Page 1 FLEX STRETCHWRAPPER MANUAL Models RTA, RTD, HPA, HPD, LPA, LPD Revision Date - February 15, 2016 Machine Manual 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...
Page 2 © 2016 Pro Mach. All Rights Reserved. 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 transfer of ownership, by rental or lease.
Page 3: Table Of Contents
How to Erect an RTA or RTD Flex Orion ....... .
Page 4 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Table of Contents 15 February 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 Flex Stretchwrapper 15 February 2016 Table of Contents Message Displays ..........3-48 Alarm Displays.
Page 6 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Table of Contents 15 February 2016 Page IV...
Page 7 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 List of Figures List of Figures Chapter 1: Introduction and Safety Fork Tube Access Sticker ......... . . 1-11 Attaching Strap .
Page 8 Machine Manual Orion Flex Stretchwrapper Revision 3.0 List of Figures 15 February 2016 The Diagnostics Screen..........3-39 The Inputs Screen .
Page 9 How to Erect an RTA or RTD Flex Orion ....... .
Page 10 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Introduction and Safety Contents 15 February 2016 Page II...
Page 11: Chapter 1: Introduction And Safety
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
15 February 2016 About this Manual Orion is committed to helping you maximize the productivity of your system. This manual is specifically designed for your packaging system, to assist you in the operation and maintenance of your new equipment. Please take the time to familiarize yourself with the contents of this manual.
Page 13: Flex Series Warranty
All defective components valued at $300 or more list price must be returned to Orion in Alexandria, MN. It is at Orion's sole discretion as to whether any given component must be returned, regardless of its value, for the purpose of determination of warranty status and the nature of the defect.
Page 14: Safety
15 February 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 Flex Stretchwrapper 15 February 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 Flex Stretchwrapper Revision 3.0 Introduction and Safety 15 February 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 Flex Stretchwrapper 15 February 2016 Introduction and Safety Operation Safety The following safety precautions are recommended for all personnel who will operate this Flex Stretchwrapper. • Operators should immediately report unsafe working conditions to a supervisor.
Page 18: Maintenance Safety
Machine Manual Orion Flex Stretchwrapper Revision 3.0 Introduction and Safety 15 February 2016 Maintenance Safety The following safety precautions are recommended for all personnel who are responsible for the maintenance or service this 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 Flex Stretchwrapper 15 February 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 Flex Stretchwrapper Revision 3.0 Introduction and Safety 15 February 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 Flex Stretchwrapper 15 February 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.
Page 22: Inspection
2. Perform a visual inspection of the electrical and mechanical parts for loosened joints and / or broken connections. Any suspected shipping damage must be reported imme- diately to the freight carrier. Any transport damage cannot be claimed to Orion Pack- aging Inc.
Page 23: Assembly Procedure
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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: How To Erect An Rta Or Rtd Flex Orion
Flex Stretchwrapper Revision 3.0 Introduction and Safety 15 February 2016 How to Erect an RTA or RTD Flex Orion Observe safety precautions in the user manual. Always follow OSHA and WARNING plant regulations when placing machinery. 1. Attach a strap around the center crossmember. Secure to properly rated lifting device.
Page 25: Positioning Wrapper
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 Introduction and Safety 3. Your spotter can position the machine precisely while the lift is holding the tower ver- tically. Figure 1 - 4 Positioning Wrapper 4. Remove the shipping feet while the machine is still held by the lift.
Page 26: Drill Mounting Holes
Machine Manual Orion Flex Stretchwrapper Revision 3.0 Introduction and Safety 15 February 2016 5. Using a hammer drill, drill the mounting holes in the floor with the correct drill bit to match the mounting hardware. Figure 1 - 6 Drill Mounting Holes 6.
Page 27: Loosen Tension Once Bolted Down
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 Introduction and Safety 7. Once the machine is properly bolted down, loosen the tension to the crossmember. Figure 1 - 8 Loosen Tension Once Bolted Down 8. Climb the ladder and remove the strap.
Page 28: Attach Safety Hoop
Machine Manual Orion Flex Stretchwrapper Revision 3.0 Introduction and Safety 15 February 2016 9. Bolt the safety hoop to the bottom of the rotary arm. Figure 1 - 10 Attach Safety Hoop 10. Verify the machine is properly secured and test the machine operation.
Page 29 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Description Contents System Description Contents Machine Specifications ..........2-1...
Page 30 Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Description Contents 15 February 2016 Page II...
Page 31: Chapter 2: System Description
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Description System Description Machine Specifications Utilities • 115 / 1ph / 60hz 20 Amp Service Standard Speed • 16 Rpm Variable Tower Speed Vfd Controlled Motor** Drive • Heavy Duty Chain Drive •...
Page 32: Structural Features
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Description 15 February 2016 • Variable Frequency Drive Motor • Multi-point Uhmw Precision Carriage Guidance System Structural Features • Structural Steel Construction Throughout • Easy Access To All Components • Limited Proprietary Parts For Ease Of Maintenance Visit our Website At www.orionpackaging.com...
Page 33: Chapter 3: System Operation
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation Contents System Operation Contents Operating Procedures ........... 3-1 How to Start and Shut Down Your Wrapping System .
Page 34 Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation Contents 15 February 2016 Alarm Displays........... . 3-52...
Page 35: Chapter 3: System Operation
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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 36: Carriage Obstacle Detect Error Recovery
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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 37: Loading The Film
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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.
Page 38: Universal Go-To Buttons
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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.
Page 39: Run Screens
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 40 Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 Table 3-2. The Run Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press this button to either stop the current wrap cycle or reset any displayed faults.
Page 41: Maintenance Prompt
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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. Press Snooze to delay the counter for 100 cycles before the prompt re-displays.
Page 42 Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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.
Page 43: Security Settings Screen
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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...
Page 44: Wrap Setting Screens
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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 45 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation Table 3-6. The Wrap Settings Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 CARRIAGE DOWN Press this button to change the speed of the carriage on the downward move, in SPEED terms of percentage.
Page 46: Menu Screens
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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...
Page 47: Jogging Screen
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation Jogging Screen This is the Jogging Screen. This screen allows jogging of each component of the machine. Figure 3 - 9 The Jogging Screen Table 3-8. The Jogging Screen Button Descriptions...
Page 48 Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 Table 3-8. The 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.
Page 49: Carriage Jog Screen
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation Carriage Jog Screen This is the Carriage Jog Screen. You can set the Carriage Up and Down Speeds, as well as jog the carriage up or down. Figure 3 - 10...
Page 50 Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 Table 3-9. The Carriage Jog Screen Button Descriptions (Continued) STATE 1 DESCRIPTION Press this button to reset faults. If you press this button while the machine is run- ning, the machine will abort the current wrap cycle.
Page 51: Recipe Screen
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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.
Page 52: Production Data Screen
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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...
Page 53: Recipe Viewing Screen
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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.
Page 54: Machine Settings Screens
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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...
Page 55 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation Table 3-13. The Machine Settings Screen Button Descriptions (Continued) STATE 1 DESCRIPTION Press this button to go to the Insta-Cut Screen. See “Insta-Cut Screen” on page 3 - INSTA-CUT Press this button to go to the Dual Turntable Screen.
Page 56: Main Drive Screen
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 Main Drive Screen This is the Main Drive screen. This screen allows adjustment of the Main Drive (turntable or rotary arm drive.) Figure 3 - 15 The Main Drive Screen Table 3-14.
Page 57: Reinforce Wrap Setup
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation 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.
Page 58: Timers Screen
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 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.
Page 59 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation Table 3-16. The Timers Screen Button Descriptions (Continued) STATE 1 DESCRIPTION Press this button to modify the Brush Extend Delay value, in terms of milliseconds. This value determines the amount of time, after the Brush and Cutter arm has begun...
Page 60: Machine Setup Screen
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 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 61 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation Table 3-17. The Machine Setup Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press this button to enable or disable the Arm ARM BACKUP Backup feature (RTA model only). When enabled,...
Page 62: Start Delay Screen
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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.
Page 63: Factory Defaults Screen
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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 64: Multistretch Settings Screen
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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 65: The Vfd Parameters Screen
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation The 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.
Page 66: Insta-Cut Screen
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 Insta-Cut Screen This is the Insta-Cut screen. This screen is only used for machine equipped with Insta-Cut. You may enable or disable Insta-Cut or adjust any of the Insta-Cut parameters.
Page 67 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation Table 3-22. The Insta-Cut Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 Press this button to modify the Insta-Cut Speed. This is the speed at which the Main INSTA-CUT SPEED HZ Drive will travel during the Insta-Cut sequence.
Page 68: Dual Turntable Screen
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 Dual Turntable Screen This is the Dual Turntable Screen. This screen is only used for Dual Turntable equipped machines. From this screen, you may set the A or B only tables to run or you can choose to alternate between running the A and B tables every other cycle.
Page 69: Dual Insta-Cut Screen
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation 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 - 25 The Dual Insta-Cut Screen Table 3-24.
Page 70 Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 Table 3-24. 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...
Page 71: S Insta-Cut Screen
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation 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.
Page 72 Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 Table 3-25. 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 3-38...
Page 73: Diagnostics Screens
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation Diagnostics Screens Diagnostics Screen This is the Diagnostics screen. This screen allows navigation to each of the Diagnostic Screens. Figure 3 - 27 The Diagnostics Screen Table 3-26. The Diagnostics Screen Button Descriptions...
Page 74: The Inputs Screens
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 The 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.
Page 75: The Outputs Screens
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation The 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.
Page 76: The Vfd Diagnostics Screen
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 The VFD Diagnostics Screen This is the VFD Diagnostics screen.This screen allows you to view the diagnostics infor- mation about each VFD. Figure 3 - 30 The VFD Diagnostics Screen Table 3-29.
Page 77: Hmi Setup
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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 78: Maintenance Log Screen
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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.
Page 79: Fault History Screen
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation Fault History Screen This is the Fault History screen. The screen displays the faults and the time they occurred. Figure 3 - 33 The Fault History Screen Table 3-32. The Fault History Screen Button Descriptions...
Page 80: Flex Dashboard Remote Viewing
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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 81: Flex Dashboard
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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 82: Information & Alarm Messages
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 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 83 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 System Operation Table 3-33. The Information and Alarm Displays (Continued) MESSAGE DESCRIPTION CORRECTION CARRIAGE GATE Close the carriage to allow oper- OPEN The carriage gate is currently open. ation. Check the interlock switch.
Page 84 Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 Table 3-33. The Information and Alarm Displays (Continued) MESSAGE DESCRIPTION CORRECTION CLAMIPING & This is for informational pur- CUTTING FILM The machine is now in the clamp and cut cycle.
Page 85 Wait until the process is com- PLEASE WAIT VFD’s from the PLC. pleted. COMMUNICATION There is an X2X communication fault, press and Contact Orion Packaging if FAULT - PRESS E-STOP release the E-stop button to clear the fault. problem persists. TO CLEAR FAULT RS485...
Page 86: Alarm Displays
Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 Alarm Displays The messages in this section are the various critical status messages. For non-critical alarms, see “Message Displays” on page 3 - 48. Correct the condition and press the Fault Reset button to clear the message and continue machine operation.
Page 87 See VFD manual for fault code information. CARRIAGE VFD NOT READY COMMUNICATION There is an X2X communication fault, press and Contact Orion Packaging if ERROR release the E-stop button to clear the fault. problem persists. RS485 COMMUNICATION There is an RS485 communication fault, press...
Page 88 Machine Manual Orion Flex Stretchwrapper Revision 3.0 System Operation 15 February 2016 Page 3-54...
Page 89 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 Troubleshooting Contents Troubleshooting Contents Troubleshooting ............4-1...
Page 90 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Troubleshooting Contents 15 February 2016 Page II...
Page 91: Chapter 4: 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 92 Check the value of the DEC list. parameter on the Table / Tower VFD. Ensure that it is set within the Orion factory default values. Check error message on the Table / Tower VFD display. Component failure. Refer to the supplied VFD user manual for error message.
Page 93 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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...
Page 94 Refer to the supplied VFD Manual for VFD parameter settings are procedure. incorrect. Refer to the VFD manual and the Orion parameter settings sheet supplied with the machine for maximum frequency settings. Check AC voltage (at the On-Off switch terminals) while the machine is running under load.
Page 95 Review the parameter settings in the VFD. Refer to the supplied VFD Manual for VFD parameter settings are incor- procedure. rect. Refer to the VFD manual and the Orion parameter settings sheet supplied with the Turntable / Tower Will Not machine for maximum frequency settings. Rotate Locate Table / Tower rotation control Blown Fuse.
Page 96 Review the parameter settings in the VFD. Refer to the supplied VFD Manual for VFD parameter settings are procedure. incorrect. Refer to the VFD manual and the Orion parameter settings sheet supplied with the machine for maximum frequency settings. Page 4-6...
Page 97 Maximum speed setting on the plied VFD Manual for procedure. Down (In Either Manual Mode VFD is incorrect. Refer to the VFD manual and the Orion Or During An Auto Wrap parameter settings sheet supplied with the Cycle) machine for maximum frequency settings.
Page 98 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Troubleshooting 15 February 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 (Up &...
Page 99 Review the parameter settings in the VFD. Refer to the supplied VFD Manual for VFD parameter settings are procedure. incorrect . Refer to the VFD manual and the Orion parameter settings sheet supplied with the machine for maximum frequency settings. Page 4-9...
Page 100 Maximum speed setting on the plied VFD Manual for procedure. VFD is incorrect. Refer to the VFD manual and the Orion parameter settings sheet supplied with the machine for maximum frequency settings. Check to make sure hall effect device is hall effect device is positioned not touching the dancer bar cam.
Page 101 VFD. Refer to the sup- Minimum speed setting on the plied VFD Manual for procedure. VFD is incorrect. Refer to the VFD manual and the Orion parameter settings sheet supplied with the machine for minimum frequency settings. Review the film's stretch capability. The film used should be able to effectively stretch 280% at ambient temperatures.
Page 102 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Troubleshooting 15 February 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 103 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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.
Page 104 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Troubleshooting 15 February 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 105 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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 106 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Troubleshooting 15 February 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 107 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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 108 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Troubleshooting 15 February 2016 Page 4-18...
Page 109 Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 Maintenance Contents Maintenance Contents Maintenance ............5-1 Motor Maintenance .
Page 110 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Maintenance Contents 15 February 2016 Page II...
Page 111: Chapter 5: Maintenance
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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 112: Tower Raceways Maintenance
Machine Manual Orion Flex Stretchwrapper Revision 3.0 Maintenance 15 February 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 113: Proximity Sensor Adjustment
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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.
Page 114: Proximity Sensor Adjustment
Machine Manual Orion Flex Stretchwrapper Revision 3.0 Maintenance 15 February 2016 14. If not satisfied repeat the procedure. Figure 5 - 2 Proximity Sensor Adjustment Page 5-4...
Page 115: Cleaning The Stretch Rollers
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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 116: Preventative Maintenance Schedule
Machine Manual Orion Flex Stretchwrapper Revision 3.0 Maintenance 15 February 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)
Page 117: All H&L Heavy Duty (Ring Bearing) Series
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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.
Page 118: Hpa Lpa Series
Machine Manual Orion Flex Stretchwrapper Revision 3.0 Maintenance 15 February 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 119: @ 17, 280 Loads Or Three Months
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 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 120 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Maintenance 15 February 2016 Page 5-10...
Page 121: Chapter 6: Electrical Prints And Mechanical Drawings
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 Electrical Prints and Mechanical Drawings Electrical Prints and Mechanical Drawings Electrical Prints ......... . . 6-1 Mechanical Drawings .
Page 122 Machine Manual Orion Flex Stretchwrapper Revision 3.0 Electrical Prints and Mechanical Drawings 15 February 2016 Page 2...
Page 123: Electrical Prints
Orion Machine Manual Revision 3.0 Flex Stretchwrapper 15 February 2016 Electrical Prints and Mechanical Drawings Electrical Prints and Mechanical Drawings Electrical Prints Page 6-1...
Page 166: Mechanical Drawings
Machine Manual Orion Flex Stretchwrapper Revision 3.0 Electrical Prints and Mechanical Drawings 15 February 2016 Mechanical Drawings Download the mechanical drawings for your particular model on the Orion Webpage. http://www.orionpackaging.com/landing/flex-manual-download/ Page 6-2...

This manual is also suitable for:

Flex series Flex rtd Flex lpa Flex lpd Flex hpa Flex hpd

Orion FLEX RTA Manual

Chapter 1: Introduction and Safety

Introduction

Flex Series Warranty

Safety

Installation and First Time Power up

How to Erect an RTA or RTD Flex Orion

Chapter 2: System Description

Machine Specifications

Chapter 3: System Operation

Chapter 3: System Operation

Operating Procedures

Universal Go-To Buttons

Run Screens

Wrap Setting Screens

Menu Screens

Machine Settings Screens

Diagnostics Screens

Flex Dashboard Remote Viewing

Information & Alarm Messages

Chapter 4: Troubleshooting

Troubleshooting

Chapter 5: Maintenance

Maintenance

Chapter 6: Electrical Prints and Mechanical Drawings

Electrical Prints

Mechanical Drawings

Quick Links

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Summary of Contents for Orion FLEX RTA

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Table of Contents