make sure nothing is pinching the power cable.

Loose clothing must NOT be worn while the machine is in operation.

Stay clear of moving parts while the machine is in operation.

Do NOT allow dampness or water to enter the machine cabinet or electrical box.

Turn OFF power to the machine when it is not in use.

NEVER try to remove jammed strap from the machine while it is running.

The heating element for sealing/welding the strap and its protective cover are
EXTREMELY HOT!
SEVERE PERSONAL INJURY AND/OR EQUIPMENT DAMAGE could result from
failure to comply with the above.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-1
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
COMPONENT SPECIFIC SAFETY CONCERNS
The machine power cord must be
unplugged when servicing motors,
electrical control controls, and
electrical components or electric
shock may result.
Loose clothing should not be worn
around running belts and pulleys.
The heater temperature can
exceed 700* F. Never handle the
heater or heater cover without
Avoid pinch points. The
allowing the components to cool
heater arm and slide plate
sufficiently.
arms can cause injury when in
motion. Disconnect electrical
power before servicing.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
The machine contains several
cooling fans. Avoid contact with all
fans when the machine is powered
on.
III-2
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
PRE-OPERATION ADJUSTMENTS
Strap Size Adjustments
Highlight has set up the machine for the specified strap core diameter and strap width
when notified of the sizes prior to shipping the machine. If the strap size or core
diameter to be used is different from the factory configuration, the machine can be
adjusted as follows to accommodate 8”or 9” strap core diameters and strap widths from
3/8” (9mm) to ½” (12mm).
Strap Core Diameter
Open the strap coil access door and slide the strap coil holder out from the machine.
Remove the large hand reel nut and the side plate to expose the brackets that support
the strap core. Loosen the four screws and adjust the core support brackets to the
desired strap coil inner diameter. The most inward position of the brackets will
accommodate 8” ID strap coils. Shift each bracket outwards to adjust for 9” ID strap
cores.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-3
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
Strap Width Adjustment
Perform the following procedures to change from the factory set strap width.
Loosen but do not
remove the 4 pool
chamber thumb screws.
Remove the 5 strap width
collars and locking
screws.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-4
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
5/8”
3/8”
Use this guide to
determine the correct
collar position for the
desired strap width.
Re-install the collars into
the pool chamber and
ensure the proper collar
position engages with
each keyhole shaped slot
on the pool chamber
panel.
1/2”
Tighten the 5 collar
screws and the 4 thumb
screws.
Remove the 4 screws
surrounding the upper
feed roller assemblies
then remove the
bandway covers and
width adjustment plates .
Note: the arch track must
be retracted from its
regular position to access
the screws.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-5
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
* Raising this lever will
tilt the feed roller
upwards, allowing for
easier removal of the
bandway covers.
Position the adjustment
plates according to the
pictures for 3/8” or ½”
strap. If changing to 5/8”
strap, a different set of
plates will be required.
Contact Highlight to
order the necessary parts.
3/8”
½”
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-6
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
Place each bandway
cover in position with the
tapered edge towards the
roller and tighten the
screws. Ensure the
covers are not making
contact with the roller
and readjust as necessary
until the roller turns
freely.
Loosen the phillips
screws and adjust the
right strap guide
(attached to the the arch
track) until the clearance
is set to the strap width +
1/32” (1mm). Use a cut
piece of the strap to check
for proper clearance and
tighten the screws.
STRAP WIDTH + 1/32”
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-7
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
Loosen the locking screw
and adjust the left strap
width guide. Use the
reference marks to assist
in the adjustment. The
guide should be set 1/32”
(1mm) wider than the
actual strap width.
Reference:
3/8” = 9mm
½” = 12mm
5/8” = 15mm
Loosen the screws that
secure the strap brushes
in the arch and adjust
until approximately
1/32” (1mm) makes
contact with the strap as
the strap exits the arch.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-8
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
Use a piece of cut strap to
test for proper contact
then tighten the screws.
Strap Pool / Accumulation Chamber Volume Adjustment
The correct amount of strap in the
pool chamber is enough to keep the
the machine supplied with strap
during operation without a short
feed. Too much is not better
however, as overcrowding the pool
chamber causes strap
overcrowding and difficulty
feeding strap into and out of the
pool chamber. To incraese the pool
volume, loosen the jam screw and
move the counterweight to the left,
then tighten the screw. To reduce
the volume, move the
counterweight to the right.
Counterweight
Jam
Screw
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
Pivot
Balance bar
Switch
III-9
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
Strap Dispenser Brake Adjustment
When the brake arm is pulled down, the brake
disengages and the strap coil should turn free
without brake drag. When the brake is engaged,
the strap coil should stop suddenly and resist
turning in the clockwise direction. If the coil still
spins freely enough to dispense an extra loop of
strap after the brake engages, the brake should
be tightened.
Feed Roller Tension Adjustment
This adjustment can be accessed by opening up
the rear table top cover. To increase the feed
roller tension, turn the knob counter-clockwise.
To decrease the tension, turn the knob clockwise.
Note: The correct setting depends on the strap
thickness, air temperature, and cycle rate. If the
spring tension is too high, strap can become
distorted from feeding around the arch and
slamming into the sensor too forcefully. On the
contrary, if the tension is too low the strap will
not feed around the arch completely.
Knob
Spring hook
Feed tension spring
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-10
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
OPERATOR PANEL
Emergency Stop
Power Indicator Light
Tension Dial
Manual Strap Feed Switch
Start Button
Symbol
Name
Power Light
Start Button
Function
The Power Light illuminates when the machine is plugged in, the
electrical disconnect is rotated to the position, and the Emergency
Stop is released.
.
The Start Button has 2 functions:
1. To trigger each strap cycle.
2.To return the strapping head to the home position and feed
strap into the arch prior to each cycle
This switch is used to manually feed strap while in the arch.
Strap Feed / Back
Feed Switch
Tension dial
Adjusts the amount of tension each strapping cycle. Turn clockwise to increase tension and counter-clockwise to decrease
tension.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-11
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
Auto / Manual Mode Switch
Jog Button
Heater Temperature Dial
Cooling Timer Dial
Name
Mode Switch
Function
Strap cycles are triggered by the Start Button or foot switch in
Manual Mode. When in Automatic Mode, the photo sensor in the
table top triggers the strap cycle.
.
The Jog Button momentarily cycles the timing gearmotor for
maintenance and diagnostic purposes.
Jog Button
Heater
Temperature Dial
Cooling Timer Dial
Adjusts the heating element temperature. Standard setting is 5.
Increase in cold environments or high strap cycle rates.
The Cooling Timer Dial adjusts the amount of time the melted
strap is allowed to cool after the strap is sealed together. Increase
if applying high tension straps to ensure the strap seal stays
together.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-12
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
STRAP THREADING DIAGRAM
WARNING: BE SURE EMERGENCY STOP IS PUSHED IN BEFORE THREADING
THE TAPE AND PULLED OUT WHEN TAPE IS THREADED!
1) Turn the electrical disconnect to the OFF position and press the E-Stop button.
2) Open the strap coil access door and slide the strap coil holder outward.
3) Load the new roll of strap on the coil holder so the strap exits from the top of the roll and secure
with the side plate and large hand reel nut.
4) Slide the strap coil holder back into the machine completely.
5) Insert strap through roller 1 and pull approx. 4’ of strap from the coil
6) Thread the strap through rollers 2 & 3.
7) Press relief lever 8 and push approx. 24” of strap into the machine past rollers 4 & 5.
8) Open the front access door and pool door 7. Feed approx. 2” of strap up through rollers 6.
9) Close the strap coil access door, front access door, and pool door 7.
10) Turn the electrical disconnect to the ON position and release the E-Stop button.
11) The strap will fill the pool chamber.
12) Once the pool motor stops running, press the Start button and strap will feed into the arch.
13) Adjust desired tension begin strapping packages.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-13
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
MACHINE OPERATIONS
After the machine has been positioned to provide easy access to a power source, you
will be ready to begin operation. Read thoroughly and follow these steps to operate
your system.
1. Before connecting power to the system, load the machine with strap. Refer to the
strap threading diagram on the inside of the strap loading door or the previous
sections containing the “Strap Threading Diagram.”
2. Turn the electrical disconnect clockwise to power up the machine. Release the
Emergency Stop switch button and the power light on the control panel will
illuminate. The machine will begin warming the strap seal heater blade to
proper temperature. After allowing the heater to warm up for approximately 1
minute, the machine is capable of running strap cycles.
3. Place the package on the table top, centered in the arch.
4. A strap cycle can be triggered in 3 different ways: Start Button, Foot Pedal, and
Sensor built into table top (Auto mode switch must be on)
When any of these controls are triggered, a strap cycle will occur. If the control
remains triggered the machine will cycle continuously until the control is
released (or the sensor is no longer block if in Auto mode)
5. When a strap cycle is triggered, the machine will automatically back feed the
strap around the package, tighten to the selected tension, cut and seal the strap,
allow the strap to cool briefly (according to the Cooling Timer setting), then
release the strap and finally re-feed strap into the arch. The entire cycle occurs in
less than two seconds.
6. If the strap becomes jammed and cannot be cleared automatically by using the
start button, the strap jam must be manually cleared. Power off the machine and
manually pull the strap from the arch and pool chamber then re-thread the strap
according to the “Strap Threading Diagram.”
7. When the strap roll is empty, a buzzer will sound and the machine will not cycle.
A new strap roll must be installed and re-threaded to continue operation.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-14
SATURN SA-3350 STRAPPING MACHINE OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
III-15
4
Chapter
IV.
Chapter 4
HIGHLIGHT INDUSTRIES, INC.
Saturn® SA-3350 Arch Strapping Machine Operation Manual
Maintenance
SATURN SA-3350 ARCH STRAPPING MACHINE OPERATION MANUAL
PREVENTIVE MAINTENANCE
Highlight’s Saturn® Strapping System is designed to provide long, trouble-free service.
However, as with all machinery, proper attention and maintenance is the key to long
component life, maximum performance, and safe operation. By spending a few minutes
reading and following these preventive measures, you should reduce the downtime
and prolong the life of your system.
It is important to understand that these maintenance schedules are minimum
recommendations. Highlight Industries cannot possibly know, evaluate or advise the
various trades in all schedules of periodic maintenance. Because of this, Highlight
Industries has not undertaken such tasks. Accordingly, anyone who maintains or
services a case sealer machine must first satisfy himself/herself as to the schedules of
preventive maintenance based on cycling operation and environmental locations.
Machine components that wear or fail should be repaired or replaced as soon as
possible to prevent damage to other machine components or to your product.
WARNING: ALWAYS TURN MACHINE OFF AND DISCONNECT FROM ITS
POWER SOURCE before doing any cleaning or maintenance work on your system.
Failure to do so will result in severe personal injury and/or machine damage.
Cleaning
Throughout normal usage, the strap feeding through the system will generate strap
dust inside the machine. If the debris is allowed to accumulate on machine
components, poor performance or premature component failure could result. A shop
vacuum is the preferred method of removing build-up, but compressed air can be used
if the technician takes extreme care to ensure the dust is blown out of and not into the
mechanisms. NEVER subject your Saturn machine to water or other liquids used to
wash down machinery. Moisture condensation could cause serious damage to
components.
Cleaning should be done approximately every two weeks or each month, more often if
the environment is dusty. A cloth dampened (not saturated) with window cleaner may
be used to remove build-up that a vacuum will not remove.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
IV-1
SATURN SA-3350 ARCH STRAPPING MACHINE OPERATION MANUAL
Lubrication
The Grippers, Slide Plate, Separator (located under the Slide Plate), and Heater Slide
Rail require periodic lubricating with a light grade machine tool oil (every 1-2 months,
depending on amount of machine usage). Lack of lubrication can cause poor machine
performance and premature component wear.
NOTE: Excess oil can contaminate areas of the machine not intended for lubrication
and attracts dust, which can cause premature mechanical jamming and/or failure.
Make sure any excess oil drips are carefully wiped up before operating the machine.
Drive Belt Replacement
It is recommended to replace the drive belt when exhibiting signs of slippage or if
cracking can be seen on the ribs of the belt.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
IV-2
SATURN SA-3350 ARCH STRAPPING MACHINE OPERATION MANUAL
5
Chapter
V.
Chapter Five
HIGHLIGHT INDUSTRIES, INC.
Saturn® SA-3350 Arch Strapping Machine Operation Manual
Troubleshooting
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
V-3
SATURN SA-3350 ARCH STRAPPING MACHINE OPERATION MANUAL
TROUBLESHOOTING GUIDE
This troubleshooting guide is not designed to solve all system problems. Rather, it is
designed to provide a few quick checks of the more common solutions to operational
issues to keep your downtime to a minimum. If the issue is not resolved by following
the tips provided in the troubleshooting guide, further help is always available from
Highlight’s experienced Mechanical/Electrical Service Department.
● Power Issues●
Symptom
(1) The power lamp does light up
(2) The power is supplied, but the buzzer sounds and the machine does not work
Symptom
1
2
○
Causes
A.
B.
C.
D.
E.
○
Remedy
Machine is not plugged in.
Main power disconnect is turned off.
Emergency Stop Button is pressed in
Pool chamber door is open
Main power fuse blown
A. Plug in power cord.
B. Rotate disconnect
clockwise
C. Twist the E-Stop knob
counter clockwise
D. Close the pool door
E. Replace the main fuse
A. The strap coil is empty
A. Install a new strap coil
B. Strap is not threaded through Roller 2 (w/ B. Refer to Strap
prox sensor) correctly
Threading Diagram and
re-thread strap correctly
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
V-4
SATURN SA-3350 ARCH STRAPPING MACHINE OPERATION MANUAL
● Trouble with strap threading and feeding ●
Symptom
(1)
Strap does not feed into machine when attempting to thread the strap.
(2)
Strap is fed into the pool chamber temporarily then reversed out of the machine.
(3)
Strap is fed only partially into the arch.
(4)
Strap does not feed at all
(5)
Strap does not back-feed completely the strap during a cycle
1
○
Symptom
2 3 4 5
○ ○
○
○
○
○
○
○
○
○
Causes
A. Strap does not feed into
machine
B. The reel brake is not
releasing properly:
1-Strap does not pull off from
coil easily
2-Strap is tangled around the
reel & dispenser assembly
Remedy
A. Refer to Strap Threading
Diagram and re-thread the strap.
B. Adjust reel brake tension
C. Feed rollers slipping on
strap
D. Strap volume in the pool
chamber is insufficient to
supply the arch with strap
C. Clean feed rollers and/or
increase feed roller tension
D. Adjust the counterweight on
the balance beam to the left to
increase pool volume.
E. Strap volume in the pool
chamber is too much causing
strap overcrowding.
F. The feed roller tension is
too much
G. The strap is twisted and
jammed in the back-feed
rollers
E. Adjust the counterweight on
the balance beam to the right to
decrease pool volume.
F. Decrease the feed roller
tension.
G. Extract the strap from the
machine, cut the damaged
portion & rethread the strap
1- Brake tension is too tight.
2- Brake Tension is too loose
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
V-5
SATURN SA-3350 ARCH STRAPPING MACHINE OPERATION MANUAL
● Trouble with triggering cycle ●
Symptom
(1)
The machine does not start when pressing the start button but still works with
the foot pedal or auto sensor.
(2)
Strap cycles repeat without intentionally triggering a cycle
Symptom
Causes
1
2
○
A. The contact block on the start button
is worn
○
B. Start button contact is stuck on
C. Foot pedal is stuck on
D. Auto switch is on and auto strap
sensor in the rear table top is blocked
Remedy
A. Replace the Start button
contact block.
B. Replace Start button
contact block
C. Replace foot pedal
D. Turn off Auto switch or
unblock auto strap sensor
● Trouble with Strap back-feeding and tensioning ●
Symptom
(1)
The strap is sealed before back-feeding completely around the package
(2)
The strap is released abruptly and does not re-feed into arch
(3)
Strap tension cannot increase, even when tension is set to the maximum
Sympto
m
1 2 3
○ ○
○
○
Causes
A. The back-feed roller does not turn
freely
B. Sensor LS0 is not functioning
C. The feeding timer (VR3) is set too
short and the strap end cannot feed
completely
○ D. The rollers are slipping due to oil
contamination.
○ E. The tension potentiometer (VR2) is
defective
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
Remedy
A. Repair or replace
back-feed roller
B. Check LS0 wiring
and/or replace sensor
C. Increase VR3
setting (located on
the control board)
D. Clean rollers with
rubbing alcohol.
E. Replace.
V-6
SATURN SA-3350 ARCH STRAPPING MACHINE OPERATION MANUAL
●Trouble with strap sealing / welding●
Symptom
(1)
Strap cannot be sealed and heater does not heat up
(2)
Strap cannot be sealed and heater is heating up
(3)
Strap shows melted area on each side of the strap seal, but does not stay stuck
together
(4)
Strap seal is melted too much.
Symptom
1 2 3 4
○
○
○
○
○
Causes
A. Heater failure or loose wire
connection
B. The end of heater plate is hitting
the side of the strap and not sliding
between the straps when sealing
C. Heater temperature is low.
○
D. Cooling timer too low for
selected tension setting
E. The cooling fan motors stopped
a) Dust clogged in the fan.
b) Fan failure
○
F. Strap tension is set too high.
G. Heater temperature is too high.
○
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
Remedy
A. Check heater connection
and/or replace heater
Allow heater to cool. Align
heater straight and replace if
heater is bent.
Raise the temperature
setting slightly.
Increase Cooling timer
setting.
a) Clean fan.
b) Inspect wiring and/or
replace fan.
F. Reduce tension setting.
G. Lower the heater
temperature setting
V-7
SATURN SA-3350 ARCH STRAPPING MACHINE OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
V-8
6
Chapter
VI.
Chapter 6
HIGHLIGHT INDUSTRIES, INC.
Saturn® SA-3350 Arch Strapping Machine Operation Manual
Electrical
References
SATURN SA-3350 ARCH STRAPPING MACHINE OPERATION MANUAL
ELECTRICAL SCHEMATIC
MAIN FUSE
POWER SWITCH
(110V 4A)
(230V 2A)
S1
L
N
AC110V
AC230V
L1
R
N
T2
F1
RLY1
R1
10
EMG.STOP
R1
STRAP POOL
LS6
21
CN3-2
16
CN3-7
12
CN3-1
17
CN3-6
CONTROL POWER
RLY1
60
61
T2
T2
10
STRAP POOL KEY
PE
DC POWER SUPPLY
2.5A
AC110-230V / DC24V(80W)
F3
Fan4
T1
T2
+ DC24V
ICS128MA12701
10
-
CONTROL
BOX FAN
M1 Fan Fan1
T2
10
M2 Fan Fan2
Fan5
STRAP OUT
SENSOR
POWER LAMP
HL1
Body Fan
LS5
VR2 BACKFEED LENGTH
22
(+)
CN2-2
Start
11
PB1
22
21
Heater Fan Fan3
CN3-8
(-)
21
AUTO
PHOTO SENSOR
LS8
(+)
Auto/Manual
30
22
LS7
CN3-3
(-)
DB1
LS2
21
CN2-5
23
Heater
Heater Fuse
in
21
TENSION OR BACKFEED
POSITION
CN2-14
(+)
LS4
Foot Switch
13
CN3-9
21
CN3-4
15
CN3-10
21
CN3-5
7
CN2-6
8
CN2-7
8
CN2-18
Feed Switch
6
CN2-8
Back Switch
9
CN2-19
CN2-17
DB1
(110V 3A)
(230V 3A)
out
Main Brake
CAM HOME
LS1
POSITION
Jog Switch
PB4
20
F2
22
CN2-4
31
CN2-16
22
CN2-3
32
CN2-15
22
CN1-2
0
CL1
24VDC
Feed&Back Brake
CL2 24VDC
PB2
Pool Motor
tr1
1
1
C3
VR2
Tension Adj
2&3
12
T2
Main Motor
M1
T2
5
CN2-11
tr2
200K
24
M3
M3
2
CN2-22
CN1-3
1
1
M1
2
CN2-20
C1
4
tr3
CN2-21
CN1-4
1
Back
2
2
1
Cool Adj
2&3
1
VR4
25
CN2-9
12
CN2-10
27
CN2-12
29
CN2-24
28
CN2-23
21
CN6-1
26
CN6-2
C2
2
200K
Temp Adj
3
1
VR1
2
200K
STRAP FEED SUCCESSFUL
LS3
SENSOR
tr4
L1
3
Feed
CN1-1
Main Motor: 120W 1:25
110V 35uF 230V 8uF
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
10
CN5-1
21
CN5-2
14
CN5-3
12
VCC
12V
Pool Motor: 120W
110V 35uF 230V 8uF
CN1-5
Feed&Back Motor
M2
T2
M2
STRAP IN MOTION SENSOR
LS0
Feed & Back Motor: 120W 1:20
110V 35uF 230V 8uF
VI-1
7
Chapter
VII.
Chapter 7
HIGHLIGHT INDUSTRIES, INC.
Saturn® SA-3350 Arch Strapping Machine Operation Manual
Mechanical
References
8
Chapter
VIII.
Chapter 8
HIGHLIGHT INDUSTRIES, INC.
Saturn® SA-3350 Arch Strapping Machine Operation Manual
Notes
SATURN SA-3350 ARCH STRAPPING MACHINE OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
VIII-1
SATURN SA-3350 ARCH STRAPPING MACHINE OPERATION MANUAL
IX.
HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465
IX-2