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Page 3-1

Orion

Machine Manual

Revision 3.0

CTS Flex Stretchwrapper

25 July 2016

System Operation

System Operation

Operating Procedures

How to Start and Shut Down Your Wrapping System

Note:

Do not use extension cords. Plug your Flex Stretch-wrapper directly

into an outlet.

POWER 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

START

button to gain Control Power prior to starting.

• The

START

switch is used to start the cycle once the load is available.

• The cycle may be stopped at anytime by pressing the

E-STOP

button.

The FLEX series machines are engineered to give the operator different levels of opera-

tion, the front panel or USER settings, and MENU DRIVEN parameters. The menu driven

parameters offer even more flexibility and security.

Содержание Orion CTS Flex Stretchwrapper

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

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Страница 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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