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Lantech G Series Machine Manual

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Manual
Serial Number: G0000000
1

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Summary of Contents for Lantech G Series

  • Page 1 Machine Manual Serial Number: G0000000...
  • Page 2 TABLE OF CONTENTS Introduction ......................... 5 Support ..........................6 Specifications ........................7 Machine Specifications ..................... 8 Options ..........................10 Ramp ..........................10 Forklift Stop ........................11 Pallet Grip® ........................12 G Force Plus Film Delivery System (FDS) ..............14 Safety ..........................16 Pictograms ........................
  • Page 3 TABLE OF CONTENTS Thread the Film ....................... 39 Operate the Machine ....................... 39 Overwrap Adjustment ..................... 40 6.8.1 Film Tension Off, On ....................40 6.8.2 Film Tension ......................41 Maintenance ........................42 Daily and Weekly Maintenance ..................42 Quarterly Maintenance ....................42 Mechanical Settings and Adjustments ................
  • Page 4 TABLE OF CONTENTS...
  • Page 5 INTRODUCTION Introduction This manual tells the operator and maintenance personnel how to safely install and operate the machine. The function of the manual is to make sure that the operator and maintenance personnel have complete instructions. 1. Introduction 2. Specifications 3.
  • Page 6 502-815-9101 Parts Phone +61 3 9796 5275 +31 (0)485 335 611 Parts 502-815-9104 Retrofits +31 (0)485 335 615 Service 502-815-9103 Service Service Service Email aus.support@lantech.com euroservice@lantech.com tsc@lantech.com Parts europarts@lantech.com tsg@lantech.com Retrofits retrofits@lantech.com +61 3 9703 2725 +31(0)485 330 755 502-267-8864...
  • Page 7 SPECIFICATIONS Specifications All Lantech® machines have a serial number tag in 1 of these locations: The serial number can also be in other areas of the machine. In the electrical enclosure Figure 2-1 The door of the enclosure Figure 2-2...
  • Page 8 SPECIFICATIONS Machine Specifications General 2769 mm L x 1702 mm W x 2515 mm H Dimensions (109” L x 67” W x 99” H) Machine Weight 385 kg (850 lbs) Shipping Weight 499 kg (1100 lbs) Performance Speed Application specific Maximum Load Height 2286 mm (90”) with 76 mm (3”) Overwrap Maximum Load Weight...
  • Page 9 SPECIFICATIONS Electrical Data 120 Volts, 20 A (Power Cord with 20 Amp Plug) Power Requirements 220 Volts, 15 A (Power Cord without plug) Controls Enclosure UL Listed Industrial Enclosure 3 Years Warranty...
  • Page 10 OPTIONS Options This section includes the options that are not on the standard machine. Ramp The ramp lets the operator use a forklift or pallet jack to put the load on the turntable. You can attach the ramp at 3 different positions. Make sure that the space is sufficient to move the load before you put the ramp in position.
  • Page 11 OPTIONS Forklift Stop The Forklift Stop helps the operator to align the load on the turntable. It attaches to the turntable skirt and is adjustable. You can attach it at 3 different positions. 1. Use the pins on the forklift stop to attach it to the turntable. 2.
  • Page 12 OPTIONS Pallet Grip® This option adds Pallet Grip® to the Film Delivery System (FDS). The Pallet Grip locks the load to the pallet. As the FDS lowers, the pallet grip engages and makes a cable of film. The option includes a Groove Roller: ·...
  • Page 13 OPTIONS Figure 3.4 Figure 3.5...
  • Page 14 OPTIONS G Force Plus Film Delivery System (FDS) The option includes an electric brake, “Wrap Assist” and Auto Film Cut-off. Electric Brake The brake controls the tension on the film during the wrap cycle. The tension decreases at the start of the cycle to keep the film on the load. The tension increases to the set value after the first revolution.
  • Page 15 OPTIONS Auto Film Cut-off (AFC) The AFC is on the bottom of the FDS. This lets the operator use films with different widths, with no adjustments. The AFC cuts the film at the end of the wrap cycle. · A solenoid assembly on the FDS creates a hole in the film as the turntable moves to the home position.
  • Page 16 SAFETY Safety This manual tells the operator and maintenance personnel how to safely install and operate the machine. The section includes: · General safety · Personnel safety · Safety & Environmental Controls · Warnings, Cautions and Notes General Safety · Read the manual to install, operate, and repair the machine safely. ·...
  • Page 17 SAFETY Lockout/Tagout Obey these procedures to prevent an injury from unexpected energizing, start-up, release of stored energy. This applies to local, regional, and federal controls, and includes the current controls for: · Australia – OSHA – Prevention of Unexpected Startup ·...
  • Page 18 SAFETY Pictograms The pictograms tell personnel of possible dangerous areas around the machine. Obey all pictograms and safety labels. Some of the pictograms in the list below do not apply to your machine. Do Not Operate without Guard No Entry in Position Maximum Capacity Do Not Step...
  • Page 19 SAFETY Film Delivery System Warning Cut Warning Crush Warning Do Not Reach Hit is Possible From The Side Machine Can Fall Obey the Safety Instructions Chemical Waste Environment Important Note Refer To Manual...
  • Page 20 INSTALLATION 5.0 Installation Instructions Read the Installation section and do the steps in sequence. Note: Illustrations are for reference only. Note: Functions, descriptions and data can be different on your machine. Refer to Section 3 Options. Prepare the Area The space requirements can be different on each machine. Use your machine dimensions when you prepare for the installation.
  • Page 21 INSTALLATION Installation 1. Set the machine in the installation area. Do not remove from the skid. Make sure that the space is sufficient for the machine and the forklift. Figure 5.1 Figure 5.2 2. Use a 13 mm wrench to remove the FDS bracket. 3.
  • Page 22 INSTALLATION 4. Use a 17 mm socket. Remove the bolts that hold the mast brackets to the skid and to the forklift pocket. Do not remove the bracket from the mast. Figure 5.3 5. Put the fork of the forklift into the tube. Use caution to prevent damage to the FDS cover. Cut the strap and remove it from the tube.
  • Page 23 INSTALLATION 6. Slowly lift the mast until it is almost in the vertical position. (Figure 5.5) Figure 5.5 7. Make sure that you do not cause damage to the cables on the base of the mast. Figure 5.6...
  • Page 24 INSTALLATION 8. Pull the mast to the full vertical position. Figure 5.7 9. Attach the mast to the base. Use a 19 mm socket to install the bolt that you removed in Step 3. Torque to 91 N-m (67 lb-ft). Figure 5.8...
  • Page 25 INSTALLATION 10. Remove the 6 bolts that hold the machine to the skid. Figure 5.9 11. Put the forks of the forklift into the tubes at the mast or at the turntable end of the base. Remove the machine from the skid and set it in position. 12.
  • Page 26 OPERATOR INSTRUCTIONS 6.0 Operator Instructions Note: Functions, descriptions and data can be different on your machine. Refer to Section 3 Options. Note: It is important to know all components. This includes how to thread the film and operate the controls. Note: Illustrations are for reference only.
  • Page 27 OPERATOR INSTRUCTIONS Sequence of Operation 1. Make sure that the power cord connects in the correct receptacle. 2. Turn the “Power Disconnect” to the “On” position. 3. Twist the “E-stop” to release it. 4. Push the blue “Reset” button and make sure that it illuminates. 5.
  • Page 28 OPERATOR INSTRUCTIONS Components Figure 6.1 Mast Film Delivery System (FDS) Turntable Base Controls Turntable Rotation Drive...
  • Page 29 OPERATOR INSTRUCTIONS Figure 6.3 Turntable Top Drive Ring with Home Proximity Actuator Bearing Support with Home Position Proximity Sensors Figure 6.2 Turntable Motor and Belt Mast Frame Cover Plate FDS Carrier Center Bearing Lift Drive Forklift tubes and access points Lift Chain Figure 6.5 –...
  • Page 30 OPERATOR INSTRUCTIONS 6.2.1 Film Delivery System (FDS) The FDS controls the tension and applies the film to the load. It includes: · Idler Rollers · Roller Brake with adjustable tension control and tension release · “Film Overwrap” photoelectric sensor The mechanical brake is standard. The electrical brake is an option.
  • Page 31 OPERATOR INSTRUCTIONS 6.2.2 FDS Lift Drive The drive raises and lowers the FDS during the wrap cycle and in the Manual Mode. Up/Down Proximity Sensors The mast includes 2 proximity sensors that sense the maximum travel of the FDS. These sensors are not adjustable. Chain Tension Switch This switch senses a loose chain condition.
  • Page 32 OPERATOR INSTRUCTIONS Controls The control console is on the aft of the mast. It includes: · Relays · PLC · Variable Frequency Drive (VFD) Figure 6.9...
  • Page 33 OPERATOR INSTRUCTIONS 6.3.1 Control Console The standard controls are on the side of the control panel, and include: · The Emergency Stop (E-stop) · The blue illuminated “Reset” button · Potentiometers for Turntable Rotation and FDS Lift speed controls · Potentiometer for the film tension is on the option for the G Force Plus FDS ·...
  • Page 34 OPERATOR INSTRUCTIONS 1 – Reset 2 – Settings 3 – Display 7 – Increase ↑ 4 – Top Count 5 – Band Count [ 8 – Decrease ↓ 6 – Bottom Count 9 – Enter 13 – Film Tension 10 – Rotation Speed 14 –...
  • Page 35 OPERATOR INSTRUCTIONS 6.3.2 Functions This button applies the control power. It illuminates when Reset the control power is on. Settings This gives access to the timing and diagnostic functions. Display This shows the machine data. The indicator shows the number of wraps to be applied to Top Wrap Count the top of the load.
  • Page 36 OPERATOR INSTRUCTIONS Settings Setting Decimal Description Default Places S. 1 Start Delay (sec.) The Time Delay to raise the FDS at the start of the S. 2 12.0 wrap cycle. (sec.) S. 3 The Time Delay to increase the film overwrap. Turntable Deceleration Position S.
  • Page 37 OPERATOR INSTRUCTIONS 6.4.1 Display Symbols Position 1 Power On Position 2 Start Position 3 Band Wrap Position 4 Cycle Pause Position 5 Wrap Assist (Option with G Force Plus FDS) Position 6 Turntable Rotation Position 7 FDS Raise Position 8 “Film Overwrap”...
  • Page 38 OPERATOR INSTRUCTIONS Initialize the Machine CAUTION Before you initialize the system, read “How to Stop the System”. 6.5.1 How to Stop the Machine Push the “Emergency Stop”. 6.5.2 How to Start the Machine 1. Connect the machine to the designated power receptacle. 2.
  • Page 39 OPERATOR INSTRUCTIONS Thread the Film Refer to the illustration below. Figure 6.12 Figure 6.13 WARNING Obey all safety label instructions and warnings. Operate the Machine 1. Connect the machine to the designated power receptacle. 2. Turn the “Power Disconnect” to the “On” position. 3.
  • Page 40 OPERATOR INSTRUCTIONS Overwrap Adjustment Move the lever on the FDS up, to increase the film overwrap. Move the lever down, to decrease the film overwrap. Figure 6.14 6.8.1 Film Tension Off, On Mechanical Brake Move the lever in the up direction to engage the film tension. Move the lever down to disengage the tension.
  • Page 41 OPERATOR INSTRUCTIONS 6.8.2 Film Tension Mechanical Brake Turn the knob clockwise to increase and counterclockwise to decrease the film tension. The level of tension shows on the gauge. Figure 6.16 Electrical Brake The brake automatically engages and disengages the film tension.
  • Page 42 MAINTENANCE 7.0 Maintenance WARNING Obey the Lockout/Tagout Procedures. NOTE: Functions, descriptions and data can be different on your machine. Refer to section 3. Daily and Weekly Maintenance · Tighten, replace loose fasteners. · Look for oil leaks. · Listen for unusual noise during operation. Quarterly Maintenance ·...
  • Page 43 MAINTENANCE Figure 7.1 Mast Film Delivery System (FDS) Turntable Base Control Panel and Console Turntable Rotation Drive...
  • Page 44 MAINTENANCE Figure 7.3 Turntable Top Drive Ring with Home Proximity Actuator Figure 7.2 Bearing Support with Home Position Proximity Sensors Mast Frame Turntable Motor and Belt FDS Carrier Cover Plate Lift Drive Center Bearing Lift Chain Forklift tubes and access points Figure 7.5 –...
  • Page 45 MAINTENANCE Mechanical Settings and Adjustments 7.3.1 Turntable Drive Belt Figure 7.6 Tools Force Gauge (Figure 7.6) 5 mm hex wrench Tape Measure 10 and 13 mm Wrench, Socket Results The tension on the belt is set correctly. New Belt Tension – 11 kg (25 lb) of force at 25 mm (1”) deflection.
  • Page 46 MAINTENANCE Standard Parts Replacement - Turntable 7.4.1 Turntable Drive Belt Tools Force Gauge 2 - 3/8-16 Eye Bolts Tape Measure Strap, chain 5 mm hex wrench Forklift Wrench and Sockets – 10 mm, 13 mm, and 17 mm Results The turntable belt is installed and the belt tension is set correctly. ·...
  • Page 47 MAINTENANCE 7. Use a 13 mm socket to remove the tension adjustment bolt from the turntable drive (Figure 7.11). 8. Use a 17 mm socket to remove the 3 bolts from the turntable drive assembly. 9. Move the drive belt into the slot on the drive ring (Figure 7.12 and 7.13).
  • Page 48 MAINTENANCE 14. Attach the drive assembly to the base. Do not tighten the bolts. 15. Set the turntable top in position on the drive ring and tighten the bolts. 16. Install the tension adjustment bolt to the drive assembly. 17. Use a 13 mm wrench, socket to adjust the tension on the belt.
  • Page 49 MAINTENANCE 7.4.2 Turntable Rotation Drive Tools Force Gauge 2 - 3/8-16 Eye Bolts Tape Measure Strap, chain 5 mm hex wrench Forklift Wrench and Sockets – 10 mm, 13 mm, and 17 mm Results The turntable drive belt is installed and the belt tension is set correctly. ·...
  • Page 50 MAINTENANCE 9. Move the drive belt into the slot on the drive ring. Turn the ring to remove the belt from the drive ring (Figure 7.19, 7.20). 10. Lift the drive assembly off the base and remove the belt. Make a note of the position of the belt on the idler pulley.
  • Page 51 MAINTENANCE 20. Connect the motor cable. 21. Attach the drive assembly to the base. Do not tighten the bolts (Figure 7.22). 22. Set the turntable top in position on the drive ring and tighten the bolts. 23. Install the tension adjustment bolt to the drive assembly (Figure 7.23).
  • Page 52 MAINTENANCE 7.4.3 Turntable Home Proximity Sensor Tools 2 – 24 mm Wrenches 2 – 3/8-16 Eye Bolts Tape Measure Strap, chain Forklift Results The turntable stops at the home position and the FDS applies the correct number of wraps to the load.
  • Page 53 MAINTENANCE 7.4.4 Turntable Wheel Assembly Tools 2 - 24 mm Wrenches 2 – 3/8-16 Eye Bolts Strap, chain Forklift Results The turntable turns smoothly. Procedure 1. Install the eye bolts on the turntable in the tapped holes. (Figure 7.27) 2. Attach the strap, chain to the eye bolts and then attach to the forklift.
  • Page 54 MAINTENANCE Standard parts Replacement - FDS 7.5.1 FDS Lift Chain Tools: 4 mm Hex Wrench Torque Wrench Needle Nose Pliers Strap, chain Forklift (recommended) Sockets - 8 mm, 13 mm, 17 mm, 19 mm Results The FDS moves up and down the mast smoothly and the chain tension switch operates correctly.
  • Page 55 MAINTENANCE 5. Put a film roll on the turntable to hold the weight of the mast. 6. Attach a strap, chain to the top of the mast and attach to the forklift (Figure 7.32). 7. Use a 19 mm socket to remove the bolt that attaches the mast to the base (Figure 7.31). 8.
  • Page 56 MAINTENANCE 10. Use a 13 mm socket to remove the bolts from the top cap. 11. Pull the top cap out and set on the floor (Figure 7.34). 12. Disconnect the motor cable. Open the junction box and disconnect the wires. Remove the cable and fastener. 13.
  • Page 57 MAINTENANCE 27. Slowly lift the mast until it is almost in the vertical position. 28. Make sure that you do not cause damage to the cables on the base of the mast. 29. Pull the mast to the full vertical position. 30.
  • Page 58 MAINTENANCE 4. Set the FDS Speed Potentiometer to the 12 o’clock position. 5. Pull down on the chain and hold it to set the tension. You can hear a “Click” ’ when the chain tension is set. 6. Push and release the blue “Reset” button. The blue “Reset” LED illuminates. Note: The failure to keep the tension on the chain causes the loss of power.
  • Page 59 MAINTENANCE Figure 7.41 Figure 7.42...
  • Page 60 MAINTENANCE 10. Use a 13 mm socket to remove the bolts from the top cap. 11. Pull the top cap out to get access to the switch (Figure 7.43). 12. Disconnect the cable from the switch. 13. Use a 4 mm hex wrench to remove the switch (Figure 7.44).
  • Page 61 MAINTENANCE 7.5.3 FDS Lift Drive Tools: Sockets – 13 mm, 17 mm, 19 mm Torque Wrench Forklift (recommended) Strap, chain To replace this drive, you must lower the mast and put it in a horizontal position. Procedure 1. Use a 13 mm socket to remove the top cover of the FDS.
  • Page 62 MAINTENANCE 5. Put a film roll on the turntable to hold the weight of the mast. 6. Attach a strap, chain to the top of the mast and attach to the forklift. 7. Use a 19 mm socket to remove the bolt that attaches the mast to the base (Figure 7.48). 8.
  • Page 63 MAINTENANCE 10. Use a 13 mm socket to remove the bolts from the top cap. 11. Pull the top cap out and set on the floor (Figure 7.51). 12. Disconnect the motor cable. Open the junction box and disconnect the wires. Remove the cable and fastener. 13.
  • Page 64 MAINTENANCE 7.5.4 FDS Roller Brake Pad – Mechanical Brake Tools 3 mm Hex Wrench Wrenches - 7 mm, 10 mm (2) 19 mm Wrenches Torque Wrench 10 mm Allen wrench Results The tension on the film roller is correct. Procedure 1.
  • Page 65 MAINTENANCE 5. Use the 3 mm hex wrench to loosen the set collar. 6. Turn the film tension knob clockwise to decrease the tension shaft and remove the compression spring (Figure 7.57). The tension shaft is reverse thread. 7. Use the (2) 19 mm wrenches to loosen and remove the jam nuts from the end of the shaft (Figure 7.58).
  • Page 66 MAINTENANCE 11. Install the new brake pad (Figure 7.60). 12. Attach the spacer block and the nylon spacer. 13. Put the 2 nuts on the end of the shaft. 14. Install the compression spring on the shaft. 15. Turn the knob counterclockwise until the shaft is inserted and the spacer block almost touches the set collar.
  • Page 67 MAINTENANCE 7.5.5 FDS Roller Brake Pad – Electrical Brake Tools: Allen wrench – 3 mm, 4mm, 10 mm 10 mm Wrench 13 mm Wrench, Socket Torque Wrench .040” Feeler Gauge Lithium Grease Figure 7.62 – Without the FDS Results Top Plate The tension on the film roller is correct.
  • Page 68 MAINTENANCE 5. Raise the top brake pad arm to the vertical position (Figure 7.65). 6. Lift and remove the film roller. (Figure 7.66). 7. Use the 4 mm Allen wrench to remove the top and bottom brake pads from the arm. Figure 7.65 Assemble the Brake 8.
  • Page 69 MAINTENANCE 7.5.6 FDS Up/Down Travel Proximity Sensor Tools: mm Hex wrench 24 mm Wrench Tape Measure Results The proximity sensors operate correctly. Procedure 1. Use a 2.5 mm hex wrench to remove the proximity sensor mount (Figure 7.62). 2. Use the 24 mm wrench to loosen and remove the sensor from the bracket.
  • Page 70 TROUBLESHOOTING Troubleshooting This section tells some of the problems that can occur. · Refer to the electrical and mechanical drawings · Refer to the Maintenance section for adjustments. See Section 1.1 for Lantech support. General Data Problem Possible Cause Solution No power at the receptacle.
  • Page 71 TROUBLESHOOTING Problem Possible Cause Solution The floor is not flat. Make sure that the floor is level. There is debris below the turntable. Remove the debris. Look for damage to: Look for damage, debris below the The turntable makes an Drive ring turntable.
  • Page 72 TROUBLESHOOTING Film Delivery System (FDS) Problem Possible Cause Solution Examine, replace the sensor (FDS- PRS1). The FDS “Up Travel” proximity sensor does not operate correctly. Examine the cable for damage. Make sure that it connects with the sensor. Make sure that the input and output The control for the FDS lift does not voltage to the drive control is correct.
  • Page 73 TROUBLESHOOTING Problem Possible Cause Solution Examine, replace the sensor (FDS- PRS1) The sensor does not operate correctly. Move the FDS to the “Up” proximity The FDS does not stop at sensor and examine for function. the “Up Travel” proximity sensor. The “Film Overwrap”...
  • Page 74 TROUBLESHOOTING Problem Possible Cause Solution There is an adhesive from the film on Use ammonia, detergent to clean the the roller. rollers. Mechanical Brake. There are sharp edges on the load. Remove the sharp edges. The film breaks during the Turn the tension knob counterclockwise wrap cycle.
  • Page 75 TROUBLESHOOTING...
  • Page 76 APPENDIX - WARRANTY Appendix CE Declaration of Conformity Glossary Warranty Glossary Auto Film Cut-off – This option automatically cuts the film at the end of the wrap cycle. Banding – This is the number of wraps that the FDS applies to a selected section of the load. The settings are from 1 to 9.
  • Page 77 · The machine is installed near joints in the floor. The warranty stops if the machine moves to a new customer. Unless Lantech agrees in writing, this warranty does not include the requirements for federal, local, safety, environmental regulations and standards.
  • Page 78 2. Find the part on the drawing and the item number for the part. 3. Use the item number to find the part on the parts list. Refer to the part number, description and quantity. Send your parts order to the local Lantech® Distributor. Refer to Section 1.1 for Lantech support.