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Orion Flex Series Manual

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AG360 Flex
STRETCHWRAPPER
MANUAL
Model
AG 360 RoboWrapper
Revision Date - June 28, 2017
Machine Manual
Revision 1.1
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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  • Page 1 AG360 Flex STRETCHWRAPPER MANUAL Model AG 360 RoboWrapper Revision Date - June 28, 2017 Machine Manual Revision 1.1 4750 County Road 13 NE Alexandria, MN 56308 Phone: (901) 888-4170 Toll Free: (800) 333-6556 FAX: (901) 365-1071...
  • Page 2 © 2017 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

    Flex Series Warranty ........
  • Page 4 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Table of Contents 28 June 2017 Chapter 3: System Operation Operating Procedures ........... 3-1 Charging the AG 360 .
  • Page 5 Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Table of Contents Alarm Message Chart........... . 4-6 Chapter 5: Maintenance Maintenance Recommendations.
  • Page 6 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Table of Contents 28 June 2017 Page IV...
  • Page 7 Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 List of Figures List of Figures Chapter 1: Introduction and Safety Fork Tube Access Locations ......... . 1-7 Securing the Lifting Eye Bolt .
  • Page 8 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 List of Figures 28 June 2017 The Manual Screen ..........3-24 The Fault History Screen .
  • Page 9 Flex Series Warranty ........
  • Page 10 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Introduction and Safety Contents 28 June 2017 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: Copyright Notice

    For most components valued at under $300 list price, Orion does not require that the defective compo- nent be returned. 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 13: Safety

    Introduction and Safety 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. All electrical power and compressed air must be disconnected prior to all inspection, maintenance or repair work.

  • Page 14: Operation Safety

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Introduction and Safety 28 June 2017 Operation Safety The following safety precautions are recommended for all personnel who will operate this AG 360 RoboWrapper. • Operators should immediately report unsafe working conditions to a supervisor.

  • Page 15: Hazard Messages

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Introduction and Safety 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 16: Lockout And Tagout Recommendations

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Introduction and Safety 28 June 2017 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 17: Installation And First Time Power Up

    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 18: Machine Installation

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Introduction and Safety 28 June 2017 Machine Installation • After the visual inspection has been completed, the electrical power shall be con- nected as specified on the diagrams supplied with the machine for charging.

  • Page 19: Bolting On The Tower

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Introduction and Safety 4. Fix and tighten the tower by three M8 bolts. Use Loctite to secure the screws. CAUTION Figure 1 - 4 Bolting on the Tower 5. Open the machine cover and check the battery connections..

  • Page 20: Installing The Tension Spring

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Introduction and Safety 28 June 2017 Check the battery cable connection. Figure 1 - 6 Connecting the Battery Cable 7. Move the steering arm towards right side, and install the tension spring.

  • Page 21: Connecting The Battery Charger

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Introduction and Safety 8. Before running the machine for the first time, please charge the battery at least 8 hours. Figure 1 - 8 Connecting the Battery Charger Page 1-11...

  • Page 22: Pallet Guide Arm And Sensing Arm Wheel

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Introduction and Safety 28 June 2017 Pallet Guide Arm and Sensing Arm Wheel Ensure the position of steering arm tension spring is in correct position and smooth turning movement, and sensing arm wheel is properly inflated. See “Aligning the AG 360 with the Pallet”...

  • Page 23: Operating Parameters

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Introduction and Safety Operating Parameters To ensure safe and reliable operation, please check the below conditions before installing the machine: • Power source available for charging • Battery charge power is 110v/220v (+- 10%) •...
  • Page 24 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Introduction and Safety 28 June 2017 Page 1-14...

  • Page 25: Chapter 2: System Description

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Description Contents System Description Contents Machine Specifications ..........2-1 Machine Layout Drawings .
  • Page 26 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Description Contents 28 June 2017 Page II...

  • Page 27: Chapter 2: System Description

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Description System Description Machine Specifications Table 2-1. Specifications DESCRIPTION AG 360 Max Load Size Unlimited Min. Load Size 24" W x 24" L Max. Load Weight Unlimited Min Load Weight Approx.

  • Page 28: Machine Layout Drawings

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Description 28 June 2017 Machine Layout Drawings Machine Dimensions The layout drawing below shows the machine dimensions, as sold. Figure 2 - 1 Machine Layout Drawing 62.32" Page 2-2...

  • Page 29: Machine Component Identification

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Description Machine Component Identification The layout drawing below shows the machine dimensions, as sold. Figure 2 - 2 Warning lamp Machine Layout Drawing Slide guide mast Control electronic device...
  • Page 30 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Description 28 June 2017 Page 2-4...

  • Page 31: Chapter 3: System Operation

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Contents System Operation Contents Operating Procedures ........... 3-1 Charging the AG 360 .
  • Page 32 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation Contents 28 June 2017 Page II...

  • Page 33: Chapter 3: System Operation

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation System Operation Operating Procedures Charging the AG 360 1. Prior to charging, ensure that the battery connector is attached. 2. Plug the supplied cord to the charging connector.

  • Page 34: How To Start And Shut Down Your Wrapping System

    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.

  • Page 35: Transporting The Ag 360

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Transporting the AG 360 When Battery Power Is Present: 1. Pivot the handle down and pull it straight outward. 2. Press A for Cart Reverse. Press B for Cart Forward.

  • Page 36: Steering Spring Tension Release

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 Steering Spring Tension Release There is a spring tension release handle located under the battery compartment at the front of the machine. The handle is on the opposite side of the direction that the machine steers.

  • Page 37: Aligning The Ag 360 With The Pallet

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Aligning the AG 360 with the Pallet Prior to wrapping a load, the AG 360 must be properly aligned with the pallet. 1. To adjust the guide wheel, loosen the bolt on the end of the guide arm with a 17 mm wrench.

  • Page 38: Loading The Film

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 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 39: Film Cling Diagram

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation 7. Verify the film cling is inward on the load. If not, the film spool will need to be flipped. Figure 3 - 10 Film Cling Diagram...

  • Page 40: Carriage Prestretch Adjustment

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 Carriage Prestretch Adjustment 1. Switch the power off and remove the pre-stretch cover. Figure 3 - 11 Removing the Pre- Stretch Cover 2. Push the safety lock in and then use the handle to adjust the prestretch percentage. Lift up the handle for high prestretch percentage or lower down to for low prestretch per- centage.

  • Page 41: Safety Line On Safety Lock

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation 3. Check the below items to ensure that the prestretch adjustment is properly locked into place: A. The mark line is back to its home position. Figure 3 - 13...

  • Page 42: Universal Go-To Buttons

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 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 43: Run Screens

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Run Screens Run Screen This is the Run screen used for primary functions of the machine. You may start the machine, view the battery power level, and alarm conditions.
  • Page 44 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 Table 3-2. The Run Screen Button Descriptions (Continued) STATE 1 DESCRIPTION This is the battery indicator. This shows the current percentage of the battery. If the battery is below a certain percentage, a warning will display to warn the operator to move the unit to a charging station.

  • Page 45: Recipe Screens

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Recipe Screens 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 46 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 Table 3-3. The Recipe Screen Button Descriptions (Continued) STATE 1 DESCRIPTION Press this button to set the delay timer for the insta-cut. This allows the user to delay INSTA CUT DELAY the timing of the instacut by increasing the timer.

  • Page 47: Recipe Select Screen

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Recipe Select 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 48: User Setting Screens

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 User Setting Screens Wrap Settings Screen This is the Wrap Settings screen. This screen allows you to set the number of top and bot- tom wraps and the speed percentage of the carriage up and down travel. You may also...
  • Page 49 Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Table 3-5. The Wrap Settings Screen Button Descriptions (Continued) STATE 1 DESCRIPTION Press this button to set the number of bottom wraps applied to the load. Parameters BOTTOM WRAPS are 1-20.

  • Page 50: Menu Screens

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 Menu Screens Menu Screen This is the Menu screen. This screen allows you to navigate the HMI screens. Figure 3 - 19 The Menu Screen Table 3-6. The Menu Screen Button Descriptions...

  • Page 51: Jogging Screen

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Jogging Screen This is the Jogging Screen. This screen allows jogging of the carriage. Figure 3 - 20 The Jogging Screen Table 3-7. The Jogging Screen Button Descriptions...

  • Page 52: Production Data Screen

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 Production Data Screen This is the Production Data screen. This screen displays the shift cycles, lifetime cycles, and revolution counters. You may also reset the shift cycle counter.

  • Page 53: Tension Sensor Calibration Screen

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Tension Sensor Calibration Screen This is the Tension Sensor Calibration screen. This screen allows the user to calibrate the tension sensor. Figure 3 - 22 The Tension Sensor Calibration Screen Table 3-9.

  • Page 54: Diagnostics Screen

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 Diagnostics Screen This is the Diagnostics screen. This screen allows navigation to each of the Diagnostic Screens. Figure 3 - 23 The Diagnostics Screen Table 3-10. The Diagnostics Screen Button Descriptions...

  • Page 55: The Inputs Status Screen

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation The Inputs Status Screen This is the Inputs Status screen. This screen shows the status of the machine inputs. There is another screen similar to this for displaying output status.

  • Page 56: The Manual Screen

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 The Manual Screen This is the Manual screen. This screen shows allows the user to view the manual. Figure 3 - 25 The Manual Screen Table 3-12. The Manual Screen Button Descriptions...

  • Page 57: Fault History Screen

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Fault History Screen This is the Fault History screen. The screen displays the faults and the time they occurred. Figure 3 - 26 The Fault History Screen Table 3-13.

  • Page 58: Hmi Setup

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 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 59: Battery Settings Screen

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Battery Settings Screen This is the Battery Settings screen. This allows the user to view the voltage and the voltage limits. Figure 3 - 28 The Battery Settings Screen Table 3-15.

  • Page 60: Machine Settings Screens

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 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 - 29...
  • Page 61 Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 System Operation Table 3-16. The Machine Settings Screen Button Descriptions (Continued) STATE 1 DESCRIPTION STATE 2 CARRIAGE HOME Press this button to display the numeric keypad to enter the carriage home timeout TIMEOUT TIME timer.
  • Page 62 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 System Operation 28 June 2017 Page 3-30...
  • Page 63 Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Troubleshooting Contents Troubleshooting Contents Component Inspections..........4-1 Battery Connections .
  • Page 64 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Troubleshooting Contents 28 June 2017 Page II...

  • Page 65: Chapter 4: Troubleshooting

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Troubleshooting Troubleshooting Component Inspections This section outlines the most common conditions prohibiting operation. If the machine is powered up, an alarm message will display if there is a sensor prohibiting operation.

  • Page 66: Main Breaker Electrical Disconnect/ Hard Reset

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Troubleshooting 28 June 2017 Main Breaker Electrical Disconnect/ Hard Reset If the machine is fully charged and all battery connections are OK, but there is no machine power, the main breaker could be off. The main breaker is located behind the right side panel.

  • Page 67: Side Panel Interlock Switch

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Troubleshooting Side Panel Interlock Switch Each side panel has an interlock switch that prevents operation when either side panel is open. Prior to startup, ensure that each side door is completely closed and the interlock connector is properly engaged into the switch.

  • Page 68: Carriage Obstacle Detect Limit Switch

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Troubleshooting 28 June 2017 Carriage Obstacle Detect Limit Switch There is an obstacle detect switch located on the bottom of the carriage. When the switch is pressed during operation, such as the case of something under the carriage, the machine will stop.

  • Page 69: Safety Bumper

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Troubleshooting Safety Bumper There is a safety bumper on the front of the machine that stops the machine when it hits and obstacle during operation. An alarm message will display on the HMI if the bumper stops the machine.

  • Page 70: Alarm Message Chart

    28 June 2017 Alarm Message Chart 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 71 Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Troubleshooting Table 4-1. Alarm Message Chart (Continued) ALARM NO FAULT SOLUTION HEIGHT PHOTOCELL NOT FIND • Photocell not find object at start OBJECT • Photocell broken or circuit fault LIFT UNIT NOT IN HOME POSI •...
  • Page 72 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Troubleshooting 28 June 2017 Page 4-8...
  • Page 73 Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Maintenance Contents Maintenance Contents Maintenance Recommendations......... . . 5-1 Opening Control Panels and Covers .
  • Page 74 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Maintenance Contents 28 June 2017 Page II...

  • Page 75: Chapter 5: Maintenance

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Maintenance Maintenance Maintenance Recommendations All general information about machine maintenance is based on normal machine working conditions: indoor, flat concrete surface, moderate to low dust and low moisture environ- ment.

  • Page 76: Left Side Enclosure

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Maintenance 28 June 2017 Left Side Enclosure The left enclosure contains the PLC and drives along with terminal blocks. Figure 5 - 3 Left Side Electrical Enclosure Right Side Enclosure The right enclosure contains the power supply, VFD, and terminal blocks.

  • Page 77: Charging And Indicator Connectors On Door

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Maintenance Charging and Indicator Connectors on Door If the batteries are not charging, an additional check would be the connector on the back of the door panel. Ensure the connections are properly plugged in and not loose.

  • Page 78: Carriage Lift Chain Adjustment

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Maintenance 28 June 2017 Carriage Lift Chain Adjustment Remove the tower cover ( A ) adjust the screw, and ( B ) adjust the chain deflection ( R ) within these parameters: 10 - 15mm (3/8” - 5/8”).

  • Page 79: Cleaning The Stretch Rollers

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Maintenance Cleaning The Stretch Rollers Inspect rubber stretch rollers every 5,760 Loads or once per month. Clean as needed per instructions below. 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.

  • Page 80: Steering Handle Tension Adjustment

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Maintenance 28 June 2017 Steering Handle Tension Adjustment The steering handle tension can be adjusted by changing the position of the spring. To adjust, removed the spring position and change to one of the three positions. The tighter the tension, the harder it will steer during operation.

  • Page 81: Chapter 6: Electrical Prints And Mechanical Drawings

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Electrical Prints and Mechanical Drawings Electrical Prints and Mechanical Drawings Electrical Prints ......... . . 6-1 Mechanical Drawings .
  • Page 82 Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Electrical Prints and Mechanical Drawings 28 June 2017 Page 2...

  • Page 83: Electrical Prints

    Orion Machine Manual Revision 1.1 AG 360 RoboWrapper 28 June 2017 Electrical Prints and Mechanical Drawings Electrical Prints and Mechanical Drawings Electrical Prints Page 6-1...

  • Page 92: Mechanical Drawings

    Machine Manual Orion AG 360 RoboWrapper Revision 1.1 Electrical Prints and Mechanical Drawings 28 June 2017 Mechanical Drawings Download the mechanical drawings for your machine on the Orion Webpage. http://www.orionpackaging.com/landing/ag360-manual-download/ Page 6-2...

This manual is also suitable for:

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