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Orion

Machine Manual

Revision 1.1

AG 360 RoboWrapper

28 June 2017

Introduction and Safety

Page 1-5

Hazard Messages

Notations appear on pages of this manual to alert the reader to important messages regard-
ing a significant hazard for personnel or equipment. These messages convey three levels
of risk as defined below. Failure to observe these instructions can result in death, serious
injury, damaged equipment, or loss of product or production.

DANGER

Denotes the possibility of serious injury or death to personnel.

WARNING

Denotes the possibility of potential injury or damage to equipment.

CAUTION

Denotes the possibility of damage to product or an interruption of produc-

tion.

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Summary of Contents for AG 360 RoboWrapper

Page 1: ...lex STRETCHWRAPPER MANUAL Model AG 360 RoboWrapper Revision Date June 28 2017 Machine Manual Revision 1 1 4750 County Road 13 NE Alexandria MN 56308 Phone 901 888 4170 Toll Free 800 333 6556 FAX 901 3...

Page 2: ...rty of the author who created the work Pro Mach Only the author or those deriving their rights through the author can right fully claim copyright Liability Waiver The information in this manual is sub...

Page 3: ...ion Safety 1 4 Maintenance Safety 1 4 Hazard Messages 1 5 Lockout and Tagout Recommendations 1 6 Electrical System 1 6 Installation and First Time Power Up 1 7 Inspection 1 7 Unloading 1 7 Machine Ins...

Page 4: ...3 11 Run Screen 3 11 Recipe Screens 3 13 Recipe Screen 3 13 Recipe Select Screen 3 15 User Setting Screens 3 16 Wrap Settings Screen 3 16 Menu Screens 3 18 Menu Screen 3 18 Jogging Screen 3 19 Produc...

Page 5: ...5 1 Left Side Enclosure 5 2 Right Side Enclosure 5 2 Charging and Indicator Connectors on Door 5 3 HMI Back Panel 5 3 Carriage Lift Chain Adjustment 5 4 Chain Maintenance 5 4 Tower Raceways Maintenanc...

Page 6: ...Machine Manual Orion AG 360 RoboWrapper Revision 1 1 Table of Contents 28 June 2017 Page IV...

Page 7: ...Drawing 2 3 Chapter 3 System Operation Charging Port 3 1 The Operator Panel 3 2 Forward and Reverse Transport Buttons 3 3 Transmission Engage Disengage 3 3 Spring Tension Release 3 4 Adjusting the Pal...

Page 8: ...connect 4 2 Side Panel Interlock Switch 4 3 Front Handle Proximity Switch 4 3 Obstacle Detect Limit Switch 4 4 Film Carriage Door Switch 4 4 Safety Bumper 4 5 Transmission Engage Disengage Lever 4 5 C...

Page 9: ...1 2 Flex Series Warranty 1 2 Safety 1 3 System Safety Recommendations 1 3 Operation Safety 1 4 Maintenance Safety 1 4 Hazard Messages 1 5 Lockout and Tagout Recommendations 1 6 Installation and First...

Page 10: ...Machine Manual Orion AG 360 RoboWrapper Revision 1 1 Introduction and Safety Contents 28 June 2017 Page II...

Page 11: ...o acquire more information about custom made features of your machine and to provide quicker service the following information is required when making an inquiry 1 Model AG 360 RoboWrapper 2 Serial Nu...

Page 12: ...her method of shipment UPS red blue Federal Express common carrier etc will be at the expense of the customer distributor PARTS RETURN POLICY For most components valued at under 300 list price Orion d...

Page 13: ...operate and or maintain automated equipment is the primary consideration Because it is very dangerous to enter the operating space of the AG 360 RoboWrapper during operation adequate safeguards must...

Page 14: ...re that all personnel are outside the system before starting operation The operator should never cross in front of the machine while in operation Maintenance Safety The following safety precautions ar...

Page 15: ...sonnel or equipment These messages convey three levels of risk as defined below Failure to observe these instructions can result in death serious injury damaged equipment or loss of product or product...

Page 16: ...ntenance each individual shall install a lockout device and tag A qualified person shall verify that the equipment is de energized by 1 Operating controls to verify equipment cannot be restarted 2 Usi...

Page 17: ...Inc 3 Check around the tower to ensure that there is no crippling of the movable parts i e casters center axle or drive assembly 4 Verify the following Check wires and conduits for crushed sections o...

Page 18: ...as specified on the diagrams supplied with the machine for charging Make sure the machine is operating on a hard and level surface Assembly Procedure 1 Secure the ring A above carriage with a chain fo...

Page 19: ...ne 2017 Introduction and Safety Page 1 9 4 Fix and tighten the tower by three M8 bolts CAUTION Use Loctite to secure the screws 5 Open the machine cover and check the battery connections Figure 1 4 Bo...

Page 20: ...on 1 1 Introduction and Safety 28 June 2017 Page 1 10 6 Check the battery cable connection 7 Move the steering arm towards right side and install the tension spring Figure 1 6 Connecting the Battery C...

Page 21: ...nual Revision 1 1 AG 360 RoboWrapper 28 June 2017 Introduction and Safety Page 1 11 8 Before running the machine for the first time please charge the battery at least 8 hours Figure 1 8 Connecting the...

Page 22: ...17 Page 1 12 Pallet Guide Arm and Sensing Arm Wheel Ensure the position of steering arm tension spring is in correct position and smooth turning movement and sensing arm wheel is properly inflated See...

Page 23: ...d surfaces not intended for outdoor use Checks Prior to Running For the safety of the operator please ensure the following conditions are met Ensure the battery is charged prior to operation Make sure...

Page 24: ...Machine Manual Orion AG 360 RoboWrapper Revision 1 1 Introduction and Safety 28 June 2017 Page 1 14...

Page 25: ...evision 1 1 AG 360 RoboWrapper 28 June 2017 System Description Contents Page I System Description Contents Machine Specifications 2 1 Machine Layout Drawings 2 2 Machine Dimensions 2 2 Machine Compone...

Page 26: ...Machine Manual Orion AG 360 RoboWrapper Revision 1 1 System Description Contents 28 June 2017 Page II...

Page 27: ...te Adjustable on Carriage 200 or 300 Corner Compensation Automatically Prevents Crushing the Corners of the Load Stretch Film Loading Fast Safe Obstacle Detection Method Sensor Bumper Immediately Stop...

Page 28: ...0 RoboWrapper Revision 1 1 System Description 28 June 2017 Page 2 2 Machine Layout Drawings Machine Dimensions The layout drawing below shows the machine dimensions as sold Figure 2 1 Machine Layout D...

Page 29: ...e 2 3 Machine Component Identification The layout drawing below shows the machine dimensions as sold Figure 2 2 Machine Layout Drawing Warning lamp Spool carriage Machine body Control electronic devic...

Page 30: ...Machine Manual Orion AG 360 RoboWrapper Revision 1 1 System Description 28 June 2017 Page 2 4...

Page 31: ...3 6 Carriage Prestretch Adjustment 3 8 Universal Go To Buttons 3 10 Run Screens 3 11 Run Screen 3 11 Recipe Screens 3 13 Recipe Screen 3 13 Recipe Select Screen 3 15 User Setting Screens 3 16 Wrap Se...

Page 32: ...Machine Manual Orion AG 360 RoboWrapper Revision 1 1 System Operation Contents 28 June 2017 Page II...

Page 33: ...360 1 Prior to charging ensure that the battery connector is attached 2 Plug the supplied cord to the charging connector 3 The indicator will show green when unplugged red when charging and both gree...

Page 34: ...e machine START AND EMERGENCY STOP SWITCHES Press the RESET button to gain Control Power prior to starting or moving the machine The START button on the run screen is used to start the cycle once the...

Page 35: ...wer is Not Present or Safety Switch Active 1 Locate the transmission lock unlock located on the back under the carriage on the right side 2 Move the transmission selector up to unlock the transmission...

Page 36: ...t at the front of the machine The handle is on the opposite side of the direction that the machine steers This allows the user to have easier control of the machine when moving it manually To release...

Page 37: ...de wheel loosen the bolt on the end of the guide arm with a 17 mm wrench 2 Use the hand knob to raise or lower the guide wheel so that it aligns with the top of the pallet where the top boards of the...

Page 38: ...m mandrel 3 Install the top mandrel on top of the roll to prevent upward movement 4 Turn the carriage door latch and pull out on the carriage door handle on the top of the carriage to open the carriag...

Page 39: ...Reset button Film will not feed until control power is present 10 Peel off the first few winds of the film multistretch will run due to displacement of the dancer roller and fix the film end onto the...

Page 40: ...Switch the power off and remove the pre stretch cover 2 Push the safety lock in and then use the handle to adjust the prestretch percentage Lift up the handle for high prestretch percentage or lower...

Page 41: ...that the prestretch adjustment is properly locked into place A The mark line is back to its home position B The lamp indicated the correct pre stretch percentage Note There are two pre stretch percen...

Page 42: ...escriptions STATE 1 DESCRIPTION Press this button to go to the Run Screen The icon will illuminate in green when the screen is currently active Press this button to go to the Recipes Screen The icon w...

Page 43: ...15 The Run Screen Table 3 2 The Run Screen Button Descriptions STATE 1 DESCRIPTION Press and hold this button to start the machine This must be held until the Start Delay timer is complete to start t...

Page 44: ...3 12 This is the battery indicator This shows the current percentage of the battery If the battery is below a certain percentage a warning will display to warn the operator to move the unit to a char...

Page 45: ...to go to the next recipe The settings on this screen are applied to the recipe displayed in the box at the top of the screen AUTO HEIGHT DELAY Press this button to modify the Autoheight Delay value in...

Page 46: ...speed of the carriage on the downward move in terms of percentage Min 5 Max 100 WRAPPING SPD Press this button to set the wrapping speed in terms of percentage FILM TENSION Press this button to modif...

Page 47: ...The Recipe Screen Button Descriptions STATE 1 DESCRIPTION STATE 2 SELECT RECIPE Press a recipe button to choose between the different recipe wrap settings Changes made to a recipe are saved to the ac...

Page 48: ...button to go to the previous recipe The settings on this screen are applied to the recipe displayed in the box at the top of the screen when the save button is pressed NEXT Press this button to go to...

Page 49: ...iage travels up and down during the cycle FILM TENSION Press this button to set the film tension percentage INSTA CUT DELAY Press this button to set the delay timer for the insta cut This allows the u...

Page 50: ...igure 3 19 The Menu Screen Table 3 6 The Menu Screen Button Descriptions STATE 1 DESCRIPTION JOGGING Press this button to go to the Jogging Screen RECIPES Press this button to go to the Recipes Screen...

Page 51: ...f the carriage Figure 3 20 The Jogging Screen Table 3 7 The Jogging Screen Button Descriptions STATE 1 DESCRIPTION Press this button to jog the carriage upwards The carriage move slowly upwards until...

Page 52: ...Production Data Screen Table 3 8 The Production Data Screen Button Descriptions STATE 1 DESCRIPTION PALLETS WRAPPER PER SHIFT This display shows the number of cycles the machine has run since the last...

Page 53: ...ws the user to calibrate the tension sensor Figure 3 22 The Tension Sensor Calibration Screen Table 3 9 The Tension Sensor Calibration Screen Button Descriptions STATE 1 DESCRIPTION START CALIBRATION...

Page 54: ...gure 3 23 The Diagnostics Screen Table 3 10 The Diagnostics Screen Button Descriptions STATE 1 DESCRIPTION INPUTS Press this button to go to the Inputs Screen MANUAL Press this button to display the m...

Page 55: ...This is the Inputs Status screen This screen shows the status of the machine inputs There is another screen similar to this for displaying output status Figure 3 24 The Inputs Screen Table 3 11 The In...

Page 56: ...on 28 June 2017 Page 3 24 The Manual Screen This is the Manual screen This screen shows allows the user to view the manual Figure 3 25 The Manual Screen Table 3 12 The Manual Screen Button Description...

Page 57: ...The screen displays the faults and the time they occurred Figure 3 26 The Fault History Screen Table 3 13 The Fault History Screen Button Descriptions STATE 1 DESCRIPTION ANY DISPLAY The displays on...

Page 58: ...calibrate the touchscreen touch points and set the date and time Figure 3 27 The HMI Setup Screen Table 3 14 The HMI Setup Screen Button Descriptions STATE 1 DESCRIPTION DATE TIME Press the numbers to...

Page 59: ...Figure 3 28 The Battery Settings Screen Table 3 15 The Battery Settings Screen Button Descriptions STATE 1 DESCRIPTION VOLTAGE LIMIT 1 CHARGING REQUIRED Press this button to set the voltage limit whe...

Page 60: ...tection alarm PALLET DETECTION ALARM ON BROKEN FILM DETECTION ALARM OFF Press this button to enable or disable the broken film detection alarm BROKEN FILM DETECTION ALARM ON BUZZER OFF Press this butt...

Page 61: ...28 June 2017 System Operation Page 3 29 CARRIAGE HOME TIMEOUT TIME Press this button to display the numeric keypad to enter the carriage home timeout timer Table 3 16 The Machine Settings Screen Butto...

Page 62: ...Machine Manual Orion AG 360 RoboWrapper Revision 1 1 System Operation 28 June 2017 Page 3 30...

Page 63: ...ontents Component Inspections 4 1 Battery Connections 4 1 Main Breaker Electrical Disconnect Hard Reset 4 2 Side Panel Interlock Switch 4 3 Handle Proximity Switch 4 3 Carriage Obstacle Detect Limit S...

Page 64: ...Machine Manual Orion AG 360 RoboWrapper Revision 1 1 Troubleshooting Contents 28 June 2017 Page II...

Page 65: ...peration Check the sensor or component to see if the device is properly connected Battery Connections If the battery will not recharge after 8 hours check the battery connections If the batteries stil...

Page 66: ...n breaker is located behind the right side panel This switch also serves as a hard reset if there are issues that are not clearing with conventional troubleshooting methods 1 Use the provided key to u...

Page 67: ...imity switch located under the front battery panel that detects for the posi tion of the front handle The manual drive walking feature will not function unless the handle is straight forward and the p...

Page 68: ...witch Check that the limit switch is operating properly and that the contact is being made when the obstacle detect mechanism is pressed Also check that the switch is off when the mechanism is down Th...

Page 69: ...mper stops the machine Check that the bumper switch is operating properly prior to running for the day Transmission Engage Disengage There is a transmission engage disengage lever located at the back...

Page 70: ...EMERGENCY STOP FAULT Check that the Emergency Stop button is not pressed to allow operation Close the carriage door Carriage obstacle detect or bumper protection tripped Carriage Door Open Pre stretch...

Page 71: ...not find object at start Photocell broken or circuit fault E 9 LIFT UNIT NOT IN HOME POSI Lift unit not in home position Lift unit low journey fault or cir cuit fault E 13 BRAKE OPEN Brake open Manua...

Page 72: ...Machine Manual Orion AG 360 RoboWrapper Revision 1 1 Troubleshooting 28 June 2017 Page 4 8...

Page 73: ...Page I Maintenance Contents Maintenance Recommendations 5 1 Opening Control Panels and Covers 5 1 Carriage Lift Chain Adjustment 5 4 Chain Maintenance 5 4 Tower Raceways Maintenance 5 4 Cleaning The S...

Page 74: ...Machine Manual Orion AG 360 RoboWrapper Revision 1 1 Maintenance Contents 28 June 2017 Page II...

Page 75: ...of actual use and conditions Opening Control Panels and Covers Remove the three screws holding on the battery cover to take off the front battery cover The screws are located at the bottom front of th...

Page 76: ...Page 5 2 Left Side Enclosure The left enclosure contains the PLC and drives along with terminal blocks Right Side Enclosure The right enclosure contains the power supply VFD and terminal blocks Figure...

Page 77: ...the batteries are not charging an additional check would be the connector on the back of the door panel Ensure the connections are properly plugged in and not loose HMI Back Panel Check the connection...

Page 78: ...hain lubri cants on the market With time the chain will tend to stretch The tower is equipped with automatic chain tensioner and does not need any adjustment Note First chain tension inspection must b...

Page 79: ...nt or cause the film to tear regularly This is completely normal under continued use and occurs on every stretch wrapper made no matter who the manufacturer is The rubber rollers are recommended to be...

Page 80: ...ll be more prone to steering bounce Bumper Tension Adjustment The steering bumper tension can be adjusted to prevent the safety bumper from tripping when not necessary Tighten the bolts to increase th...

Page 81: ...rion Machine Manual Revision 1 1 AG 360 RoboWrapper 28 June 2017 Electrical Prints and Mechanical Drawings Page 1 Electrical Prints and Mechanical Drawings Electrical Prints 6 1 Mechanical Drawings 6...

Page 82: ...Machine Manual Orion AG 360 RoboWrapper Revision 1 1 Electrical Prints and Mechanical Drawings 28 June 2017 Page 2...

Page 83: ...6 Page 6 1 Orion Machine Manual Revision 1 1 AG 360 RoboWrapper 28 June 2017 Electrical Prints and Mechanical Drawings Electrical Prints and Mechanical Drawings Electrical Prints...

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Page 92: ...rapper Revision 1 1 Electrical Prints and Mechanical Drawings 28 June 2017 Page 6 2 Mechanical Drawings Download the mechanical drawings for your machine on the Orion Webpage http www orionpackaging c...

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