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Orion

Machine Manual

Revision 3.1

Sentry HP/ LP Flex Stretchwrapper

21 May 2020

System Description

System Description

Machine Specifications

Utilities

•

115 / 1ph / 60hz / 10 Amp Service

Standard Speed

•

12 Rpm Variable Tower Speed VFD Controlled Motor

Drive

•

Heavy Duty Chain Drive

•

Electronically Adjustable Acceleration/ Deceleration and Running Speeds (At VFD)

•

Positive Alignment Feature (True Home Position)

Control Features

•

Nema 12 Control Panel

•

IntelleVue

™

User Friendly Interface

•

IP Address is Modifiable for Networking

•

Easy to Use Icon Based Interface

•

Web-based Production Data Dashboard

•

Optional Wireless Connection to the PLC/ HMI

•

Downloadable VFD Parameters

•

Variable Speed Film Carriage Up/ Down Control

•

Film Carriage Manual Jog Functionality

•

Photocell For Automatic Load Height Detection

•

Main Drive Jogging

•

Variable Speed Main Drive

•

Semi-automatic Reinforce Wrap Feature

•

On-Screen Interactive Troubleshooting Guide

Film Delivery

•

Powered Pre-stretch Film Carriage

•

200% Film Prestretch with optional 260% Prestretch Carriage

•

20" Film Width Capacity up to 95 Gauge Film Thickness

•

High Strength Chain Lift

•

Variable Frequency Drive Motor

Summary of Contents for ORION Sentry HP

Page 1: ...Revision Date May 21 2020 Revision 3 1 Sentry HP LP STRETCHWRAPPER MANUAL...

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: ...ecommendations 1 6 Hazard Messages 1 7 Operation Safety 1 8 Maintenance Safety 1 9 Lockout and Tagout Recommendations 1 10 Electrical System 1 10 Installation and First Time Power Up 1 11 Unloading 1...

Page 4: ...ntry Carriage Recipe Viewing Screen 3 17 Orion Carriage Recipe Viewing Screen 3 18 Production Data Screen 3 19 Film Usage Screen 3 20 Film Usage Settings Screen 3 21 Fault Tracking Screen 3 23 Machine...

Page 5: ...Troubleshooting Troubleshooting 4 1 Chapter 5 Maintenance Maintenance 5 1 Motor Maintenance 5 1 Reducer Oil Change 5 1 Chain Maintenance 5 2 Proximity Sensor Adjustment 5 3 Cleaning The Stretch Rolle...

Page 6: ...Machine Manual Orion Sentry HP LP Flex Stretchwrapper Revision 3 1 Table of Contents 21 May 2020 Page IV...

Page 7: ...e Run Screen 3 6 The Maintenance Prompt Screen 3 8 The Security Settings Screen 3 10 The Wrap Settings Screen 3 11 The Menu Screen 3 13 The Jogging Screen 3 14 The Recipe Screen 3 16 The Sentry Carria...

Page 8: ...The Diagnostics Screen 3 40 The Inputs Screen 3 41 The Outputs Screen 3 42 The VFD Diagnostics Screen 3 43 The HMI Setup Screen 3 44 The Maintenance Log Screen 3 45 The Fault History Screen 3 46 Sett...

Page 9: ...ght Notice 1 1 About this Manual 1 2 Sentry Series Warranty 1 3 Safety 1 5 System Safety Recommendations 1 6 Hazard Messages 1 7 Operation Safety 1 8 Maintenance Safety 1 9 Lockout and Tagout Recommen...

Page 10: ...Machine Manual Orion Sentry HP LP Flex Stretchwrapper Revision 3 1 Introduction and Safety Contents 21 May 2020 Page II...

Page 11: ...may not be fully covered due to their unique application Every effort has been made to ensure document accuracy how ever Orion Packaging retains the right to change specifications without notice In o...

Page 12: ...ion This section discusses safety lock out tag out hazard messages and installation information Section 2 is the System Description section This section discusses machine specifica tions A Machine Lay...

Page 13: ...epair or replace any failed component This warranty does not include any labor travel or equipment downtime cost for part replacement POLYURETHANE PRE STRETCH ROLLERS The polyurethane pre stretch roll...

Page 14: ...reight prepaid within 30 days of shipment of the replacement part except for components valued at under 300 list price under the conditions stated above De fective parts must be returned in their orig...

Page 15: ...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 16: ...rate the equipment with any of the safety guards 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...

Page 17: ...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...

Page 18: ...ator 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 can...

Page 19: ...with the power OFF Lockout and tag out procedures should be followed to protect personnel from injury and to indicate the equipment is being serviced Place a lock on the main electrical disconnect wh...

Page 20: ...ing 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 restarte...

Page 21: ...inimum capacity of 2500 lbs WARNING Use caution when uprighting the tower Injury could occur 1 If your model is a high tower it may have the tower pivoted downward 2 Use a secured strap to pivot the t...

Page 22: ...justed 4 Lift the machine only to the necessary height to move it with no bouncing or friction on the floor 5 Sit the machine down assuring uniform contact with the floor which is necessary to ensure...

Page 23: ...must be reported imme diately to the freight carrier Any transport damage cannot be claimed to Orion Pack aging Inc Items that are vulnerable to damage and must be inspected are as follows Motors and...

Page 24: ...ted to facilitate transport is marked with a number located on the junction box to which the wiring must be reconnected Any wire run that appears too short or long may indicate that the position of th...

Page 25: ...Orion Machine Manual Revision 3 1 Sentry HP LP Flex Stretchwrapper 21 May 2020 System Description Contents Page I System Description Contents Machine Specifications 2 1...

Page 26: ...Machine Manual Orion Sentry HP LP Flex Stretchwrapper Revision 3 1 System Description Contents 21 May 2020 Page II...

Page 27: ...dly Interface IP Address is Modifiable for Networking Easy to Use Icon Based Interface Web based Production Data Dashboard Optional Wireless Connection to the PLC HMI Downloadable VFD Parameters Varia...

Page 28: ...1 650 lbs Wraps Loads 52 x52 x80 up to 4 000 lbs with Optional Tall Tower Available Structural Steel Construction Throughout Easy Access to all Components Limited Proprietary Parts for Ease of Mainten...

Page 29: ...Orion Machine Manual Revision 3 1 Sentry HP LP Flex Stretchwrapper 21 May 2020 System Description Page 2 3 Figure 2 2 Sentry HP...

Page 30: ...Machine Manual Orion Sentry HP LP Flex Stretchwrapper Revision 3 1 System Description 21 May 2020 Page 2 4...

Page 31: ...17 Orion Carriage Recipe Viewing Screen 3 18 Production Data Screen 3 19 Film Usage Screen 3 20 Film Usage Settings Screen 3 21 Fault Tracking Screen 3 23 Machine Settings Screens 3 24 Machine Setting...

Page 32: ...LP Flex Stretchwrapper Revision 3 1 System Operation Contents 21 May 2020 Page II Flex Dashboard Remote Viewing 3 47 Setting up Dashboard Remote Viewing 3 47 Information Alarm Messages 3 49 Message Di...

Page 33: ...SWITCH Located on the panel door the lockable power switch has two settings ON connects a power source to the machine OFF disconnects the power source START AND EMERGENCY STOP SWITCHES Press the STAR...

Page 34: ...e roll When using tacky film verify that the tacky surface of the film is inward on the load 1 Remove the top mandrel spool 2 Put the roll of film on the bottom mandrel 3 Install the top mandrel on to...

Page 35: ...must then sever the wrap between the car riage and the load and remove the load with a forklift or pallet jack with optional ramp The film carriage is equipped with a switch that detects when the carr...

Page 36: ...ilm carriage is equipped with a magnetic switch that detects when the carriage 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 r...

Page 37: ...ess 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...

Page 38: ...y functions of the machine The red block in the Orion block logo will travel the perimeter of the logo showing the position of the turntable in relation to the home proximity sensor Figure 3 7 The Run...

Page 39: ...ed as long as the Reinforce button is pressed REINFORCING Press this button to toggle between High Speed and Low Speed operation When High Speed is selected the Main Drive will travel at the predefine...

Page 40: ...was completed and reset the counter Press Snooze to delay the counter for 100 cycles before the prompt re displays Figure 3 8 The Maintenance Prompt Screen Table 3 3 The Maintenance Prompt Screen But...

Page 41: ...ADS INSPECT RUBBER MULTISTRETCH ROLLERS CLEAN AS NEEDED 5 760 INSPECT BENEATH TURNTABLE CLEAN DEBRIS AS NEEDED 17 280 INSPECT TURNTABLE SUPPORT CASTERS FOR GOOD CONDITION 17 280 INSPECT TURNTABLE CHAI...

Page 42: ...log 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 securit...

Page 43: ...uch 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 on th...

Page 44: ...cle 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 button to enable or disable the...

Page 45: ...JOGGING Press this button to go to the Jogging Screen See Jogging Screen on page 3 14 RECIPES Press this button to go to the Recipes Screen See Recipe Screen on page 3 16 PRODUCTION DATA Press this b...

Page 46: ...The Jogging Screen Table 3 8 The 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 turntable in...

Page 47: ...the carriage downwards The carriage move slowly down wards until the operator releases the jog button Press this button while the machine is running to stop the current wrap cycle When not running pre...

Page 48: ...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 attempt...

Page 49: ...pful for a quick glance at each recipe s parameters Figure 3 14 The Sentry Carriage Recipe Viewing Screen Table 3 10 The Sentry Carriage Recipe Viewing Screen Button Descriptions STATE 1 DESCRIPTION R...

Page 50: ...pful for a quick glance at each recipe s parameters Figure 3 15 The Orion Carriage Recipe Viewing Screen Table 3 11 The Orion Carriage Recipe Viewing Screen Button Descriptions STATE 1 DESCRIPTION REC...

Page 51: ...ycle counter Figure 3 16 The Production Data Screen Table 3 12 The Production Data Screen Button Descriptions STATE 1 DESCRIPTION LIFETIME CYCLES This display shows the number of cycles the machine ha...

Page 52: ...th in inches used to calculate the film usage FILM GAUGE Press the numeric display to enter the film gauge used to calculate the film usage PRE STRETCH Press the numeric display to enter the prestretc...

Page 53: ...PALLET LENGTH Press the numeric display to enter the pallet length in percentage PALLET WIDTH Press the numeric display to enter the pallet width in percentage FILM GAUGE Press the numeric display to...

Page 54: ...on machines equipped with the Orion carriage with the Sentinel film scale option CALCULATION MODE SENTINEL Press this button to toggle to Sentinel film usage mode The Sentinel mode is only available...

Page 55: ...ast counter reset CARRIAGE OBSTACLE DETECTED This display shows the number of carriage obstacle detections switch on the bot tom of the carriage since the last counter reset E STOP PRESSED This displa...

Page 56: ...REINFORCE Press this button to go to the Reinforce Screen See Reinforce Wrap Setup on page 3 27 TIMERS Press this button to go to the Timers Screen See Sentry Carriage Timers Screen on page 3 28 MACHI...

Page 57: ...LP Flex Stretchwrapper 21 May 2020 System Operation Page 3 25 INSTA CUT Press this button to go to the Insta Cut Screen See Insta Cut Screen on page 3 38 Table 3 16 The Machine Settings Screen Button...

Page 58: ...to decel before stopping at home An earlier slow down position might be needed for heavier loads and a later slowdown position for lighter loads The value is the tooth count in which the machine will...

Page 59: ...he user to set the number of reinforce wraps that are applied when the reinforce button on the Run Screen is pressed Figure 3 22 The Reinforce Setup Screen Table 3 18 The Reinforce Wraps Screen Button...

Page 60: ...ION AUTOHEIGHT DELAY Press this button to modify the Autoheight Delay value in terms of milliseconds This value determines the amount of time that the Carriage will continue to travel up during the wr...

Page 61: ...l continue to travel up during the wrap cycle after the Autoheight photoeye no longer detects a load This is used to adjust the amount of overlap on the top of the load Min 0 ms Max 10000 ms TENSION E...

Page 62: ...arriage SELECT SENTRY CARRIAGE SELECT ORION CARRIAGE Press this button to select the Orion Carriage SELECT ORION CARRIAGE SELECT TURNTABLE Press this button to select that the machine is a turn table...

Page 63: ...AY Press this button to modify the Start Delay value in terms of milliseconds This value determines the amount of time that the Start pushbutton must be pressed before the machine will start Min 500 m...

Page 64: ...e Factory Defaults Screen Table 3 23 The Factory Defaults Screen Button Descriptions STATE 1 DESCRIPTION RESTORE FACTORY DEFAULTS Press this button to delete the currently entered factory settings and...

Page 65: ...peed Screen Table 3 24 The Maximum Speed Screen Button Descriptions STATE 1 DESCRIPTION MAXIMUM MULTISTRETCH SPEED HZ Press the numeric display to set the Maximum Multistretch speed in hertz This limi...

Page 66: ...arriage Multistretch Screen Button Descriptions STATE 1 DESCRIPTION TENSION HIGH SPEED Press this numeric display to set the tension percentage applied while the machine is running in high speed mode...

Page 67: ...bar at rest Min 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 Multistretc...

Page 68: ...this button to enter the film tension percentage from 0 100 while the car riage is wrapping the top TENSION BOTTOM Press this button to enter the film tension percentage from 0 100 while the car riage...

Page 69: ...the current 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...

Page 70: ...at which 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...

Page 71: ...1 Sentry HP LP Flex Stretchwrapper 21 May 2020 System Operation Page 3 39 This indicator will glow green when the Insta Cut puncher is active Table 3 28 The Insta Cut Screen Button Descriptions Contin...

Page 72: ...to go to the Outputs Screen See The Outputs Screens on page 3 42 VFD S Press this button to go to the VFD s Screen See The VFD Diagnostics Screen on page 3 43 HMI Press this button to go to the HMI S...

Page 73: ...creens 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 34 The Inputs Screen Table 3 30 The In...

Page 74: ...eens This 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 35 The Outputs Screen Table 3 31 The Ou...

Page 75: ...stics Screen Button Descriptions STATE 1 DESCRIPTION SERIAL NUMBER This displays the serial number of the selected VFD MODULE ID This displays the Module ID of the selected VFD DRIVE STATE This displa...

Page 76: ...lide 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 o...

Page 77: ...en allows you to look back at the mainte nance alarms and whether they were Acknowledged or Snoozed Figure 3 38 The Maintenance Log Screen Table 3 34 The Maintenance Log Screen Button Descriptions STA...

Page 78: ...een This is the Fault History screen The screen displays the faults and the time they occurred Figure 3 39 The Fault History Screen Table 3 35 The Fault History Screen Button Descriptions STATE 1 DESC...

Page 79: ...be used 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 syst...

Page 80: ...Operation 21 May 2020 Page 3 48 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...

Page 81: ...ION CORRECTION MACHINE SETUP REQUIRED SELECT MACHINE OPTIONS The machine setup parameters are not set See Orion Carriage Timers Screen on page 3 29 APPLYING TOP WRAPS The machine is currently applying...

Page 82: ...o run Press and hold the start button for the amount of time set in the parameters to start the machine APPLYING REINFORCEMENT WRAPS Reinforce wraps are currently being applied Once the reinforce wrap...

Page 83: ...or obstruction on the track 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...

Page 84: ...n 3 1 System Operation 21 May 2020 Page 3 52 MODIFYING MULTISTRETCH SETTINGS The stretch settings modification is in progress Allow the settings to complete prior to start up Table 3 36 The Informatio...

Page 85: ...opened during the cycle Check for the cause 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 moni...

Page 86: ...nformation MAIN DRIVE VFD NOT READY CARRIAGE VFD NOT READY X2X COMMUNICATION ERROR There is an X2X communication fault press and release the E stop button to clear the fault Contact Orion Packaging if...

Page 87: ...Orion Machine Manual Revision 3 1 Sentry HP LP Flex Stretchwrapper 21 May 2020 Troubleshooting Contents Page I Troubleshooting Contents Troubleshooting 4 1...

Page 88: ...Machine Manual Orion Sentry HP LP Flex Stretchwrapper Revision 3 1 Troubleshooting Contents 21 May 2020 Page II...

Page 89: ...tion to allow opera tion Turntable Will Not Turn The turntable speed is set too low The carriage obstacle detect switch carriage door open switch located on the bottom of the carriage is pressed Adjus...

Page 90: ...Revision 3 1 Troubleshooting 21 May 2020 Page 4 2 Continual Film Breakage Film tension is set too high Bad or old film Decrease the film tension on the HMI Replace the film spool Table 4 1 Troubleshoo...

Page 91: ...y 2020 Maintenance Contents Page I Maintenance Contents Maintenance 5 1 Motor Maintenance 5 1 Reducer Oil Change 5 1 Chain Maintenance 5 2 Proximity Sensor Adjustment 5 3 Cleaning The Stretch Rollers...

Page 92: ...Machine Manual Orion Sentry HP LP Flex Stretchwrapper Revision 3 1 Maintenance Contents 21 May 2020 Page II...

Page 93: ...checked 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 s...

Page 94: ...s working in a dusty and damp environment it may be necessary to repeat the cleaning operation more often Regarding chain lubricants please use the most common chain lubricants on the market With time...

Page 95: ...4 Turn the Proximity sensor to create the gap between 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 m...

Page 96: ...Machine Manual Orion Sentry HP LP Flex Stretchwrapper Revision 3 1 Maintenance 21 May 2020 Page 5 4 14 If not satisfied repeat the procedure Figure 5 2 Proximity Sensor Adjustment...

Page 97: ...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 cleaned at every 2000 hours of running Do not...

Page 98: ...t any loose debris in the carriage Monitor the machine during operation for any abnormal noises or vibrations 5 760 Loads or one month Inspect rubber stretch rollers Clean as needed per instructions i...

Page 99: ...chine Manual Revision 3 1 Sentry HP LP Flex Stretchwrapper 21 May 2020 Electrical Prints and Mechanical Drawings Page 1 Electrical Prints and Mechanical Drawings Electrical Prints 6 1 Mechanical Drawi...

Page 100: ...Machine Manual Orion Sentry HP LP Flex Stretchwrapper Revision 3 1 Electrical Prints and Mechanical Drawings 21 May 2020 Page 2...

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