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Wulftec WRTA-150, User Manual And Reference Manual

The Wulftec WRTA-150 User Manual and Reference Manual are essential guides for operating and maintaining the WRTA-150 model. These comprehensive manuals provide detailed instructions and helpful tips, ensuring seamless usage. Download these manuals for free from manualshive.com and unlock the full potential of your Wulftec WRTA-150 machine.

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Wulftec / M.J. Maillis Group 

Page 2 of 36

 

 

 

Version 1.7.1 /November 2014 

 

Table of Contents 

 

TABLE OF CONTENTS

 .................................................................................................................................. 2

 

L

IST OF 

F

IGURES

 .............................................................................................................................................. 3

 

AUTOMATIC WARRANTY

 ............................................................................................................................ 4

 

SAFETY LABELS

 ............................................................................................................................................. 5

 

SAFETY

 ............................................................................................................................................................... 7

 

INSPECTION AND INSTALLATION

 ........................................................................................................... 8

 

INSTALLATION OF FENCE HANDLE

 .................................................................................................... 10

 

INSTALLATION OF LIGHT CURTAINS

 ................................................................................................. 11

 

FILM LOADING AND THREADING

 ......................................................................................................... 12

 

WRAPPER CONTROLS

 ................................................................................................................................ 14

 

MODE OF OPERATION – STANDARD SYSTEM

 ................................................................................ 17

 

OPTIONAL PRE-STRETCH RATIOS – CHAIN DRIVEN

 ................................................................... 18

 

OPTIONAL PRE-STRETCH RATIOS – BELT DRIVEN

 ..................................................................... 19

 

SETTING WRAP PARAMETERS

 .............................................................................................................. 20

 

F

ILM 

C

ARRIAGE 

/

 

R

OTATION 

S

PEED

 ............................................................................................................ 20

 

U

PPER

/L

OWER 

L

IMIT 

S

ETTINGS

................................................................................................................... 20

 

T

OP 

W

RAPS

 ..................................................................................................................................................... 20

 

B

OTTOM 

W

RAPS

 ............................................................................................................................................. 20

 

O

VERWRAP

 ...................................................................................................................................................... 20

 

F

ILM 

T

ENSION 

(P

OST 

S

TRETCH

)

 ................................................................................................................... 20

 

P

HOTOEYE 

S

ETTINGS

 ..................................................................................................................................... 21

 

DS-35

 

P

HOTOEYE 

A

DJUSTMENT

 ................................................................................................................. 23

 

P

HOTOEYE 

R

ESPONSE 

D

ELAY 

T

IME

 ............................................................................................................. 24

 

A

UTOMATIC 

H

EIGHT 

S

ENSING

 ...................................................................................................................... 24

 

S

ETTING THE 

L

IMIT 

S

TOP

 .............................................................................................................................. 24

 

A

NALOG 

S

ENSOR 

A

DJUSTMENT

 .................................................................................................................... 25

 

P

ROXIMITY 

S

ENSOR

 ........................................................................................................................................ 26

 

R

EVOLUTION AND 

H

OME 

P

OSITION 

S

ENSORS

 ............................................................................................. 26

 

R

EED 

S

WITCHES 

A

DJUSTMENT

 .................................................................................................................... 26

 

P

ROXIMITY 

S

ENSOR 

R

EPLACEMENT

 ............................................................................................................. 27

 

MOTOR SPEED CONTROL

 ........................................................................................................................ 27

 

DRIVE PARAMETER SETTINGS

 ............................................................................................................. 28

 

MAINTENANCE

 .............................................................................................................................................. 29

 

G

ENERAL 

M

AINTENANCE

 ............................................................................................................................... 29

 

F

ILTER 

R

EGULATOR

 ....................................................................................................................................... 29

 

C

ARRIAGE 

L

IFT 

C

HAIN 

T

ENSION 

A

DJUSTMENTS

 ......................................................................................... 30

 

P

RE

-S

TRETCH 

B

ELTS 

A

DJUSTMENT

 ............................................................................................................ 30

 

P

RE

-S

TRETCH 

C

HAIN 

A

DJUSTMENT

............................................................................................................. 30

 

P

HOTOEYES

 ..................................................................................................................................................... 30

 

S

LIDER 

B

LOCKS

/C

ARRIAGE 

R

AILS

 .............................................................................................................. 31

 

Summary of Contents for WRTA-150

Page 1: ...User s Manual and Reference Guide WRTA 150 ...

Page 2: ... CARRIAGE ROTATION SPEED 20 UPPER LOWER LIMIT SETTINGS 20 TOP WRAPS 20 BOTTOM WRAPS 20 OVERWRAP 20 FILM TENSION POST STRETCH 20 PHOTOEYE SETTINGS 21 DS 35 PHOTOEYE ADJUSTMENT 23 PHOTOEYE RESPONSE DELAY TIME 24 AUTOMATIC HEIGHT SENSING 24 SETTING THE LIMIT STOP 24 ANALOG SENSOR ADJUSTMENT 25 PROXIMITY SENSOR 26 REVOLUTION AND HOME POSITION SENSORS 26 REED SWITCHES ADJUSTMENT 26 PROXIMITY SENSOR REP...

Page 3: ... 150 34 List of Figures FIGURE 1 INSTALLATION OF A WRTA 150 8 FIGURE 2 ANCHORING POINTS FOR A WRTA 150 9 FIGURE 3 FILM LOADING AND THREADING 12 FIGURE 4 DIFFUSE PHOTOEYE 21 FIGURE 5 RETROFLECTIVE PHOTOEYE 21 FIGURE 6 DIFFUSE PHOTOEYE SPECIAL APPLICATIONS 22 FIGURE 7 ANALOG SENSOR ADJUSTMENT 25 FIGURE 8 PROXIMITY SENSOR 26 FIGURE 9 FILM IN CLAMP 29 ...

Page 4: ...anty does not apply to machinery or equipment deemed by Wulftec to have been subjected to misuse neglect or that has been started up repaired or altered by unauthorized personnel Defective parts must be returned to Wulftec within thirty 30 days of shipment of a replacement and must be returned prepaid and in their original state Failure to do so will void this warranty Defective parts that have be...

Page 5: ...ints to alert them of potential hazards Please check equipment and note all safety labels Make sure your personnel are vigilant and obey these warnings Shown below are typical labels that are attached to the equipment PLACED ON ALL CONTROL PANELS PLACED ON ALL CONTROL PANELS PLACED ON AUTOMATIC MACHINE CONTROL PANELS PLACED ON ALL CONVEYORS PLACED ON ALL POWERED CONVEYORS NEAR DRIVE PLACED ON ALL ...

Page 6: ...Wulftec M J Maillis Group Page 6 of 36 Version 1 7 1 November 2014 Safety Labels cont d PLACED ON ALL MACHINE LEGS TOWER NOTE SPANISH FRENCH AND PORTUGESE LABELS ARE AVAILABLE UPON REQUEST ...

Page 7: ...ng to wrap a new load configuration all personnel should be well clear of the wrapping area The load should not be wrapped at a higher speed than the machine was designed to handle Always assume the machine is in an active mode Disconnect control power prior to servicing adjusting or performing routine maintenance procedures WARNING Unless specifically stated preceding all instructions in this man...

Page 8: ...ft Figure 1 Installation of a WRTA 150 Unpacking procedure 1 Remove lag bolts holding skid together 10 pieces 2 Leave cross member attached to machine 1 piece and lift machine from side with strap as shown to remove skid then set machine down on floor 3 Insert forks as far as possible into lifting tubes See forklift requirement above 4 Lift machine while moving forward until machine is in vertical...

Page 9: ...e line shall be such that the voltage at the outlet will not drop more than 5 under full load Use of extension cords is not recommended To measure the voltage drop measure the voltage at the outlet with nothing connected to it this is VA then measure the lowest voltage during machine operation Please read during the complete cycle and note the lowest value this is VB Take the difference between VA...

Page 10: ...e the installation of the handle on the safety fencing Refer to assembly drawing 6MFEN00496 1 Clamp key switch plate in place with edge flush with post Transfer holes approximately center of slot for adjustment Drill 9 32 hole through post Install key switch with carriage bolts 0MINS00006 rev 1 Align slide bolt with key switch Shims must pinch door panel angle iron Tighten nuts 1 ...

Page 11: ...cally adjusting the light curtains components using the top light beams as guide 5 The alignment mode is automatically activated when the light curtain is switched on if the light beams are not yet aligned or the light path is interrupted Top light beams A Red light beam light curtain is misaligned or an obstacle is blocking the path Green light beam system clear Yellow light beam muting in action...

Page 12: ...t the roll is securely in place 7 Pull the film from the roll until a good film web is reached cut the film and discard the damaged portion 8 Pull out the film manually ensure enough length to reach the clamp when it s closed 9 Place film loosely between door and pre stretch rollers then close the door and ensure that the carriage locks are correctly locked this is a 2 position lock make sure to r...

Page 13: ...ll not work If the E Stop is pressed pull it The machines equipped with a standard carriage are programmed to stop when a lack of film occurs In a wrap cycle during which the rotation speed is higher than 10Hz and the pre stretch motor stops working for more than three 3 seconds the machine will fall into a stop state The cause is either a stop a lack of film or a film break Follow the film thread...

Page 14: ... the ability to Pause the cycle when the film carriage reaches the top of the load in order for the operator to place a top sheet on the load Once top sheet is in place the operator presses Start Stop button and the cycle resumes wrapping the top sheet with the specified wraps The machine then completes the rest of its wrap cycle Spiral up up down Controls the way pallet load is wrapped In spiral ...

Page 15: ... the top of the load adjustable from 0 to 9 Bottom wraps Determines the number of wrap layers at the bottom of the load adjustable from 0 to 9 Rotation speed Allows the rotation to be set at the speed best suited to the load variable from min being the lowest speed attainable without stopping to 12 RPM Reinforce wrap Reinforce wrap function allows the operator to reinforce any section of the load ...

Page 16: ...es the clamp jaws There is a four 4 second delay before the clamp jaws close to allow the operator enough time to place film in jaws The carriage will not feed the film if the clamp jaws are closed Reset Brings the carriage down and moves the rotary arm back to home position Cut arm Off on Used to activate or deactivate the cut arm Auto manual mode Used to select the automatic or the manual mode W...

Page 17: ...itiated 7 Place the load in the center of the wrapping zone 8 Activate the pull cord or push customer ready to wrap communication to begin rotation 9 After 1 5 turns the clamp releases the film 10 The carriage moves up 11 The top of the load is sensed 12 The machine completes the top wraps 13 The carriage moves down 14 The carriage stops at bottom limit switch 15 The machine completes the bottom w...

Page 18: ... 22 0MSPK00065 150 16 0MSPK00015 30 0MSPK00011 175 13 0MSPK00016 27 0MSPK00184 185 14 0MSPK00008 30 0MSPK00011 200 14 0MSPK00008 32 0MSPK00014 225 13 0MSPK00016 32 0MSPK00014 250 12 0MSPK00022 32 0MSPK00014 275 14 0MSPK00008 40 0MSPK00140 300 12 0MSPK00022 36 0MSPK00070 RPM C WULFTEC 12 35B12 0MSPK00171 15 35B12 0MSPK00171 17 35B12 0MSPK00171 21 35B15 0MSPK00108 24 35B15 0MSPK00108 30 35B18 0MSPK0...

Page 19: ...MCHN00047 185 15 0MSPK00124 32 0MSPK00129 187L050 0MCHN00046 200 14 0MSPK00130 32 0MSPK00129 187L050 0MCHN00046 225 13 0MSPK00132 32 0MSPK00129 187L050 0MCHN00046 250 12 0MSPK00168 32 0MSPK00129 187L050 0MCHN00046 275 14 0MSPK00130 40 0MSPK00170 210L050 0MCHN00057 300 13 0MSPK00132 40 0MSPK00170 202L050 0MCHN00065 RPM C WULFTEC BELT 2 WULFTEC D WULFTEC 12 12FL050 0MSPK00133 210L050 0MCHN00057 40L0...

Page 20: ...en It can be set to apply zero 0 to nine 9 wraps to the top of the load Bottom Wraps The number of bottom wraps applied to the bottom of the load has to be set on the touch screen It can be set to apply zero 0 to nine 9 wraps to the bottom of the load Overwrap The film overwrap is the extent to which the film carriage wraps above the load Under stretch the film tends to fold itself over the top pr...

Page 21: ... 4 Diffuse Photoeye Diffuse photoeye above Top rotary switch is to set the timer Middle rotary switch always left at position Left 1 Bottom switch is for the sensitivity adjustment Sensitivity Adjustment When the light flashes adjust the desired distance with the or sensitivity rotary switch Figure 5 Retroflective Photoeye ...

Page 22: ...ld up will interfere in operation A flashing signal strength indicator will trigger the alarm output Light Dark Switching Light and dark switching can be toggled using the switch below and between the red signal strength and green power LEDs Simply move the switch toward light for light switching or dark for dark switching Sensitivity Adjustment Using a small screwdriver turn the sensitivity adjus...

Page 23: ...lect The Q1 near and Q1 far lights switch on There are no adjustments to be made in this mode 6 Press select The Q2 near light switches on 7 Place the load at its farthest position Press set Do not hold down Q1 and Q2 lights blink simultaneously to confirm the adjustment If these lights blink alternately the adjustment is not correct 8 Press select The Q2 far light switches on 9 Place the load at ...

Page 24: ... equipped with manual override limit switches NOTE When using a 30 carriage with a 20 film on the machine the autoheight photoeye will not work on small load higher than 20 and smaller than 33 NOTE The upper limit stop controls the overwrap of the pallet when the photoeye mounted on the carriage is not in use Setting the Limit Stop Lower Loosen the lower limit stop Slide stop block into desired po...

Page 25: ...e back gradually until the light on the detector stops flashing and becomes constant and then tighten the detector in position 7 Rearm the emergency stop circuit Caution the pre stretch motor can restart 8 For PowerFlex 4 make sure that parameter A110 is set at 20 PowerFlex 40 jump at step 10 9 Make sure that when the dancer bar is completely retracted with its initial position the motor does not ...

Page 26: ... and also because the WCRT series uses two 2 counts per rotary arm revolution to give the second count required Figure 8 Proximity Sensor Revolution and Home Position Sensors Wrappers from Wulftec use proximity sensor to count revolutions and to determine the arm s home position These two 2 sensors can be found on the top of the ring gear and they are reading off a piece of steel glued on the top ...

Page 27: ...n all wires and guards if applicable have been replaced turn on the power and jog the rotary arm by using the arm jog switch Then verify if the related input blinks WARNING Make sure that the power is disconnected and that a pad lock is installed on the main switch of the wrapper before you carry out these operations Motor Speed Control Your Wulftec pallet wrap machine utilizes AC drives from Alle...

Page 28: ...to Out 1 Sel 0 0 0 0 A059 Opto Out 1 Level 0 0 0 0 A061 Opto Out 2 Sel 0 0 0 0 A062 Opto Out 2 Level 0 0 0 0 A067 Accel 2 Secs 20 20 20 20 A068 Decel 2 Secs 20 20 1 8 1 Need new value A069 Internal Frequency Hz 60 60 60 60 Default value A070 Fixed Frequency 0 Hz 0 0 0 0 A071 Fixed Frequency 1 Hz 5 35 With clamp 5 5 A080 DC Brake Time Secs 0 1 1 1 A081 DC Brake Level Amps 0 2 0 2 0 2 0 2 A082 DB Re...

Page 29: ...ps the water contained in the air line A drain plug is located at the bottom of the filter section This function should be done automatically and should not have to be touched The second section of the FR contains a Regulator that shows how much air pressure going is into the machine The pressure may be regulated by the knob located at the top of the center section of the FR This pressure should b...

Page 30: ... the four 4 motor mounting bolts and sliding the motor in the mounting slots The pre stretch belt tension is adjusted with the tension adjustment arm This arm can be rotated and moved within the mounting slot to obtain correct tension Pre Stretch Chain Adjustment The pre stretch chains should be checked to ensure the proper tension approx every 2000 hours of operation If the chains are found to ha...

Page 31: ...mith recommends a gradual application of load during the first several hours after start up The reducer may run hot during this initial break in period This is normal A few drops of oil may weep from the lip seals during the break in stage After a short period of operation clean off any excess oil around the shaft seals and recheck the oil level adjust if necessary Subsequent oil changes should be...

Page 32: ...Wulftec M J Maillis Group Page 32 of 36 Version 1 7 1 November 2014 Reducer Chart Legend F Refill Plug V Vent Plug L Level Plug D Drain Plug ...

Page 33: ...grooves and that they are intact and preventing contaminants from entering the bearing Teeth Visually inspect the teeth once a month Remove buildup if present With steel pinion if teeth are dry apply grease with a brush all around ring gear Use high quality open gear grease Mobile Unirex EP2 GCLB or equivalent With nylon pinion no greasing is necessary Backlash between gear and pinion needs to be ...

Page 34: ...hrough mode The center photoeye may not see the load The infeed safety may not see the load Select Wrapping On on the touch screen Clear the photoeye and or clean it Clear the photoeye and or clean it Carriage Does not stop at the top of the load The autoheight may be off The photoeye may reflect on something in the background Activate the autoheight See Automatic Height Sensing paragraph Push arm...

Page 35: ...y be a lack of air pressure to the system The cylinder may be defective Look for kink in the hose If none adjust the valve flow control Look for the air pressure gage should not be below 80 PSI Change the defective cylinder Machine stops in the middle of a cycle An alarm is activated Look for the alarm on the touch screen take the corrective measure then accept the alarm and restart the cycle Moto...

Page 36: ...tion Check for short if none change the main fuse using the right rating Check for short if none change the fuse using the right rating Start blue light does not come on after pushing on start Light bulb may be burned out An alarm might be activated One of the automatic modes was not engaged Wrapping or passthrough Change the light bulb Accept the alarm Make sure that the machine is in automatic m...

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