Pro Mach Orion SENTRY System Manual
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Pro Mach Orion SENTRY System Manual

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SENTRY
SYSTEM MANUAL
Revision Date - 27 August 2014
4750 County Road 13 NE
Alexandria, MN 56308
Phone: (901) 888-4170
Toll Free: (800) 333-6556
FAX: (901) 365-1071
Sentry by Orion
Revision 2.8

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  • Page 1 SENTRY SYSTEM MANUAL Revision Date - 27 August 2014 Sentry by Orion Revision 2.8 4750 County Road 13 NE Alexandria, MN 56308 Phone: (901) 888-4170 Toll Free: (800) 333-6556 FAX: (901) 365-1071...
  • 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 Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 Table of Contents Table of Contents Chapter 1: Introduction and Safety Introduction............1-1 About this Manual .
  • Page 4 Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Table of Contents 27 August 2014 Additional LCD Screens..........3-13 Language Screen .
  • Page 5 Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 List of Figures List of Figures Chapter 1: Introduction and Safety Tower Pivot Point........... 1-9 Tower to Base Bolts (1 of 4 shown).
  • Page 6 Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 List of Figures 27 August 2014 Page II...

  • Page 7: Chapter 1: Introduction And Safety

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 Introduction and Safety Contents Introduction and Safety Contents Introduction............1-1 About this Manual .
  • Page 8 Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Introduction and Safety Contents 27 August 2014 Page II...

  • Page 9: Chapter 1: Introduction And Safety

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 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 10: About This Manual

    Copyright Notice © 2014 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 11: Safety

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 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.

  • Page 12: System Safety Recommendations

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Introduction and Safety 27 August 2014 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 13: Hazard Messages

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 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 14: Operation Safety

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Introduction and Safety 27 August 2014 Operation Safety The following safety precautions are recommended for all personnel who will operate this Semi-Automatic Stretch Wrapping Machine. • Operators should immediately report unsafe working conditions to a supervisor. •...

  • Page 15: Maintenance Safety

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 Introduction and Safety Maintenance Safety The following safety precautions are recommended for all personnel who are responsible for the maintenance or service this Semi-Automatic Stretch Wrapping Machine. •...

  • Page 16: Lockout And Tagout Recommendations

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Introduction and Safety 27 August 2014 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

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 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. Use caution when uprighting the tower.

  • Page 18: Machine Lifting Fork Tubes

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Introduction and Safety 27 August 2014 3. Carefully insert the forks into the lifting tubes to the maximum possible depth. The forktruck tine width may have to be adjusted. Figure 1 - 3 Machine Lifting Fork Tubes 4.

  • Page 19: Inspection

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 12 May 2017 Introduction and Safety 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 stretchwrap film covering the machine, care Note: must be taken not to cut any of the electrical wires and/ or polyure-...

  • Page 20: Machine Installation

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Introduction and Safety 27 August 2014 Machine Installation After the visual inspection has been completed, the electrical power and the compressed air (Optional) shall be connected as specified on the diagrams supplied with the machine. An electrical diagram is provided with each machine.
  • Page 21 Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 System Description Contents System Description Contents Machine Specifications ..........2-1 Machine Floor Plan.
  • Page 22 Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 System Description Contents 27 August 2014 Page II...

  • Page 23: Chapter 2: System Description

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 System Description System Description Machine Specifications Utilities • 110 / 1ph / 60hz / 10 Amp Service Standard Speed • Variable to 9 Rpm Drive • Self-adjusting Heavy Duty Chain Drive •...

  • Page 24: Machine Floor Plan

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 System Description 27 August 2014 Machine Floor Plan Figure 2 - 1 Machine Layout Drawing Page 2-2...

  • Page 25: Chapter 3: System Operation

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 System Operation Contents System Operation Contents Control Panel ............3-1 Operating Procedures .
  • Page 26 Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 System Operation Contents 27 August 2014 Page II...

  • Page 27: Chapter 3: System Operation

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 System Operation System Operation Control Panel Below is the control panel for the Sentry by Orion Semi-Automatic Stretch Wrapping Machine. Be aware of the movement of the carriage near the control panel. It is pos- WARNING sible to be struck by the moving carriage when the machine is running.
  • Page 28 Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 System Operation 27 August 2014 Table 3-1. The Control Panel Button/ Knob Descriptions BUTTON DESCRIPTION TURNTABLE SPEED Turn this potentiometer knob toward (+) to increase the turntable speed and toward (-) to decrease the turntable speed for any of the programs you are executing.

  • Page 29: Operating Procedures

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 System Operation Operating Procedures Loading The Film The film roll can be loaded on the carriage mandrel from either end of the roll. When using tacky film, verify that the tacky surface of the film is inward on the load. 1.

  • Page 30: Film Properly Threaded

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 System Operation 27 August 2014 7. Create some slack where the center roller pushes in on the film. Close the carriage door. 8. Fix the film end onto the load. The system is now ready to begin the first wrapping cycle.

  • Page 31: Starting And Shutting Down

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 System Operation Starting and Shutting Down Power On/ Off Switch Located on the control panel, the rotary power switch has two settings: • ON - connects a power source to the machine. •...

  • Page 32: Viewing And Selecting Parameters

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 System Operation 27 August 2014 Viewing and Selecting Parameters 1. Plug in the machine to a 110 power supply. 2. Turn the Power On/ Off Switch to the ON position. 3.
  • Page 33 Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 System Operation 6. Press 1 to choose the number of top wraps to apply to the load. Figure 3 - 9 The Top Wrap Modification Screen 7. Press SET to highlight the photocell delay timer. Use the up and down arrows or the numeric keypad to enter the desired delay before the carriage stops moving up during the automatic cycle.

  • Page 34: The Up And Down Number Modification Screen

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 System Operation 27 August 2014 13. Press 3 to choose the number of times the carriage goes up and down during the cycle. Figure 3 - 11 The Up and Down Number Modification Screen 14.

  • Page 35: Selecting A Program

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 System Operation Selecting a Program 1. On the Menu Screen, press 2 to choose a wrapping program to run. Figure 3 - 12 The Menu Screen 2. On the Program select screen, you can choose Up/ Down mode, Manual mode, Up only mode, and Topsheet mode.

  • Page 36: The Up/ Down Program

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 System Operation 27 August 2014 The Up/ Down Program Up/ Down mode will wrap the number of top wraps chosen in the parameters previously described, then wrap the bottom wraps chosen in the parameters previously described and repeat this process for the number entered in the Up and Down Num parameter.

  • Page 37: The Manual Program

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 System Operation The Manual Program Manual mode will allow you to choose a component to jog. 1. On the Program Screen, press 2 to choose the Manual program to run. Figure 3 - 15 The Manual Screen 2.

  • Page 38: The Topsheet Program

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 System Operation 27 August 2014 The TopSheet Program Topsheet mode will wrap the load up, then pause. Once the operator is done placing the topsheet on, the operator must restart by press the green Program Execute button or 0. 1.

  • Page 39: Additional Lcd Screens

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 System Operation Additional LCD Screens Language Screen This screen allows you to choose the English or French for the HMI language. Figure 3 - 18 The Language Screen Password Screen This is the Password Screen.
  • Page 40 Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 System Operation 27 August 2014 Page 3-14...
  • Page 41 Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 Troubleshooting Contents Troubleshooting Contents Troubleshooting ............4-1 Page I...
  • Page 42 Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Troubleshooting Contents 27 August 2014 Page II...

  • Page 43: Chapter 4: Troubleshooting

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 Troubleshooting Troubleshooting Troubleshooting Problems are listed in the left column, and causes in the middle column. Solutions, along with further manual references, are listed in the right column. 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 44 Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Troubleshooting 27 August 2014 Table 4-1. Troubleshooting Charts (Continued) PROBLEM POSSIBLE CAUSE SOLUTION • The photocell delay setting found on The Carriage Continues Too the Top Wraps Modification Screen • Decrease the photocell delay.
  • Page 45 Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 Maintenance Contents Maintenance Contents Maintenance ............5-1 Motor Maintenance .
  • Page 46 Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Maintenance Contents 27 August 2014 Page II...

  • Page 47: Chapter 5: Maintenance

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 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 9 RPM. They should be regarded as guidelines, reviewed and corrected according to requirements of actual use and conditions.

  • Page 48: Tower Raceways Maintenance

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Maintenance 27 August 2014 Tower Raceways Maintenance The film carriage is sliding on the plastic guides attached behind its back plate. The sec- tion of the tower on which the plastic guides move (raceways) should be cleaned and re- greased approximately every 600 hours of machine operation.
  • Page 49 Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 Maintenance This procedure should only be performed by qualified service personnel. CAUTION 1. Raise carriage to chest height. 2. Disconnect power from the machine. 3. Remove the film from the carriage. 4.

  • Page 50: Preventative Maintenance Schedule

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Maintenance 27 August 2014 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 51: Chapter 6: Electrical Prints And Mechanical Drawings

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 Electrical Prints and Mechanical Drawings Electrical Prints and Mechanical Drawings Electrical Prints ......... . . 6-1 Mechanical Drawings .
  • Page 52 Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Electrical Prints and Mechanical Drawings 27 August 2014 Page II...

  • Page 53: Electrical Prints

    Orion Sentry by Orion Revision 2.8 Semi-Automatic Stretch Wrapping Machine 27 August 2014 Electrical Prints and Mechanical Drawings Electrical Prints and Mechanical Drawings Electrical Prints Page 6-1...

  • Page 61: Mechanical Drawings

    Sentry by Orion Orion Semi-Automatic Stretch Wrapping Machine Revision 2.8 Electrical Prints and Mechanical Drawings 27 August 2014 Mechanical Drawings Page 6-2...
  • Page 62 Base Base Part Ref Description Part # Quantity 1 Turntable 2 Base 3 Casters 735499 4 Driven Sprocket 738806 5 Travel Switch Touch Block 738807 6 Tensioner 738810 7 Tension Sprocket 738975 8 Table Count Limit Switch 734379 9 Turntable Chain 0297067NO 10 Motor Jacking Screw 11 Cover Plate 1 12 Cover Plate 2 13 Main Motor Base 14 Main Motor Drive Sprocket 738977 15 Turntable Motor 750W 1:30 734351...
  • Page 63 Double Casters Double Casters Part Ref Description Part # Quantity 1 Space Ring 735426 2 Roller Shaft 735500 3 Roller Body 735499 4 Space Ring 735501 5 Roller Stand Welded to Base Not Available For Sale Single Casters Single Casters Part Ref Description Part # Quantity 1 Space Ring 735502 2 Roller Shaft 735500 3 Roller Body 735499 4 Roller Stand Welded to Base Not Available For Sale...
  • Page 64 Tower Tower Part Ref Description Part # Quantity 1 Tower Cover 2 Tower 3 Frame Setting Plate 4 Carriage Lift Chain Adjust Screw 738981 5 Tower Motor 734350 Tower Gearbox 744999 Tower Lift Kit (Motor, Gearbox, Shaft) 1011889 6 Carriage Lift Motor Shaft 736968 7 Transition Frame 748439 8 Lifting Frame 748440 9 Tower Frame 10 Driven Shaft Fixing Buckle 748441 11 Carriage Lift Driven Shaft 738980 12 Carriage Lift Driven Sprocket 738979 13 Carriage Lift Chain (8' Tower) 0364241NO...
  • Page 65 Carriage...
  • Page 66 Carriage Part Ref Description Part # Quantity 1 Motor Cover 735671 2 Pre‐stretch Motor 745000 Pre‐stretch Gearbox 735672 Pre‐stretch Kit (Motor and Gearbox) 1011893 3 Pre‐stretch Upper Cover 735673 4 Bearing Base 735674 4.5 Bearing 741616 5 Pre‐Stretch Roller 735675 6 Tightening Ring 735676 7 Tightinging Scre 735677 8 Film‐Locating Plate 735678 9 Film Shaft 735679 10 Micro‐Active Switch Frame 735680 11 Locating Plate 735681...

  • Page 67: Panel Access Key

    Electrical BOM Description Part # PLC MASTER K7M‐DR14UEMASTER PLC FOR SENTRY MACHINE 734381 VFD'S VFD SCHNEIDER 1/2 HP AC DRIVE 120V SINGLE PHASE 732691 VFD SCHNEIDER 1 HP AC DRIVE 120V SINGLE PHASE 732692 CIRCUIT BREAKERS CBRK EATON  CURVE, 3 AMP, 2 POLE, UL 1077 CBRK 735971 CBRK EATON  CURVE, 10 AMP, 2 POLE, UL 1077 CBRK 735972 E‐STOP PB TELEMECANIQUE MUSHROOM HEAD NON‐ILLUMINATED PUSHBUTTON 019323 PB TELEMECANIQUE ON CONTACT BLOCK 1 N.O. 016211 PB TELEMECANIQUE1NO CONT (ORION 014156) 706659 START P.B. SENS SQUARE D GREEN PB NON‐ILLUMINATED 734380 PB TELEMECANIQUE ON CONTACT BLOCK 1 N.O. 016211 INDICATOR LIGHT PB SQUARE D  2MM ILLUMINATED INDICATOR 734382 SERV TELEMECANIQUE Contactor CEI Non‐Reversing; 3Poles; 2HP@200/240VAC 014201 AUTO HEIGHT P.E. (STD) SENS PEPERL IR SENSOR SENTRY 734385 AUTO HEIGHT P.E. (DARK LOAD) SENS SICK DARK LOAD PE, 24VDC, QD 731972 CABLE (Required for Conversion when ordering 731972) 729580 PE MOUNT (Required for Conversion when ordering 731972) 322602NO CARRIAGE OBSTACLE DETECT SWITCH...

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