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Machine Manual

Orion

CTS Flex Stretchwrapper

Revision 3.0

System Operation

25 July 2016

Page 3-30

DOWNLOAD CONV. 1

Downloads the default Conveyor 1 VFD parameters from the PLC to the VFD.

DOWNLOAD CONV. 2

Downloads the default Download Conveyor 2 VFD parameters from the PLC to the

VFD.

DOWNLOAD ALL VFD'S

Downloads the default VFD parameters from the PLC to the VFD.

Table 3-21. The VFD Parameters Screen Button Descriptions (Continued)

STATE 1

DESCRIPTION

Summary of Contents for Orion CTS Flex Stretchwrapper

Page 1: ...y 25 2016 Revision 3 0 To Navigate Contents In Acrobat Choose View Navigation Panes Make sure Bookmarks are Checked May vary slightly depending on your version of Acrobat 4750 County Road 13 NE Alexan...

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: ...mmendations 1 5 Hazard Messages 1 6 Operation Safety 1 7 Maintenance Safety 1 8 Lockout and Tagout Recommendations 1 9 Electrical System 1 9 Pneumatic and Vacuum Systems 1 10 Installation and First Ti...

Page 4: ...Jogging Screen 3 15 Recipe Screen 3 17 Production Data Screen 3 18 Recipe Viewing Screen 3 19 Machine Settings Screens 3 20 Machine Settings Screen 3 20 Main Drive Screen 3 21 Reinforce Wrap Setup 3 2...

Page 5: ...0 Loads or one month 5 6 17 280 Loads or three months 5 6 All H L Heavy Duty Ring Bearing Series 5 7 5 760 Loads Or One Month 5 7 17 280 Loads or three months 5 7 34 560 Loads or 6 months 5 7 Ring Bea...

Page 6: ...Machine Manual Orion CTS Flex Stretchwrapper Revision 3 0 Table of Contents 25 July 2016 Page IV...

Page 7: ...ng Screen 3 15 The Recipe Screen 3 17 The Production Data Screen 3 18 The Recipe Viewing Screen 3 19 The Machine Settings Screen 3 20 The Main Drive Screen 3 21 The Reinforce Setup Screen 3 22 The Tim...

Page 8: ...ex Stretchwrapper Revision 3 0 List of Figures 25 July 2016 Page II Chapter 4 Troubleshooting Chapter 5 Maintenance The Multistretch Screen 5 3 Proximity Sensor Adjustment 5 4 Chapter 6 Electrical Pri...

Page 9: ...this Manual 1 2 Copyright Notice 1 2 Flex Series Warranty 1 3 Safety 1 4 System Safety Recommendations 1 5 Hazard Messages 1 6 Operation Safety 1 7 Maintenance Safety 1 8 Lockout and Tagout Recommenda...

Page 10: ...Machine Manual Orion CTS Flex Stretchwrapper Revision 3 0 Introduction and Safety Contents 25 July 2016 Page II...

Page 11: ...this manual carefully and keep it handy Following these simple operating instructions will insure the safe and efficient performance of this machine while simple maintenance procedures will guarantee...

Page 12: ...erator control panels the Human Machine Interface and operational procedures Section 4 is the Troubleshooting section A Troubleshooting chart is found in this sec tion Section 5 is the Maintenance sec...

Page 13: ...port is the responsibility of the carrier and is not covered under our warranty FREIGHT CHARGES There will be no freight charges for warranty parts that are ordered for shipment via UPS regular ground...

Page 14: ...g equip ment To achieve this our machines must be efficient easy to maintain and safe to oper ate Before attempting to operate the equipment become familiar with the safety recommen dations and operat...

Page 15: ...s removed Do not wear neckties loose clothing or long loose hanging hair around any equip ment Observe and follow the DANGER WARNING and CAUTION messages throughout this manual in vendor manuals and d...

Page 16: ...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 prod...

Page 17: ...erator should understand the complete task that the system is designed to accomplish The operator should know the location and functional status of all devices switches sensors control signals that ca...

Page 18: ...from injury and to indicate the equipment is being serviced Place a lock on the main electrical disconnect as shown below while performing maintenance Personnel should pay careful attention to all de...

Page 19: ...maintenance 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...

Page 20: ...r locking out the system If several personnel are performing maintenance each individual shall install a lockout device and tag Qualified personnel shall vent any stored or accumulated air in pneumati...

Page 21: ...ing tubes to the maximum possible depth Depending on the model a forklift access may be either at the tower end of the machine frame the tower end or both Look for the forklift tube access stickers sh...

Page 22: ...Motors and transmissions Junction boxes Electrical conduits Proximity and limit switches Photocells 3 Check around the tower to ensure that there is no crippling of the movable parts i e casters cente...

Page 23: ...have to be installed on a lev eled floor The base deviation from vertical must not exceed 1 4 on the distance of 10 feet angle 0 degrees 6 Move the wrapper into its final position If the wrapper is t...

Page 24: ...Machine Manual Orion CTS Flex Stretchwrapper Revision 3 0 Introduction and Safety 25 July 2016 Page 1 14...

Page 25: ...Orion Machine Manual Revision 3 0 CTS Flex Stretchwrapper 25 July 2016 System Description Contents Page I System Description Contents Machine Specifications 2 1...

Page 26: ...Machine Manual Orion CTS Flex Stretchwrapper Revision 3 0 System Description Contents 25 July 2016 Page II...

Page 27: ...in Drive Electronically Adjustable Acceleration deceleration And Running Speeds At Vfd Positive Alignment Feature True Home Position Control Features Nema 12 Control Panel User Friendly Interface with...

Page 28: ...ered Prestretch Electronic Film Tension Control Adjustment On The Panel Or 90 Ga Film Capac ity Higher Gauge Film Requires A Heavy Film Upgrade Film Carriage Elevator Drive High Strength Belt Lift Opt...

Page 29: ...17 Production Data Screen 3 18 Recipe Viewing Screen 3 19 Machine Settings Screens 3 20 Machine Settings Screen 3 20 Main Drive Screen 3 21 Reinforce Wrap Setup 3 22 Timers Screen 3 23 Machine Setup...

Page 30: ...Machine Manual Orion CTS Flex Stretchwrapper Revision 3 0 System Operation Contents 25 July 2016 Page II...

Page 31: ...two settings ON connects a power source to the machine OFF disconnects the power source START AND EMERGENCY STOP SWITCHES Press the START button to gain Control Power prior to starting The START switc...

Page 32: ...cle detect error occurs the brake must be released 2 To release the brake pull outward on the carriage strap on the front side of the tower until the brake releases 3 Align the limit switch on the ins...

Page 33: ...e threading door is open When opened it will set off an alarm on the HMI and prevent the car riage from moving 6 Pass the roped tail of the film through opening 7 Close the carriage door Ensure the la...

Page 34: ...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 Wrap Settings Screen The icon will illuminate in green when the...

Page 35: ...ure 3 4 The Run Screen Table 3 2 The Run Screen Button Descriptions STATE 1 DESCRIPTION STATE 2 Press and hold Start Cycle to start the machine This must be held until the Start Delay timer is complet...

Page 36: ...button is pressed REINFORCING Press this button to stop the current wrap cycle Press this button to reset the current fault condition Press this button to toggle between High Speed and Low Speed opera...

Page 37: ...completed and reset the counter Press Snooze to delay the counter for 100 cycles before the prompt re displays Figure 3 5 The Maintenance Prompt Screen Table 3 3 The Maintenance Prompt Screen Button...

Page 38: ...TURNTABLE SUPPORT CASTERS FOR GOOD CONDITION 17 280 INSPECT TURNTABLE CHAIN APPLY LUBRICATION AS NEEDED 17 280 INSPECT ROTARY ARM CHAIN APPLY LUBRICATION AS NEEDED 17 280 INSPECT MULTISTRETCH CHAIN A...

Page 39: ...out on powerup or after the logout timer has expired USER LEVEL Press this button to set the Default Security level to User When selected the machine will automatically log in to the User security le...

Page 40: ...ns such as Wrap Bottom First Wrap Top First Low Speed High Speed Unstable Load Enabled or Disabled Autoheight Enabled or Disabled or Film Fault Enabled or Disabled You can view each pattern settings o...

Page 41: ...Speed value during the wrap cycle When Low Speed is selected the Main Drive will travel at the predefined Low Speed value during the wrap cycle HIGH SPEED SELECTED UNSTABLE LOAD DISABLED Press this b...

Page 42: ...reen Button Descriptions STATE 1 DESCRIPTION WRAPPER JOGGING Press this button to go to the Jogging Screen See Wrapper Jogging Screen on page 3 13 RECIPES Press this button to go to the Recipes Screen...

Page 43: ...pper Jogging Screen Table 3 8 The Wrapper Jogging Screen Button Descriptions STATE 1 DESCRIPTION Press this button to move the machine to the home position Press this button to jog the main drive turn...

Page 44: ...The carriage move slowly down wards until the operator releases the jog button Press this button to manually trigger the brush and cut sequence Press this button to toggle through the film clamp stag...

Page 45: ...yor Jogging Screen Button Descriptions STATE 1 DESCRIPTION Press this button to enable the indicated infeed conveyor jog Press and hold the Jog Forward or Jog Reverse button to jog the enabled conveyo...

Page 46: ...ton to jog the enabled conveyors backwards Release this button to stop the jog Press and hold this button to jog the enabled conveyors forward Release this button to stop the jog Press this button to...

Page 47: ...ton 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 active recipe If you att...

Page 48: ...also reset the shift cycle counter Figure 3 12 The Production Data Screen Table 3 11 The Production Data Screen Button Descriptions STATE 1 DESCRIPTION LIFETIME CYCLES This display shows the number o...

Page 49: ...helpful for a quick glance at each recipe s parameters Figure 3 13 The Recipe Viewing Screen Table 3 12 The Recipe Viewing Screen Button Descriptions STATE 1 DESCRIPTION RECIPE Press the recipe name...

Page 50: ...to go to the Reinforce Screen See Reinforce Wrap Setup on page 3 22 TIMERS Press this button to go to the Timers Screen See Timers Screen on page 3 23 MACHINE SETUP Press this button to go to the Mach...

Page 51: ...ion for lighter loads The value is the tooth count in which the machine will start to decelerate HIGH SPEED Press this button to modify the High Speed value in terms of hertz This value determines the...

Page 52: ...ser to set the number of reinforce wraps that are applied when the reinforce button on the Run Screen is pressed Figure 3 16 The Reinforce Setup Screen Table 3 15 The Reinforce Wraps Screen Button Des...

Page 53: ...TENSION ENGAGE DELAY Press this button to modify the Tension Engage Delay value in terms of millisec onds This value determines the amount of time at the beginning of the wrap cycle that the Multistr...

Page 54: ...the Hot Wire Cut Duration value in terms of millisec onds This value determines the amount of time after the Hot Wire has turned on that it will remain on to cut the film Warning too high of a value m...

Page 55: ...n You will not need to make any changes on this screen in day to day use Figure 3 18 The Machine Setup Screen Table 3 17 The Machine Setup Screen Button Descriptions STATE 1 DESCRIPTION STATE 2 DEFAUL...

Page 56: ...must be pressed before the machine starts Figure 3 19 The Start Delay Screen Table 3 18 The Start Delay Screen Button Descriptions STATE 1 DESCRIPTION START DELAY Press this button to modify the Star...

Page 57: ...ctory Defaults Screen Table 3 19 The Factory Defaults Screen Button Descriptions STATE 1 DESCRIPTION RESTORE FACTORY DEFAULTS Press this button to delete the currently entered factory settings and rep...

Page 58: ...n 3 mA Max 8 mA GAIN Press this button to modify the Gain datapoint in terms of percentage This value sets percentage of deflection of the dancer bar that is required for the Multistretch to pay out f...

Page 59: ...VFD as half horsepower drive 1 HP IDENTIFIED Displayed if the machine identifies the current VFD as a one horsepower drive SELECT VFD SIZE If the machine cannot automatically identify the size of the...

Page 60: ...he default Conveyor 1 VFD parameters from the PLC to the VFD DOWNLOAD CONV 2 Downloads the default Download Conveyor 2 VFD parameters from the PLC to the VFD DOWNLOAD ALL VFD S Downloads the default V...

Page 61: ...ast the load at conveyor sensor This screen will vary depending on your machine configuration Figure 3 23 The Conveyor Timers Screen Table 3 22 The Conveyor Timers Screen Button Descriptions STATE 1 D...

Page 62: ...table B This allows the operator to disable the Insta Cut function INSTA CUT TABLE B DISABLED A INSTA CUT PUNCH POSITION Press this button to modify the table A Insta Cut Punch Position This is the to...

Page 63: ...stay activated to create a hole in the film Min 2 Max 15 B INSTA CUT BRAKE POSITION Press this button to modify the table B Insta Cut Brake Position This is the tooth count position at which the Multi...

Page 64: ...ich the Insta Cut puncher activates to punch a hole in the film INSTA CUT PUNCH DWELL Press this button to modify the Insta Cut Punch Dwell This is the amount of teeth that the Insta Cut puncher will...

Page 65: ...3 0 CTS Flex Stretchwrapper 25 July 2016 System Operation Page 3 35 This indicator will glow green when the Insta Cut puncher is active Table 3 24 The Insta Cut S Screen Button Descriptions Continued...

Page 66: ...o go to the Outputs Screen See Outputs Screens on page 3 38 VFD S Press this button to go to the VFD s Screen See VFD Parameters Screen on page 3 29 HMI Press this button to go to the HMI Screen See H...

Page 67: ...This is the Inputs screen This screen shows the status of the machine inputs There is another screen similar to this for displaying output status Figure 3 27 The Inputs Screen Table 3 26 The Input Sc...

Page 68: ...his is the Outputs screen This screen shows the status of the machine outputs There is another screen similar to this for displaying input status Figure 3 28 The Outputs Screen Table 3 27 The Output S...

Page 69: ...is displays the serial number of the selected VFD MODULE ID This displays the Module ID of the selected VFD DRIVE STATE This displays the current Drive State of the selected VFD CARRIAGE Press this bu...

Page 70: ...lex Stretchwrapper Revision 3 0 System Operation 25 July 2016 Page 3 40 Gray represents an inactive input Green represents an active input Table 3 28 The VFD Diagnostics Screen Button Descriptions Con...

Page 71: ...to the right to increase the brightness Slide to the left to decrease the brightness TOUCH CALIBRATION Press this button to go to the touch calibration screen This is used to set the align ment of th...

Page 72: ...llows you to look back at the mainte nance alarms and whether they were Acknowledged or Snoozed Figure 3 31 The Maintenance Log Screen Table 3 30 The Maintenance Log Screen Button Descriptions STATE 1...

Page 73: ...This is the Fault History screen The screen displays the faults and the time they occurred Figure 3 32 The Fault History Screen Table 3 31 The Fault History Screen Button Descriptions STATE 1 DESCRIPT...

Page 74: ...sed for your flex machine 1 Press Login to log into Admin level security 2 Enter the user password Press Enter 3 Press Diagnostics 4 Press HMI 5 Enter the IP network settings approved by your system a...

Page 75: ...6 System Operation Page 3 45 10 Once the correct address is entered followed by dashboard asp the dashboard will display 11 This screen allows you to view the Status of your machine the Production dat...

Page 76: ...ION CORRECTION MACHINE SETUP REQUIRED SELECT MACHINE OPTIONS The machine setup parameters are not set See Machine Setup Screen on page 3 25 APPLYING TOP WRAPS The machine is currently applying the top...

Page 77: ...informational pur poses only No correction neces sary CARRIAGE OBSTACLEDETECTED CLEAR PRESS RESET The obstacle detection is tripped See Carriage Obstacle Detect Error Recovery on page 3 2 READY TO WRA...

Page 78: ...informational pur poses only No correction neces sary CARRIAGE OBSTACLEDETECTED CLEAR PRESS RESET The obstacle detection is tripped See Carriage Obstacle Detect Error Recovery on page 3 2 READY TO WRA...

Page 79: ...ult con dition once the cause is cor rected CARRIAGE MOVING UP TOO SLOWLY The carriage is moving upward too slowly Check for the cause of the car riage not moving correctly Check the belt drive behind...

Page 80: ...on fault press and release the E stop button to clear the fault Contact Orion Packaging if problem persists RS485 COMMUNICATION FAULT PRESS E STOP TO CLEAR FAULT There is an RS485 communication fault...

Page 81: ...se of the unlatch Re latch and restart when ready END OF ROLL OR BROKEN FILM The film has broken or the roll ran out Re load a new roll if out If bro ken monitor the film Replace roll if problem persi...

Page 82: ...art when ready MULTISTRETCH VFD NOT READY The indicated VFD is not ready to run Check the fault code on the VFD display in the electrical cabinet See VFD manual for fault code information MAIN DRIVE V...

Page 83: ...Orion Machine Manual Revision 3 0 CTS Flex Stretchwrapper 25 July 2016 Troubleshooting Contents Page I Troubleshooting Contents Troubleshooting 4 1...

Page 84: ...Machine Manual Orion CTS Flex Stretchwrapper Revision 3 0 Troubleshooting Contents 25 July 2016 Page II...

Page 85: ...button on screen Safety Photocells not aligned Photocell alignment RT models and Table machines with safety fencing Photocell lights should change state when objects block then unblock photocells Re a...

Page 86: ...wer preset speeds are set incorrectly The table turnta ble is overhauling and the drive can not stop the load fast enough Check the value of the SP 2 SP 3 and SP 4 parameters on the Table Tower VFD En...

Page 87: ...evo logic sensor has failed Check for 24VDC at the sensor Check for 24VDC Switching on the return wire to PLC at the sensor No VDC Switching out Replace sensor Wiring in the Revo logic sen sor circuit...

Page 88: ...tage is too low Check AC voltage at the On Off switch terminals while the machine is running under load If voltage drops below 115 the supply is not strong enough to run the machine cor rectly Contact...

Page 89: ...incor rect Review the parameter settings in the VFD Refer to the supplied VFD Manual for procedure Refer to the VFD manual and the Orion parameter settings sheet supplied with the machine for maximum...

Page 90: ...requirement position within the machine s capability or a jam may occur 2 Position the Bottom travel striker to the lowest wrapping requirement level within the machine s capability or a false Belt Er...

Page 91: ...rrectly aligned belt or carriage safety cam locks Identify and repair or replace worn parts Maximum speed setting on the VFD is incorrect Review the maximum frequency parame ter settings in the VFD Re...

Page 92: ...ll Not Move Up Or Down In Auto Wrap Cycle Only but Works Fine In Manual Mode Auto height photocell positioned incorrectly Check the position of the Auto height photocell Make sure it is aimed at the l...

Page 93: ...switch activates it s PLC input before the carriage physically hits the machine s framework The belt will need to be removed and re wound cor rectly The carriage will need to be brought down manually...

Page 94: ...bar cam is positioned incorrectly Make sure the cam rotates in such a way as to create a gap between the hall effect device and the cam itself Adjust the cam correctly hall effect sensor has failed C...

Page 95: ...e hall effect device and the cam itself Adjust the cam correctly Hall effect device has failed Perform tests mentioned above If this does not resolve the issue replace the hall effect device Minimum s...

Page 96: ...cor rectly on the trailing rubber roller Film mandrel drag or resistance is not allowing the film to unwind properly Look for excessive wear under the bottom mandrel Lubricate the bottom and center o...

Page 97: ...touchscreen Re set the ZERO and GAIN values according to the film feed setup instruc tions in the manual ZERO setting should be a value of at least ten above the hall effect feedback value to operate...

Page 98: ...g the feed axis of the film This is known as gauge banding Replace improper film with film in good condition Stretch chain and or belt geome try is incorrect Out of alignment components can cause feed...

Page 99: ...the flow controls on the clamp cylinders so that they operate smoothly Air lines are pinched or obstructed observe all 1 4 inch polyflow tubing Remove any obstruction Correct any pinched lines Debris...

Page 100: ...e cutter jog function on the touchscreen Adjust the flow controls on the clamp cylinders so that they operate smoothly Air lines are pinched or obstructed observe all 1 4 inch polyflow tubing Remove a...

Page 101: ...h extend timer at the touch screen is incorrect for the applica tion Look for the arm to activate smoothly but at the wrong time Observe the factory preset value on the settings screen Re adjust the b...

Page 102: ...Machine Manual Orion CTS Flex Stretchwrapper Revision 3 0 Troubleshooting 25 July 2016 Page 4 18...

Page 103: ...nce 5 1 Motor Maintenance 5 1 Reducer Oil Change 5 1 Tower Raceways Maintenance 5 2 Chain Maintenance 5 2 Proximity Sensor Adjustment 5 3 Cleaning The Stretch Rollers 5 5 Preventative Maintenance Sche...

Page 104: ...Machine Manual Orion CTS Flex Stretchwrapper Revision 3 0 Maintenance Contents 25 July 2016 Page II...

Page 105: ...ked for tightness after the first week It is recommended to change the oil every six months or at least 1800 hours of operation whichever comes first When adding or changing oil the transmission shoul...

Page 106: ...rosive environment the race ways should be re greased more often at least every 100 hours Chain Maintenance To clean the stretch chain wipe it with an oily cloth once a service quarter When machine is...

Page 107: ...n the cam and the front side of proximity sensor about 1 8 5 Tighten on the nuts securing the Proximity Sensor 6 Put the cover back on 7 Power up machine 8 To adjust the multistretch settings you must...

Page 108: ...Machine Manual Orion CTS Flex Stretchwrapper Revision 3 0 Maintenance 25 July 2016 Page 5 4 14 If not satisfied repeat the procedure Figure 5 2 Proximity Sensor Adjustment...

Page 109: ...pletely normal under continued use and occurs on every stretch wrapper made no matter who the manufacturer is The rubber rollers are recommended to be cleaned at every 2000 hours of running Do not cle...

Page 110: ...ents of actual use and conditions All H L Standard Series 5 760 Loads or one month Inspect rubber stretch rollers Clean as needed per instructions in manual Inspect belt condition Adjust as needed 17...

Page 111: ...ectly on the ring bearing Pump one full shot of grease into the zerk every six months This should be plenty of lubrication for most applications Pumping too much grease into the ring bearing can destr...

Page 112: ...t casters for good condition Inspect turntable chain Apply a light coating of lubricant per instructions in manual Inspect prestretch chain and belt Tension as needed Apply a light coating of lubrican...

Page 113: ...icate per instructions in manual Inspect commutator assembly Blow out debris per instructions in the manual RTA Series 5760 Loads or one month Inspect rubber stretch rollers Clean as needed per instru...

Page 114: ...Machine Manual Orion CTS Flex Stretchwrapper Revision 3 0 Maintenance 25 July 2016 Page 5 10...

Page 115: ...n Machine Manual Revision 3 0 CTS Flex Stretchwrapper 25 July 2016 Electrical Prints and Mechanical Drawings Page 1 Electrical Prints and Mechanical Drawings Electrical Prints 6 1 Mechanical Drawings...

Page 116: ...Machine Manual Orion CTS Flex Stretchwrapper Revision 3 0 Electrical Prints and Mechanical Drawings 25 July 2016 Page 2...

Page 117: ...6 Page 6 1 Orion Machine Manual Revision 3 0 CTS Flex Stretchwrapper 25 July 2016 Electrical Prints and Mechanical Drawings Electrical Prints and Mechanical Drawings Electrical Prints...

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Page 129: ...DC OK Adjust 24V 2 5A L N 100 240V 1 5A 50 60Hz G R...

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Page 132: ...apper Revision 3 0 Electrical Prints and Mechanical Drawings 25 July 2016 Page 6 2 Mechanical Drawings Download the mechanical drawings for your particular model on the Orion Webpage http www orionpac...

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