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Lantech QL-400 Manual Download Page 69

MAINTENANCE 

69 

 

7.0

 

Maintenance 

Note:

  Illustrations are for reference only. 

Note:  

Functions, descriptions and data can be different on your machine.  Refer to section 3 for options. 

Note:  

Some machines have a remote Emergency Stop.  It is important to know the location of all E-stops 

before you operate the machine.  

Note

:  Make sure that only qualified personnel complete the steps for Installation, Maintenance and 

Troubleshooting. 
 

 

WARNING 
Obey all Lockout/Tagout procedures before you change, adjust, repair a part. 

 

 

WARNING 
Obey all safety decal instructions and warnings. 

 

 

WARNING 
Do not make a change to this machine without approval from Lantech.  It can 
cause a safety hazard and cancel the warranty.    

 

 

WARNING 
Obey all safety procedures.  You must apply the power to the machine for 
some electrical adjustments. 

 

 

WARNING 
Do not use this machine with hazardous materials. 
Do not operate this machine in a hazardous environment. 
Do not operate this machine in an explosive environment. 

 

 

CAUTION 
Do not use a sharp object to remove the film that is wound onto the pre-stretch 
roller.   It can cause damage to the roller.   

 

 

CAUTION 
Do not let a heavy load stay on the turntable for a long period of time.  This can 
cause damage to the Urethane Ring. 

 

 

CAUTION 
Obey the torque specifications to prevent damage to the fasteners.  Too much 
torque can cause the fasteners to loosen.   

 

 

CAUTION 
The Load Height Sensor is a Class 1 Laser.  Do not stare into the Laser Beam 

Summary of Contents for QL-400

Page 1: ...1 QL 400 Semi Automatic Stretch Wrap Machine Manual Serial Number QM0056781 ...

Page 2: ... 4 7 Residual Risk 18 5 0 Installation Instructions 19 5 1 Prepare the Area 19 5 2 Personnel Equipment and Tools 20 5 3 Installation 21 6 0 Operator Instructions 25 6 1 Sequence of Operation 26 6 2 Components 27 6 3 Assemblies 29 6 3 1 FDS and Counterweight 29 6 3 2 FDS Lift Drive 29 6 3 3 EZ Thread Gate 30 6 3 4 Pallet Grip 31 6 4 Controls 32 6 4 1 Icon List 33 6 5 Operator Controls 35 6 5 1 Sele...

Page 3: ...ead the Film 65 6 8 Operate the Machine 66 6 8 1 Manual Override 67 6 9 Film Roll is Empty 68 6 10 Film Break Recovery 68 7 0 Maintenance 69 7 1 Daily and Weekly Maintenance 70 7 1 1 Pallet Grip 70 7 2 Monthly Maintenance 70 7 3 Settings and Adjustments 71 7 3 1 FDS Up Down Travel 71 7 3 2 Belt Slack Switch 72 7 3 3 Home Proximity Sensor for the Turntable 73 7 3 4 Turntable Drive Belt 75 7 3 5 Loa...

Page 4: ...8 Load Twists 91 8 3 9 The Load Slides off the Pallet 92 8 3 10 Increase the Throughput 92 8 3 11 Belt Slack Condition 93 8 3 12 Wrap to Custom Height 93 8 4 Wrap Quality 94 8 4 1 What is Load Guardian 94 8 4 2 How to Select the Film for Your Load 94 8 4 3 How to Select the Correct Film 94 8 4 4 Find the Correct Pre stretch 95 8 4 5 What is Containment Force 95 8 4 6 Set Adjust the Tension on the ...

Page 5: ...points out the Warnings and Cautions to make sure that all personnel work in a safe environment Section 5 Installation Section 6 Operator Instructions These sections tell you how to install and use the machine safely and efficiently Section 7 Maintenance This section tells you how to make sure that the machine stays at top performance Section 8 Appendix This section can include the CE Declaration ...

Page 6: ...ne Email Fax 61 3 9796 5275 Parts aus spares lantech com 61 3 9703 2725 Service aus service lantech com Support aus support lantech com LANTECH CHINA SHANGHAI Phone Email Parts 86 21 6221 5688 Parts LCH Parts Lantech com Service Hotline 86 40 0877 1972 Service LCH Service Lantech com LANTECH NORTH SOUTH AMERICA LOUISVILLE KENTUCKY Phone Email Fax Parts 502 815 9101 Parts tsg lantech com 502 267 88...

Page 7: ...losure On the Electrical Enclosure Note The exposed metal parts on all Stretch Wrap Machines have a heavy Rust Preventative applied before shipment You can use Mineral Spirits or a similar cleaner to remove it If you remove it make sure that you apply a light Rust Preventative to the exposed metal before you operate the machine ...

Page 8: ...d Dimensions 762 mm x 762 mm x 508 mm 30 W x 30 L x 20 H Maximum Load Dimensions Standard Height Note Maximum wrap height increases 254 mm 10 for 762 mm 30 FDS option 2032 mm 80 Wrap Height 1321 mm x 1321 mm x 2032 mm 52 W x 52 L x 80 H Maximum Load Dimensions Extended Height 2794 mm 110 Wrap Height 1321 mm x 1321 mm x 2794 mm 52 W x 52 L x 110 H Load Dimensions Diagonal 1829 mm 72 Recommended Max...

Page 9: ... Film Pre stretch Percentage 250 Film All Commercial Grade Films 50 150 Gauge Standard Film Capacity 254 mm 10 Diameter 508 mm 20 Width Standard 762 mm 30 Width Optional Film Tension Electronically controlled with Reduced Film Tension at the start of the wrap cycle Auto Film Cut off Automatically cuts the film at the end of the wrap cycle Electrical Requirements Electrical Supply Dedicated Grounde...

Page 10: ... Force based on the settings for the Film Coverage Load Guardian monitors and adjusts to changes in the film tension and the number of layers of film on the load Load Guardian is what gives you Safe to Ship Loads How Select or Create a Profile for each type of load There are 10 Ready to Wrap Profiles already set in your machine Put a load on the turntable and see if you can identify your load in t...

Page 11: ...OPTIONS 11 3 0 Options This section includes the options that are not on the standard machine ...

Page 12: ...OPTIONS 12 ...

Page 13: ... all safety decals Obey all warnings to prevent an injury to personnel Obey all cautions to prevent damage to the machine Obey all Lockout Tagout procedures before you change adjust repair a part Refer to the adjustment data to prevent a safety hazard 4 2 Personnel Safety Personnel Safety To prevent an injury and safety risk do not install operate repair the machine while influenced by drugs alcoh...

Page 14: ... pneumatic valve to the Off position b Lock the main pneumatic valve in the Off position Semi Automatic Machines 1 Move the Main Disconnect switch to the Off position 2 Lock the Main Disconnect switch in the Off position 3 Disconnect the power cord from the electrical outlet 4 Lock the power cord 4 4 Safety and Environmental Controls Safety and Environmental Controls Make sure that you recycle all...

Page 15: ...d Notes Warning Tells the operator that there is a hazard that can cause a serious injury Caution Tells the operator that there is a hazard that can cause A minor injury Damage to the equipment environment Note Gives additional data that is helpful to the operator ...

Page 16: ...decals Some of the pictograms in the list below do not apply to your machine Do Not Operate Without Guard in Position No Entry Maximum Capacity Do Not Step Do Not Reach Fire Can Occur Chemical Waste Environment Important Note Refer To Manual Hot Surface Electrical Warning Explosion Warning Release of Pressure Electrical Shock Warning ...

Page 17: ...n Warning Do Not Walk on Conveyor Hit is Possible From Above Machine Can Fall Obey the Safety Instructions Hit is Possible From The Side Fall Warning Do Not Reach Cut Warning Film Delivery System Warning Crush Warning ...

Page 18: ...se of PPE against injury is not applicable Q Series and S Series Risk The Film Delivery System FDS can fall during maintenance if you do not use sufficient support to hold the FDS Make sure that the supports hold the FDS when you change adjust repair the lift motor or belt PPE Use of PPE against injury is not applicable Q Series Risk The counterweight can fall during maintenance if you do not use ...

Page 19: ...uch torque can cause the fasteners to loosen Note The exposed metal parts on all Stretch Wrap Machines have a heavy Rust Preventative applied before shipment You can use Mineral Spirits or a similar cleaner to remove it If you remove it make sure that you apply a light Rust Preventative to the exposed metal before you operate the machine 5 1 Prepare the Area The space requirements can be different...

Page 20: ... 5 m 15 lift 1 Ladder Tools Wrenches and Sockets Metric and Standard Extended Height Mast Ships in Horizontal Position Personnel and Safety Equipment 2 Forklift Operators 1 Mechanical Technician 1 Electrical Technician Equipment 2 Forklifts with 2000 kg 4000 lb capacity and 5 m 15 lift 1 Ladder Tools Wrenches and Sockets Metric and Standard Allen wrenches Metric and Standard Torque wrench Straps C...

Page 21: ...emove the turntable plate to prevent damage to the turntable base If the Machine has Extended Base The length of the turntable is more than 3048 mm 120 Oversize Turntable The diameter of the turntable plate is more than 1651 mm 65 1 Remove the Turntable Plate a Attach 2 eye bolts to the turntable Make sure that the eye bolts align correctly b Attach a strap to the eye bolts and to the forklift c R...

Page 22: ...3 Remove and Stow the Counterweight Bracket The counterweight is in the access panel on the mast There are 2 brackets that hold the counterweight in position 1 Remove the 2 M10 bolts 2 Remove the brackets 3 Stow the shipping brackets and the counterweight brackets in the mast CAUTION Before you move the machine to a different location install the brackets for the FDS and the counterweight Counterw...

Page 23: ... FDS Remove the wire ties from the FDS Step 5 Connect the power cord to the dedicated grounded electrical supply Note The machine has a 3 6 m 12 power cord with a 20 amp plug Use a 20 amp receptacle Do not use an extension cord Do not use on GFCI circuit ...

Page 24: ...INSTALLATION 24 ...

Page 25: ...pair a part WARNING Obey all safety decal instructions and warnings WARNING Do not make a change to this machine without approval from Lantech It can cause a safety hazard and cancel the warranty WARNING Do not use this machine with hazardous materials Do not operate this machine in a hazardous environment Do not operate this machine in an explosive environment CAUTION Do not use a sharp object to...

Page 26: ...and the FDS moves up 10 The film pre stretches and is applied to the load 11 The load height sensor senses the top of the load and the FDS stops to apply the set number of layers 12 The FDS lowers to wrap the bottom of the load 13 Pallet Grip engages and makes a cable of film on the bottom edge of the film 14 The tilting roller engages and applies the cable of film to the pallet 15 On the last rot...

Page 27: ...OPERATOR INSTRUCTIONS 27 6 2 Components 1 Mast 2 Film Delivery System FDS 3 Turntable 4 Controls 1 2 3 4 ...

Page 28: ...PERATOR INSTRUCTIONS 28 Turntable 1 Turntable Top 2 Urethane Ring 3 Drive Ring with Home Proximity Actuator 4 Bearing Support Ring 5 Center Bearing 6 Motor and Belt Tensioner Motor not Shown 1 2 3 4 5 6 ...

Page 29: ...s and lowers the FDS during the wrap cycle 1 FDS Lift Drive 2 Turntable Drive FDS Up Down Proximity Sensors The mast includes 2 proximity sensors that sense the maximum travel of the FDS These sensors are adjustable Use them to set the maximum up and down travel limits of the FDS 3 FDS Up Travel proximity sensor FDS Belt Slack Switch This switch senses a loose belt condition A loose belt stops the...

Page 30: ...Z Thread Gate The gate opens to 2 positions To thread the film Release the latch to open the gate to thread the film To get access to the Rollers and the Gate Lift the lever on the bottom right side of the gate for the access position ...

Page 31: ... boards of the pallet to lock the load to the pallet Groove Roller The Groove Roller rolls the film into a cable when the FDS is at the bottom of the load Adjust the roller to increase decrease the quantity of film that makes the cable It sets the height of the cable on the pallet Tilting Roller The Tilting Roller moves the cable of film down on the pallet The actuator is adjustable to increase de...

Page 32: ...HMI The standard HMI is a touch screen Reset This blue illuminated button controls the power to the machine The button illuminates and all functions are available to the operator Emergency Stop E stop This red button disengages the control power to the machine 1 Push the E stop to stop the machine in an emergency condition 2 Reset the E stop before you push the Reset button ...

Page 33: ...ease Main Menu Diagnostics Manual Jog Dispenser Options Display Settings Personalization Edit Profile Production Counter Erase Production Reports Film Assist Profile Icon Film Calibration Profile Name Film Coverage Profile Usage Film Height Above Load Profiles Film Settings Reports Film Tension Reset Help Rotation Speed ...

Page 34: ...OPERATOR INSTRUCTIONS 34 Service Visual Start Wrap Apps Defaults System Wrap Cycle Data System Information Wrap Height Turntable Home Wrap Problems User Access Wrap Quality ...

Page 35: ...5 6 5 Operator Controls The HMI shows the machine status fault conditions and instructions The list below includes the selections that can show on the HMI Login Push this button to get access to the profiles and the settings ...

Page 36: ... load that does not fit squarely on the pallet Applies Light Film Tension Irregular Heavy Heavy load that does not fit squarely on the pallet Applies Light Film Tension Sharp Edges Load has sharp edges and is inboard Applies Moderate Film Tension Incomplete Top Layer Load has a few extra boxes on top requires hand roping 4 Revolutions at a slow turntable speed Soft Top Soft or Light Top Layer Appl...

Page 37: ...e Create a Profile Push this button to create a new profile Select the Load Height Short The height of the load is less than 1016 mm 40 Medium The height of the load is 1016 mm to 2032 mm 40 to 80 Tall The height of the load is more than 2032 mm 80 ...

Page 38: ...s with layers of different dimensions This load type uses a lower Film Tension and more layers of film Select How the Load Fits on the Pallet Fits The dimensions of the load are equal to greater than the pallet Inboard The load is set less than 75 mm 3 from the edge of the pallet Inboard Extreme The load is set more than 75 mm 3 from the edge of the pallet This load type decreases the wrap force o...

Page 39: ...Displays Beverage Cans Light order pick 2 3 kg 5 7 lb High These loads include Tall heavy cartons Cased Bottles Bags Grocery order pick 3 5 kg 7 12 lb Extreme These loads include Bottled water Cased Bottles Bags Other Heavy Loads 5 9 kg 12 20 lb Set the Wrap Height This sets the quantity of film to wrap above the top of the load 1 Use the Plus Minus symbols to increase decrease the quantity of fil...

Page 40: ...ust the wrap sequence You can add multiple Wrap Apps for the wrap sequence The Wrap Apps include Corner Boards Labels One way Wrap Stack Band Stack Wrap Top Box Secure Top Sheet Select Next Profile Name Give the profile a name 1 Enter a profile name 2 Select Next ...

Page 41: ...OPERATOR INSTRUCTIONS 41 Profile Color Select a Profile Color 1 Select the color 2 Select Save ...

Page 42: ...omponents in the start position Film Assist Push this button to release the film from the FDS for a preset time Wrap Profile Menu Use this menu to Select a Profile Make a new Profile Edit a Profile Main Menu Push this button to get access to the list of menus Manual Jog Film Wrapper Settings Film Calibration Wrap Apps Defaults Options Defaults System Service Personalization User Access Reports Hel...

Page 43: ...ws to move the FDS in the up down directions Use the Speed control to increase decrease the FDS travel speed Rotation Use the arrows to move the Turntable in the forward reverse directions Use the Speed control to increase decrease the Rotation speed 6 5 5 Film Settings Film Settings Use this screen to set the width mm inch and the thickness gauge micron of the film ...

Page 44: ...6 5 6 Wrapper Settings Wrapper Settings Use this menu to change adjust the settings Film Delivery System Settings Film Assist Time Film Assist Tension Film Break Time Home Rotation on Film Break FDS Position after a Film Break ...

Page 45: ...ATOR INSTRUCTIONS 45 Troubleshoot This module collects data and lets the Operator send a report for a Program fault 6 5 7 Film Calibration Film Calibration Use this screen to calibrate the Containment Force ...

Page 46: ...Wrap Apps for the wrap sequence The Wrap Apps include Cornerboards Labels One way Wrap Stack Band Stack Wrap Top Box Secure Top Sheet 6 5 9 Options Defaults Options Defaults This screen shows the available options that the operator can engage disengage Wrap Cycle Alternate Wrap Limits Auto Film Cutoff Raise FDS at end of Cycle Reverse Load ...

Page 47: ...rk Settings Shift Setup Language Formats Date Time Load Guardian Introduction Show Ready to Wrap Profiles Auto Select Profile 6 5 11 Service Service Use this menu to change adjust the settings The settings include Clean Display Machine Calibration Backup Restore Restore Factory Defaults Export Import Diagnostic Window Data Export Logging ...

Page 48: ...6 5 12 Personalization Personalization Use this menu to change adjust the settings The settings include Language Formats User Image Display Color 6 5 13 User Access User Access Use this screen to create adjust the User settings ...

Page 49: ... machine Bypass Mode Gives permission to put the machine in Bypass Mode Film Settings Gives permission to set adjust the film settings Settings Gives permission to set adjust the settings Profile Management Gives permission to create select or edit Profiles Manual Override Gives permission to manually override the Profile ...

Page 50: ...ata includes Cycle Data Alarm History Alarm Counter Loads Per Hour Production Reports Production Counter Profile Usage Cycle Tension Cycle Data This screen shows All Loads Total Machine Cycles Total Machine Revolutions Peak Cycle Time Last Load Cycle Time Height Revolutions Containment Force Counters Cycles ...

Page 51: ... INSTRUCTIONS 51 Alarm History This screen shows the list of the faults and alarms that have occurred Alarm Counter This screen shows the list of the alarms and the number of times that each alarm has occurred ...

Page 52: ...OPERATOR INSTRUCTIONS 52 Loads Per Hour Production Reports This screen shows machine Loads Wrapped Film Breaks Stops Operator Stops Fault Available Downtime ...

Page 53: ...OPERATOR INSTRUCTIONS 53 Production Counter This screen shows machine Loads Wrapped Film Breaks Stops Operator Stops Fault Available Downtime Profile Usage ...

Page 54: ...OPERATOR INSTRUCTIONS 54 Cycle Tension ...

Page 55: ...hine This menu includes Wrap Quality Wrap Problems Profile Details Machine User Manual CF Tool Manual Videos System Information Wrap Quality This screen gives information and tips to improve the wrap quality The screens for Wrap Quality include Load Guardian Film Selection Film Settings Film Grade Pre stretch Containment Force Film Tension ...

Page 56: ...the wrap cycle The Wrap Problems include Excessive Film Breaks Containment Force Variation Excessive Film Use Increase the Throughput Decrease the Film Tails Crushes the Top of the Load Crushes the Edge of the Load Load Twists during Wrap Load Shifts in Shipment Load Slides Off the Pallet Examine Belt Slack Condition Wrap to Custom Height ...

Page 57: ...OPERATOR INSTRUCTIONS 57 Profile Details This screen gives information and tips to create a load profile ...

Page 58: ...rofiles on the Home menu 2 Select a profile 3 Push Edit Profile This gives access to the Profile Settings menu Film Tension Increase decrease the film tension for the top the bottom and the middle of the load These adjustments are not available when Load Guardian is engaged ...

Page 59: ...tion of the film and the tension on the film to hold the set Containment Force Monitored by Load Guardian This is for special applications It shows the Containment Force based on the settings for the Film Coverage Load Guardian Disabled This gives manual control of the position of the film by adjustments to The Top and the Bottom wraps The Overlap Up and Down Film Height Above Load Increase decrea...

Page 60: ...table rotation speed during the FDS up and down travel Wrap Apps Use this menu to change adjust the wrap sequence You can add multiple Wrap Apps for the wrap sequence The Wrap Apps include Cornerboards Labels One way Wrap Stack Band Stack Wrap Top Box Secure Top Sheet ...

Page 61: ...OPERATOR INSTRUCTIONS 61 Options This screen shows the available options that the operator can engage disengage Name Change the name of the profile 1 Enter the new name of the profile 2 Select Save ...

Page 62: ...OPERATOR INSTRUCTIONS 62 Visual Change the color icon for the profile 1 Select the new color icon 2 Select Save Clone Profile Use this screen to copy a profile ...

Page 63: ...rrent profile 1 Select the Profile 2 Select Erase 3 Select Yes to erase the profile Help This menu includes information and instructions for Wrap Quality Wrap Problems Profile Details Machine User Manual CF Tool Manual Videos System Information ...

Page 64: ...nnect switch in the Off position 3 Disconnect the power cord from the electrical outlet 4 Lock the power cord 6 6 2 How to Stop the Machine Push the E stop This red button safely stops the operation of the machine Note Some machines have a remote Emergency Stop It is important to know the location of all E stops before you operate the machine 6 6 3 Apply the Power to the Machine 1 Move the Main Di...

Page 65: ... 4 The Tackifier is on this Side Thread the Film The standard film roll is 254 mm 10 in diameter and 508 mm 20 in width 1 Move the FDS up until Pallet Grip disengages 2 Push the E stop 3 Look for damage on the film roll 4 Put the film roll on the film post 5 Release the latch on the EZ Thread gate 6 Pull out 914 1219 mm 3 4 of film and twist it into a rope See illustration below 7 Refer to the dia...

Page 66: ...is only available after you select a profile 12 Pull the film and attach it to the load pallet 6 8 Operate the Machine 1 Reset the E stop 2 Push Reset 3 Select a profile 4 Push Film Assist 5 Pull the film and attach it to the load 6 Push Start Step 8 Step 6 ...

Page 67: ... decrease the FDS travel speed Rotation Use the Speed control to increase decrease the turntable rotation speed Film Dispense Use the Force control to increase decrease the Film Tension Programmed Push this button to continue the current wrap cycle Apply Band Push this button to apply a set number of bands to the load Refer to the settings for the Banding Counter in the Wrapper Settings menu to se...

Page 68: ...o the load 8 Push Start If the button is pushed in the Film Break Recovery mode Use the Manual Jog screen to move the FDS and the turntable to the home position 6 10 Film Break Recovery The FDS and the turntable stop The fault screen for Film Break shows on the touch screen 1 Push to go to the Manual Override screen 2 Push Film Assist 3 Pull the film and attach it to the load 4 Push Resume ...

Page 69: ... approval from Lantech It can cause a safety hazard and cancel the warranty WARNING Obey all safety procedures You must apply the power to the machine for some electrical adjustments WARNING Do not use this machine with hazardous materials Do not operate this machine in a hazardous environment Do not operate this machine in an explosive environment CAUTION Do not use a sharp object to remove the f...

Page 70: ...e tilting roller moves freely and retracts fully Examine the groove roller and make sure that it turns freely Make sure that the film moves over the groove in the roller as the load wraps 7 2 Monthly Maintenance Examine the FDS belt for wear Examine all belts for correct tension Examine all belts for wear Examine the pre stretch chains and sprockets for wear Lubricate the chains with SAE 30 oil Re...

Page 71: ... sensors 1 Loosen the nuts on the sensor 2 Move the sensor until it sees the FDS 3 Tighten the nuts To adjust the up down travel limit positions 1 Loosen the adjustment knob on the sensor 2 Move the sensor up down to the correct height 3 Tighten the knob Adjust the sensor to limit the Up Travel The Factory Setting is 89 mm 3 Adjust the sensor to limit the Down Travel The Factory Setting is 38 mm 1...

Page 72: ...MAINTENANCE 72 7 3 2 Belt Slack Switch The Belt Slack switch senses a fault in the FDS down travel The switch is on the bottom side of the top cap Install the switch through the top door of the mast ...

Page 73: ...en the tension on the drive belt 5 Remove the turntable top a Install 2 3 8 16 eyebolts into the holes on the turntable top b Remove the 4 M8 flat head screws from the middle of the turntable c Attach a strap chain to the turntable top and to the forklift d Remove the turntable top 6 Examine the sensor a Connect the power to the machine b Reset the E stop c Push Reset CAUTION Use caution when the ...

Page 74: ...NCE 74 9 Push Reset 10 Turn the drive ring to the home position 11 Replace the turntable top 12 Apply an anti seize compound to the M8 screws before you attach to the turntable top 13 Torque to 24 N m 18 lb ft ...

Page 75: ...e moves freely 4 Put a 3 8 torque wrench with a short extension into the 3 8 square opening on the pivot plate 5 Torque counterclockwise to 34 N m 25 lb ft Tighten the flange locknut by hand as you set the torque 6 Use the torque wrench to tighten the 10 mm locknut on the plate to 52 N m 39 lb ft 7 Replace the cover Belt Tensioner 1 Pivot Plate Locknut 2 3 8 Drive Slot 3 Flange Locknut 1 2 3 1 2 3...

Page 76: ...is a Class 1 Laser Do not stare into the Laser Beam 7 4 Variable Frequency Drives VFD The Variable Frequency Drives control the speed of the motors Refer to the electrical drawings for the settings for the VFDs Refer to the VFD manufacturer manual WARNING Make sure that only qualified personnel make these adjustments WARNING Obey all safety procedures You must apply the power to the machine for so...

Page 77: ...h to the Off position 9 Obey the Lockout Tagout procedures 10 Look at the routing of the belt and the rollers in the mast 11 Remove the cotter pins from the shaft at the top cap of the mast 12 Remove the belt from the shaft 13 Remove the belt from around the rollers in the mast down to the FDS lift drive 14 Unwind the belt from the drum and count the number of revolutions 15 Remove the pin from th...

Page 78: ...the roller on the FDS c Attach the belt to the shaft on the top cap d Replace the cotter pins in the shaft 21 Apply the power to the machine To tighten the belt move the FDS up at minimum speed 22 Remove the FDS shipping bracket and counterweight supports and stow in the mast 1 Counterweight Roller and Belt 2 FDS Lift Belt and Rollers 23 Apply the power to the machine 24 Push the FDS Up and Down b...

Page 79: ...elt is slack 6 Push the E stop 7 Move the Main Disconnect switch to the Off position 8 Obey the Lockout Tagout procedures 9 Open and remove the access door 10 Remove the panels from the mast to get access to the drive 11 Disconnect the motor wires in the electrical panel and remove the motor cable 12 Use a 10 mm socket to remove the M6 bolt on the lift drum 13 Remove the lift drum from the reducer...

Page 80: ...ot Plate Locknut 2 3 8 Drive Slot 3 Flange Locknut 9 Loosen the 10 mm locknut on the pivot plate 10 Loosen the flange locknut on the tensioner rod 11 Remove the drive belt from the pulley and the drive ring on the turntable 12 Install the new belt on the drive ring and then on the pulley Note Do not use force to install the belt on the pulleys 13 Attach the turntable top to the drive ring on the t...

Page 81: ...e tension on the belt e Put the Phillips screwdriver into the hole on the plate to hold the assembly in position 9 Install 2 3 8 16 eyebolts in the holes in the turntable top 10 Remove the 4 M8 flat head screws near the middle of the turntable and lift the top 11 Attach a strap chain in the eyebolts and attach to the forklift 12 Remove the bolts and remove the drive 13 Remove the brackets from the...

Page 82: ... the pallet The Factory Setting is 61 1 Adjust the actuator to increase decrease the angle of the roller when it is engaged 2 Increase the movement of the roller to lower the position of the cable on the pallet The standard adjustment for the roller is 61 from floor level 3 Loosen the bolts to adjust 61 ...

Page 83: ...The Factory Setting is 219 mm 8 5 8 Adjust the groove roller to increase decrease the quantity of film that makes the cable To adjust 1 Fully engage the tilting roller and loosen the 2 bolts on the groove roller 2 Adjust the roller The standard adjustment for a standard height 127 mm 5 pallet 219 mm 8 5 8 from the floor to the top of the groove in the guide roller 219 mm 8 5 8 ...

Page 84: ...MAINTENANCE 84 ...

Page 85: ...p cycle HMI Human Machine Interface Gives information to an operator or user about the status of a process It accepts and implements the operators control instructions Initialize This sets the safety circuits and puts all components in the start position Jog To move a machine component with manual functions controls Examples are to Jog the wrap arm turntable Load Cell A transducer that changes the...

Page 86: ...he height shape containment force etc Proximity Sensor A component that senses objects in the range of the sensor without physical contact The sensors change information on the movement or presence of an object into an electrical signal Tensioner A component to adjust the tension This usually applies to a belt or chain Top Wrap The layers of film that the Film Delivery System applies to the top of...

Page 87: ...ed An environment where the weather conditions can cause the machine to be damaged The failure to operate the machine by the environmental specifications This includes o An environment where moisture causes corrosion of parts o Explosive environment o The failure to prepare the area correctly for installation and maintenance This includes o The electrical supply is not sufficient o The floor is no...

Page 88: ...d specific Profile for an inboard condition Decrease the Film Tension at the top or the bottom of the load Increase the Film Coverage at the bottom of the load or decrease the Film Coverage at the top of the load Solution Lower the Film Height Above the Load 8 3 2 Product Crushes at the Edges of the Load Crushes Edge of Load Problem The Edges of the Load are crushed Solution Use a lower gauge film...

Page 89: ...the load Solution Lower the wrap height 8 3 4 Excessive Film Breaks Excessive Film Breaks Common causes of film breaks are Problem Film Quality Solution Decrease the Film Tension Solution Change to a premium film Solution Examine the film for Cuts Damaged Edges Damaged Core Other Defects Problem Sharp corners at the top of the load and inboard loads Solution Make a load specific profile for an inb...

Page 90: ...se the number of layers of film on the load Monitor for Load Damage 8 3 6 Reduce Eliminate the Film Tails Decrease Film Tails Problem Your machine operates correctly but you continue to see film tails Solution If your machine has Auto Film Cut off Make sure that the load is in the correct position on the turntable Make sure that the tacky side of the film is against the load Make sure that the set...

Page 91: ...nment Force Select Film Coverage Select Protected by Load Guardian Select Top or Bottom Add 1 layer on the top or bottom of the load Monitor for Film Breaks Monitor for Load Damage 8 3 8 Load Twists Load Twists During Wrap Problem Your load twists during the wrap cycle Solution Decrease the Containment Force Select Film Coverage Select Protected by Load Guardian Decrease the Containment Force Moni...

Page 92: ...load Monitor for Film Breaks Monitor for Load Shift Solution Make sure that the FDS is at the lowest setting Solution Make sure that the Pallet Grip settings are correct 8 3 10 Increase the Throughput Increase the Throughput 1 Increase the Rotation speed 2 Increase the Film Tension which decreases the number of layers of film on the load 3 Decrease the Containment Force Select Film Coverage Select...

Page 93: ...in the path of the Film Delivery System FDS Solution Jog the FDS Up to remove the slack Problem Defective FDS Down Proximity Sensor Solution Examine replace the sensor 8 3 12 Wrap to Custom Height Wrap to Custom Height Problem Laser does not see the load Solution Use Alternate Wrap Limits to wrap a custom height ...

Page 94: ...ainment Force for your load Look for a film with the highest possible film tension without breaks 8 4 3 How to Select the Correct Film How to Select the Correct Film 1 Find the correct Containment Force for your load 2 Make sure that the film can hold the Containment Force and wrap the correct number of layers Thin Film is 40 60 gauge film 10 15 microns Use thin film for light Containment Force le...

Page 95: ...ercentage lowers the film tension and can cause film breaks 8 4 5 What is Containment Force What is Containment Force Containment Force is the number of layers of film x the film tension Containment Force holds the load together and is the best indicator for load shipment success Examples of Containment Force for a range of products Containment Force Range Low These loads include Paper Towels Tiss...

Page 96: ...lms you can set the tension at a higher setting and not cause film breaks 5 Low quality film and lower gauge film can require a lower setting 8 5 Profile Build Descriptors 8 5 1 Load Height Load Height The Load Height is a parameter that is set through Load Guardian The Height of the Load is an important entry when you create the load profile The correct Load Height value makes sure that the syste...

Page 97: ...ad profile The load fits on the pallet A load that fits on the pallet can wrap with a higher film tension at the bottom of the load Inboard Load A load is inboard when the dimensions length or width of the load are less than the dimensions of the pallet An inboard load can be difficult to wrap at the bottom of the load The edges of the pallet are exposed and can be sharp which can cause film break...

Page 98: ...for special applications for specific loads The Wrap Apps can control Film Tension Speed Number of Layers Time to complete the specific task for the App Machine adjustments occur automatically This is to make sure that the operator can complete the task safely and in a repeatable manner Available adjustments are different for each App You can keep the default settings for an App or set it for each...

Page 99: ...s standard and identifies the load profile by the color assignment Note If your machine has the Click n Go remote or the Multi Lanyard Beacon there are 2 color palettes The top palette Profile Color Remote Assignment shows the color selection for the profile for the lanyard or the remote Save Use this function to save the selections from the Profile Build process This saves the Profile to the prog...

Page 100: ...APPENDIX HELP SCREENS 100 ...

Page 101: ...The drawings follow each parts list How to Find a Part Number 1 Find the drawing that contains the part 2 Find the part on the drawing and the item number for the part 3 Use the item number to find the part on the parts list Refer to the part number description and quantity Send your parts order to the local Lantech Distributor Refer to Section 1 1 for Lantech support ...

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