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Pro Mach Orion CTS Flex Stretchwrapper Manual

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CTS
STRETCHWRAPPER
MANUAL
Model
CTS Flex Stretchwrapper
Revision Date - July 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
Alexandria, MN 56308
Phone: (901) 888-4170
Toll Free: (800) 333-6556
FAX: (901) 365-1071

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Summary of Contents for Pro Mach Orion CTS Flex Stretchwrapper

  • Page 1 STRETCHWRAPPER MANUAL Model CTS Flex Stretchwrapper Revision Date - July 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 Alexandria, MN 56308 Phone: (901) 888-4170 Toll Free: (800) 333-6556...
  • Page 2 The information in this manual is subject to change without notice and does not represent a commitment on the part of Pro Mach and assumes no responsibility for any errors that may appear in this manual. In no event will Pro Mach or its employees, partners, contracted workers/ companies or any association who participates in the writing of this manual be liable for technical or editorial omissions made herein;...

  • Page 3: Table Of Contents

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Table of Contents Table of Contents Chapter 1: Introduction and Safety Introduction............1-1 About this Manual .
  • Page 4 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Table of Contents 25 July 2016 Chapter 3: System Operation Operating Procedures ........... 3-1 How to Start and Shut Down Your Wrapping System .
  • Page 5 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Table of Contents Alarm Displays........... . 3-51 Chapter 4: Troubleshooting Troubleshooting .
  • Page 6 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Table of Contents 25 July 2016 Page IV...
  • Page 7 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 List of Figures List of Figures Chapter 1: Introduction and Safety Fork Tube Access Sticker ......... . . 1-11 Chapter 2: System Description Chapter 3: System Operation Pulling Strap to Release Brake .
  • Page 8 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 List of Figures 25 July 2016 Chapter 4: Troubleshooting Chapter 5: Maintenance The Multistretch Screen..........5-3 Proximity Sensor Adjustment.
  • Page 9 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Introduction and Safety Contents Introduction and Safety Contents Introduction............1-1 About this Manual .
  • Page 10 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Introduction and Safety Contents 25 July 2016 Page II...

  • Page 11: Chapter 1: Introduction And Safety

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Introduction and Safety Introduction and Safety Introduction Thank you for choosing Orion stretch-wrapping equipment. It is a wise choice, which will benefit your company now and in the future. Orion uses a unique combination of functional, rugged steel structure and sophisticated control systems to offer equipment high in durability and low in maintenance require- ments.

  • Page 12: About This Manual

    Copyright Notice © 2016 Pro Mach Section 106 of the 1976 Copyright Act forbids any party other than the author (Pro Mach) to: Reproduce owned work in copies or phonorecords, to prepare derivative works based upon the work; to distribute copies or phonorecords of the work to the public by sale or other trans- fer of ownership, by rental or lease.

  • Page 13: Flex Series Warranty

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Introduction and Safety Flex Series Warranty Effective January 1, 2013- For all products in the Flex Series, Orion provides an industry leading warranty from the delivery date of its products to be free from defects in materials and workmanship as described below. This warranty assumes that normal service will be performed by the user.

  • Page 14: Safety

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Introduction and Safety 25 July 2016 Safety Orion's stretch wrappers should be operated with caution and common sense as any other industrial equipment. To prevent injury and/or electrical shocks, careful operation of the machine and awareness of its many automatic functions is required.

  • Page 15: System Safety Recommendations

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Introduction and Safety System Safety Recommendations Safeguarding personnel that operate and/or maintain automated equipment is the primary consideration. Because it is very dangerous to enter the operating space (work envelope) of a machine during operation, adequate safeguards must be in place and safety precau- tions must be observed.

  • Page 16: Hazard Messages

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Introduction and Safety 25 July 2016 Hazard Messages Notations appear on pages of this manual to alert the reader to important messages regard- ing a significant hazard for personnel or equipment. These messages convey three levels of risk as defined below.

  • Page 17: Operation Safety

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Introduction and Safety Operation Safety The following safety precautions are recommended for all personnel who will operate this CTS Flex Stretchwrapper. • Operators should immediately report unsafe working conditions to a supervisor. •...

  • Page 18: Maintenance Safety

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Introduction and Safety 25 July 2016 Maintenance Safety The following safety precautions are recommended for all personnel who are responsible for the maintenance or service this CTS Flex Stretchwrapper. • Personnel should ensure that all safety devices are functioning and periodically checked for proper operation before performing maintenance.

  • Page 19: Lockout And Tagout Recommendations

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Introduction and Safety Lockout and Tagout Recommendations Electrical System (See OSHA 1910.147 & OSHA 1910.333 (b)(2) for exception to procedures) To avoid hazards of electrical shock or other personal injuries, the main power disconnect for the system and any other separate sources of power for the system shall be locked out &...

  • Page 20: Pneumatic And Vacuum Systems

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Introduction and Safety 25 July 2016 Pneumatic and Vacuum Systems To avoid hazards of moving mechanisms, pinch points and other personal injuries, the main compressed air supply valve for the system shall be locked out & tagged as a safety precaution during entry and maintenance to the system.

  • Page 21: Installation And First Time Power Up

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Introduction and Safety Installation and First Time Power Up Unloading Machine can be easily unloaded and transported by a forklift with a minimum capacity of 2500 lbs. 1. Carefully insert the forks into the lifting 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.

  • Page 22: Inspection

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Introduction and Safety 25 July 2016 Inspection 1. Remove all packing and supporting additions - these may include the blocks under the carriage and the restraining bar over the table. When removing the packing materials covering the machine, care Note: must be taken not to cut any of the electrical wires and/ or polyure- thane covering on the film carriage rollers.

  • Page 23: Assembly Procedure

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Introduction and Safety Assembly Procedure The structural frames of the machine have to be installed on a lev- Note: eled floor. The base deviation from vertical must not exceed 1/4" on the distance of 10 feet (angle: 0 degrees 6').
  • 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 System Description Contents Machine Specifications ..........2-1 Page I...
  • Page 26 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Description Contents 25 July 2016 Page II...

  • Page 27: Chapter 2: System Description

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Description System Description Machine Specifications Utilities • 115 / 1ph / 60hz 20 Amp Service Standard Speed • 16 Rpm Variable Turntable Speed Vfd Controlled Motor** Features • Orion Model Flex CTS Conveyorized Two Station Automatic Stretch Wrapping Machine (available in various flow direction/ conveyor configurations) •...

  • Page 28: Film Delivery

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Description 25 July 2016 Film Delivery • Instathread Full Corner Compensating Powered Film Drive. • 260 % Stretch From The Factory. 20" Film Tension Delivery System. **optional 30" • Full Authority, Corner Compensating, Vfd Powered Prestretch •...

  • Page 29: Chapter 3: System Operation

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Contents System Operation Contents Operating Procedures ........... 3-1 How to Start and Shut Down Your Wrapping System .
  • Page 30 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation Contents 25 July 2016 Page II...

  • Page 31: Chapter 3: System Operation

    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 Do not use extension cords. Plug your Flex Stretch-wrapper directly Note: into an outlet. POWER SWITCH Located on the panel door, the lockable power switch has two settings: •...

  • Page 32: Carriage Obstacle Detect Error Recovery

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Carriage Obstacle Detect Error Recovery 1. When the obstacle 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.

  • Page 33: Loading The Film

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Loading The Film The film roll can be loaded on the carriage mandrel from either end of the roll. When using tacky film, please verify that the tacky surface of the film is inward on the load. 1.

  • Page 34: Universal Go-To Buttons

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Universal Go-To Buttons The buttons in the chart below are found throughout most HMI screens. The buttons allow the user to easily navigate back to any of the screens. Table 3-1.

  • Page 35: Run Screens

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Run Screens Run Screen This is the Run screen used for primary 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.
  • Page 36 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Table 3-2. The Run Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press this button to wrap the load again. The same wrap parameters are used. Press this button to index the load to the exit conveyor.

  • Page 37: Maintenance Prompt

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Maintenance Prompt This is the Maintenance Prompt Screen. When preventative maintenance is required the prompt and picture of the maintenance is displayed. Press Acknowledge to confirm that the procedure was completed and reset the counter.
  • Page 38 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Table 3-4. The Maintenance Prompts PREVENTATIVE MAINTENANCE REQUIRED FREQUENCY (LOADS) INSPECT RUBBER MULTISTRETCH ROLLERS. CLEAN AS NEEDED. 5,760 INSPECT BELT CONDITION. ADJUST AS NEEDED. 5,760 INSPECT BENEATH TURNTABLE. CLEAN DEBRIS AS NEEDED. 17,280 INSPECT TURNTABLE SUPPORT CASTERS FOR GOOD CONDITION.

  • Page 39: Security Settings Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Security Settings Screen This is the Security Settings screen. This screen allows you to choose the default security setting used after the login expires. Figure 3 - 6 The Security Settings Screen Table 3-5.

  • Page 40: Wrap Setting Screens

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Wrap Setting Screens Wrap Settings Screen To adjust the wrap settings, you must be logged in. Press the login Note: button in the bottom left corner of the screen. Enter ADMIN then press the checkmark, then X to close the keypad.
  • Page 41 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Table 3-6. The Wrap Settings Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press this button to change the speed of the carriage on the downward move, in CARRIAGE DOWN terms of percentage.

  • Page 42: Menu Screens

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Menu Screens Menu Screen This is the Menu screen. This screen allows you to navigate the HMI screens. Figure 3 - 8 The Menu Screen Table 3-7. The Menu Screen Button Descriptions STATE 1 DESCRIPTION Press this button to go to the Jogging Screen.

  • Page 43: Wrapper Jogging Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Wrapper Jogging Screen This is the Wrapper Jogging Screen. This screen allows jogging of each component of the machine. Figure 3 - 9 The Wrapper Jogging Screen Table 3-8.
  • Page 44 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Table 3-8. The Wrapper Jogging Screen Button Descriptions (Continued) STATE 1 DESCRIPTION Press this button to jog the carriage downwards. The carriage move slowly down- wards until the operator releases the jog button. Press this button to manually trigger the brush and cut sequence.

  • Page 45: Conveyor Jogging Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Conveyor Jogging Screen This is the Conveyor Jogging Screen. Your screen may vary depending on the configura- tion of your CTS. Figure 3 - 10 The Conveyor Jogging Screen Table 3-9.
  • Page 46 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Table 3-9. The Conveyor Jogging Screen Button Descriptions (Continued) STATE 1 DESCRIPTION Press and hold this button to jog the enabled conveyors backwards. Release this button to stop the jog. Press and hold this button to jog the enabled conveyors forward.

  • Page 47: Recipe Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Recipe Screen This is the Recipe screen. This screens allows the user to select different wrap recipes quickly. Changes made to a recipe are saved to the active recipe. Figure 3 - 11 The Recipe Screen Table 3-10.

  • Page 48: Production Data Screen

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Production Data Screen This is the Production Data screen. This screen displays the lifetime cycles and shift cycles. You may also reset the shift cycle counter. Figure 3 - 12 The Production Data Screen Table 3-11.

  • Page 49: Recipe Viewing Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Recipe Viewing Screen This is the Recipe Viewing screen. This screen allows you to view each recipe settings. This is helpful for a quick glance at each recipe’s parameters. Figure 3 - 13 The Recipe Viewing Screen...

  • Page 50: Machine Settings Screens

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Machine Settings Screens Machine Settings Screen This is the Machine Settings Screen. This screen allows access to each of the machine set- ting adjustments. Figure 3 - 14 The Machine Settings Screen Table 3-13.

  • Page 51: Main Drive Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Main Drive Screen This is the Main Drive screen. This screen allows adjustment of the Main Drive (turnta- ble.) Figure 3 - 15 The Main Drive Screen Table 3-14.

  • Page 52: Reinforce Wrap Setup

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Reinforce Wrap Setup This is the Reinforce Wraps Setting Screen. This screen allows the user 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...

  • Page 53: Timers Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Timers Screen This is the Timers Screen. This screen allows adjustment of the timers involved in the machine cycle. See the Table below for descriptions and parameters of each setting. Figure 3 - 17 The Timers Screen Table 3-16.
  • Page 54 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Table 3-16. The Timers Screen Button Descriptions (Continued) STATE 1 DESCRIPTION Press this button to modify the Hot Wire On Delay value, in terms of milliseconds. This value determines the amount of time, after the Brush and Cutter arm has begun HOT WIRE ON DELAY to extend, that the Hot Wire will delay before turning on to cut the film.

  • Page 55: Machine Setup Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Machine Setup Screen This is the Machine Setup Screen. This screen is used when setting up the initial machine configuration. The technicians who assembled you machine already set the type of machine you have on this screen.

  • Page 56: Start Delay Screen

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Start Delay Screen This is the Start Delay screen. On this screen, you may set the amount of time, in millisec- onds that the start button must be pressed before the machine starts. Figure 3 - 19 The Start Delay Screen...

  • Page 57: Factory Defaults Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Factory Defaults Screen This is the Factory Defaults Screen. This screen allows authorized users to go back to the factory default settings. Figure 3 - 20 The Factory Defaults Screen Table 3-19.

  • Page 58: Multistretch Settings Screen

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Multistretch Settings Screen This is the Multistretch Settings (MIB) screen. This page is useful primarily to repair per- sonnel when troubleshooting the machine. Figure 3 - 21 The Multistretch Screen Table 3-20.

  • Page 59: Vfd Parameters Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation VFD Parameters Screen This is the VFD Parameters screen. On this screen, you can identify the horsepower for each drive or transfer VFD parameters from the PLC to the VFD’s. Figure 3 - 22 The VFD Parameters Screen...
  • Page 60 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Table 3-21. The VFD Parameters Screen Button Descriptions (Continued) STATE 1 DESCRIPTION Downloads the default Conveyor 1 VFD parameters from the PLC to the VFD. DOWNLOAD CONV. 1 Downloads the default Download Conveyor 2 VFD parameters from the PLC to the DOWNLOAD CONV.

  • Page 61: Conveyor Timers Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Conveyor Timers Screen This is the Conveyor Timers screen. On this screen, you may set the amount of time, in milliseconds that each conveyor runs past the load at conveyor sensor. This screen will vary depending on your machine configuration.

  • Page 62: Dual Insta-Cut Screen

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Dual Insta-Cut Screen This is the Dual Turntable Insta-Cut Screen. This screen is only used for Dual Turntable machines which also have Insta-Cut. Figure 3 - 24 The Dual Insta-Cut Screen Table 3-23.
  • Page 63 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Table 3-23. The Insta-Cut Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press this button to modify the table A Insta-Cut Tear Duration. This is the amount of teeth that the Main Drive will continue to travel at the predefined Insta-Cut A INSTA-CUT TEAR Speed before slowing down to Jog Speed and stopping at home.

  • Page 64: S Insta-Cut Screen

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 S Insta-Cut Screen This is the S Insta-Cut screen. This screen allows adjustments to the timing and speed set- ting associated with the Insta-Cut on the HPS or LPS machines, if so equipped. Figure 3 - 25 The S Insta-Cut Screen...
  • Page 65 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Table 3-24. The Insta-Cut “S” Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 This indicator will glow green when the Insta-Cut puncher is active. Page 3-35...

  • Page 66: Diagnostics Screens

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Diagnostics Screens Diagnostics Screen This is the Diagnostics screen. This screen allows navigation to each of the Diagnostic Screens. Figure 3 - 26 The Diagnostics Screen Table 3-25. The Diagnostics Screen Button Descriptions STATE 1 DESCRIPTION Press this button to go to the Inputs Screen.

  • Page 67: Inputs Screens

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Inputs Screens 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.

  • Page 68: Outputs Screens

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Outputs Screens 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 - 28 The Outputs Screen Table 3-27.

  • Page 69: Vfd Diagnostics Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation VFD Diagnostics Screen This is the VFD Diagnostics screen.This screen allows you to view the diagnostics infor- mation about each VFD. Figure 3 - 29 The VFD Diagnostics Screen Table 3-28.
  • Page 70 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Table 3-28. The VFD Diagnostics Screen Button Descriptions (Continued) STATE 1 DESCRIPTION Gray represents an inactive input. Green represents an active input. Page 3-40...

  • Page 71: Hmi Setup

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation HMI Setup This is the HMI Setup Screen. This screen allows you to choose the HMI language, set the screen brightness, adjust the network settings, calibrate the touchscreen touch points, and set the date and time.

  • Page 72: Maintenance Log Screen

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Maintenance Log Screen This is the Maintenance Log screen. This screen allows you to look back at the mainte- nance alarms and whether they were Acknowledged or Snoozed. Figure 3 - 31 The Maintenance Log Screen...

  • Page 73: Fault History Screen

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Fault History Screen 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.

  • Page 74: Flex Dashboard Remote Viewing

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Flex Dashboard Remote Viewing Setting up Dashboard Remote Viewing Your new flex machine has the capability of remotely viewing the status from your com- puter browser on the same network. You will need your network administrator to advise what IP address should be used for your flex machine.

  • Page 75: Flex Dashboard

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation 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 data, Recent Faults, and Current Recipe running.

  • Page 76: Information & Alarm Messages

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Information & Alarm Messages The message and alarm displays are divided into two separate charts in this section. • Message Displays - Various non-critical status messages • Alarm Displays - Operation critical alarms/faults Message Displays The messages in this section are the various non-critical status messages.
  • Page 77 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Table 3-32. The Information and Alarm Displays (Continued) MESSAGE DESCRIPTION CORRECTION Close the carriage to allow oper- CARRIAGE GATE The carriage gate is currently open. ation. Check the interlock OPEN switch.
  • Page 78 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Table 3-32. The Information and Alarm Displays (Continued) MESSAGE DESCRIPTION CORRECTION Close the carriage to allow oper- CARRIAGE GATE The carriage gate is currently open. ation. Check the interlock OPEN switch.
  • Page 79 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Table 3-32. The Information and Alarm Displays (Continued) MESSAGE DESCRIPTION CORRECTION This is for informational pur- CLAMIPING & The machine is now in the clamp and cut cycle. poses only.
  • Page 80 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Table 3-32. The Information and Alarm Displays (Continued) MESSAGE DESCRIPTION CORRECTION DOWNLOADING VFD The VFD parameters are transferring to the Wait until the process is com- PARAMETERS - VFD’s from the PLC.

  • Page 81: Alarm Displays

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 System Operation Alarm Displays The messages in this section are the various critical status messages. For non-critical alarms, see “Message Displays” on page 3 - 46. Correct the condition and press the Fault Reset button to clear the message and continue machine operation.
  • Page 82 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 System Operation 25 July 2016 Table 3-33. The Information and Alarm Displays (Continued) MESSAGE DESCRIPTION CORRECTION Check the pneumatic supply. LOW AIR PRESSURE The machine pneumatic pressure is low. Ensure 80 PSI is available. Cycle the brush and cutter.
  • Page 83 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Troubleshooting Contents Troubleshooting Contents Troubleshooting ............4-1 Page I...
  • Page 84 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Troubleshooting Contents 25 July 2016 Page II...

  • Page 85: Chapter 4: Troubleshooting

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Troubleshooting Troubleshooting Troubleshooting This troubleshooting chart details problems you may encounter with your Flex series stretchwrapper along with the cause and solution. If the problem(s) cannot be solved after consulting this section and/or appropriate sections of this manual, call Orion at (800) 333-6556.
  • Page 86 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Troubleshooting 25 July 2016 Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Turntable end of cycle positioning counter value is set incorrectly. Refer to the factory default settings value Observe the Turntable end of list.
  • Page 87 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Troubleshooting Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Verify the machine type against the set- tings screen. Note: Standard E and D Table Sprocket tooth count in the models are shipped with 96 tooth table global setup screen is set incor- sprockets, only A and HD (heavy duty)
  • Page 88 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Troubleshooting 25 July 2016 Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Check for a mechanical bind in the rota- tion mechanicals, such as: worn bearing(s) Current Limiter in the rotation or casters, incorrectly tensioned chain, VFD is activating.
  • Page 89 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Troubleshooting Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION E-Stop button is Flashing or Green Start button is not illuminated. No control Power / E-Stop Condi- Perform E-Stop Reset (pull E-Stop button tion.
  • Page 90 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Troubleshooting 25 July 2016 Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Check the numerical value of the carriage up and down speeds on the touchscreen. Password may be required depending on Carriage Speeds set below 5%.
  • Page 91 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Troubleshooting Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Remove upper-rear access panel on the back of the mast. Observe the position of the lift belt roller switch at the top, inside of the mast.
  • Page 92 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Troubleshooting 25 July 2016 Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Locate carriage lift control fuse. Remove Blown Fuse. fuse and check continuity. Bad Fuse? Replace with correct type. Carriage Lift Perform motor test per motor manufac- (Up &...
  • Page 93 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Troubleshooting Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Belt is tangled around drum. Belt is wrapped backwards or twisted. Check switch by manually activating (wiggling) the roller tip. If the switch does Carriage bottom travel switch did not activate and release it's input on the not activate correctly, possibly...
  • Page 94 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Troubleshooting 25 July 2016 Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Observe the feedback value of the hall effect located on the touchscreen. Zero or Gain settings for the hall Re-set the ZERO and GAIN values effect (Film Feed Trigger) are according to the film feed setup instruc-...
  • Page 95 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Troubleshooting Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Perform motor test per motor manufac- Film Feed / Stretch Functions Motor failure. turer's recommendations. No Power Feed Replace Motor as needed. Observe the feedback value of the hall effect located on the touchscreen.
  • Page 96 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Troubleshooting 25 July 2016 Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Film may be wound incorrectly from the manufacturer. Look for heavy, raised stripes along the feed axis of the film. This Film is wound incorrectly.
  • Page 97 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Troubleshooting Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Carefully review the rubber rollers for cuts or nicks. Any raised spots can dam- Film Breakage Issues age the film and propagate a tear. Film Breaks Inside The Rubber rollers are damaged Raised spots can be carefully shaved or...
  • Page 98 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Troubleshooting 25 July 2016 Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Observe the load. See if the film break starts at the corners of the pallet. Options are: 1. Reduce the film tension at the touch- Pallet greatly overhangs the load.
  • Page 99 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Troubleshooting Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Look for the clamp to close smoothly, but Clamp close delay timer at the at the wrong time. touchscreen is incorrect for the Observe the factory preset value on the application.
  • Page 100 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Troubleshooting 25 July 2016 Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Look for the arm to activate smoothly, but Brush extend timer at the touch- at the wrong time. screen is incorrect for the applica- Observe the factory preset value on the tion.
  • Page 101 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Troubleshooting Table 4-1. Troubleshooting Chart (Continued) PROBLEM POSSIBLE CAUSE SOLUTION Look for underhung loads, or loads that are not centered on the table or in the proper wrap zone (RT only). The rear side of the load must be in line with the pallet Load not positioned properly.
  • Page 102 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Troubleshooting 25 July 2016 Page 4-18...
  • Page 103 Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Maintenance Contents Maintenance Contents Maintenance ............5-1 Motor Maintenance .

  • Page 104: Maintenance Contents

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Maintenance Contents 25 July 2016 Page II...

  • Page 105: Chapter 5: Maintenance

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Maintenance Maintenance Maintenance All general information about machine maintenance is based on normal machine working conditions: indoor, moderate dust and low moisture environment, and maximum rotation of 15 RPM. They should be regarded as guidelines, reviewed and corrected according to requirements of actual use and conditions.

  • Page 106: Tower Raceways Maintenance

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Maintenance 25 July 2016 Tower Raceways Maintenance The film distributor (carriage) is sliding on the plastic guides attached behind its back plate. The section of the tower on which the plastic guides move (raceways) should be cleaned and re-greased approximately every 600 hours of machine operation.

  • Page 107: Proximity Sensor Adjustment

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Maintenance Proximity Sensor Adjustment Occasionally the Feed Back Proximity Sensor may need some adjustment. The position of the feed back proximity sensor against the cam is shown in Figure 5 - 1. 1.
  • Page 108 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Maintenance 25 July 2016 14. If not satisfied repeat the procedure. Figure 5 - 2 Proximity Sensor Adjustment Page 5-4...

  • Page 109: Cleaning The Stretch Rollers

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Maintenance Cleaning The Stretch Rollers The film carriage requires the most attention when cleaning. The film carriage requires regular cleaning even if there are no product spills into the carriage area. Absolutely DO NOT use wash down methods on the film carriage.

  • Page 110: Preventative Maintenance Schedule

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Maintenance 25 July 2016 Preventative Maintenance Schedule PM Intervals PM Intervals are based on an average usage of a 16 hour production day. Table 5-2. PM Frequency FREQUENCY PERIOD DESCRIPTION (Hour) (Shift) (Day) 5760 (Month)

  • Page 111: All H&L Heavy Duty (Ring Bearing) Series

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Maintenance All H&L Heavy Duty (Ring Bearing) Series 5,760 Loads Or One Month • Inspect rubber stretch rollers. Clean as needed per instructions in manual. • Inspect belt condition. Adjust as needed. 17,280 Loads or three months.

  • Page 112: Hpa Lpa Series

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Maintenance 25 July 2016 HPA LPA Series 5,760 Loads or one month • Inspect rubber stretch rollers. Clean as needed per instructions in manual. • Inspect belt condition. Adjust as needed. 17,280 Loads or three months. •...

  • Page 113: @ 17, 280 Loads Or Three Months

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Maintenance RTD Series @ 5760 Loads or one month • Inspect rubber stretch rollers. Clean as needed per instructions in manual. • Inspect belt condition. Adjust as needed. @ 17, 280 Loads or three months. •...
  • Page 114 Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Maintenance 25 July 2016 Page 5-10...

  • Page 115: Chapter 6: Electrical Prints And Mechanical Drawings

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Electrical Prints and Mechanical Drawings 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: Electrical Prints

    Orion Machine Manual Revision 3.0 CTS Flex Stretchwrapper 25 July 2016 Electrical Prints and Mechanical Drawings Electrical Prints and Mechanical Drawings Electrical Prints Page 6-1...
  • Page 129 2.5A Adjust DC OK 100-240V~1.5A 50-60Hz...

  • Page 132: Mechanical Drawings

    Machine Manual Orion CTS Flex Stretchwrapper Revision 3.0 Electrical Prints and Mechanical Drawings 25 July 2016 Mechanical Drawings Download the mechanical drawings for your particular model on the Orion Webpage. http://www.orionpackaging.com/landing/cts-manual-download/ Page 6-2...

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