contents pro-series lpportal.affordinc.com/documents/arpacpro.pdfthis manual provides installation,...

Semi-AutomaticPlatform Stretch Wrapper Installation, Operation & Service

Manual

P/N 100003.251

Revision: A, March 15, 2007

Table ofContents

Introduction

Installation

Operation

PeriodicMaintenance

Inspection &Maintenance

Trouble-shooting

ElectricalSchematics

ServiceInformation

IllustratedParts List

Safety

Notes

Pro-SeriesLP

Copyright 2007, Arpac L.P. All rights reserved.

This document contains confidential and proprietary information owned by Arpac L.P. Any unauthorized copying, use or disclosure of it without the prior written permission of Arpac L.P. is

strictly prohibited.

Attention: Consult Accompanying Documents - As Applicable

This manual was originally written in English in the United States.

Arpac L.P.9511 West Rive Street Phone:1-847-678-9034Schiller Park, IL Fax:1-847-671-700660176 USA www.arpac.com

Revision History i-1

iRecord of Revisions

Revision History

Table i-1. Revision History

List of Affected Pages

Table i-2. List of Affected Pages

REV Date Reason for Change

A 3-15-2007 Original

PPage Number Rev Level



All A

Pro-Series LP Installation, Operation & Service Manual

i-2

ii-1

iiWarranty Information

Stretch wrappers manufactured by ARPAC® are warranted to be free from defects in material or workmanship for a period of three (3) years, from the date of factory shipment, while owned by the original buyer. If installed, maintained and used in accordance with factory specifications and this manual, ARPAC®’s liability under such warranty or in connection with any other claim relating to the products shall be limited to, at its discretion, repair or replacement of any stretch wrapper parts, defective in material or workmanship, returned to ARPAC ® freight prepaid (see paragraph 3).

This warranty does not apply to machinery or equipment deemed by ARPAC ® to have been subjected to misuse, neglect, overload, inadequate air or voltage supply, or that has been repaired by unauthorized personnel. Use of genuine ARPAC ® repair components is required to maintain this warranty. Any alterations to the machine during the warranty period must be pre-approved by ARPAC ®, in writing, to maintain this warranty. This warranty only applies if the alterations or repairs are made by an authorized ARPAC ® technician and does not cover labor, expenses or workmanship in the field.

If warranty parts are required, ARPAC ® will, at its discretion, repair or replace any defective stretch wrapping parts with a charge to a valid purchase order number. Defective parts, with a valid Return Material Authorization number, must be returned to ARPAC ® within thirty (30) days of warranty part shipment, freight prepaid, to receive a credit to this purchase order number. Failure to do so will result in zero credit being applied to the original P.O. or may void this warranty. All returned parts are subject to factory inspection. ARPAC ® reserves the right to determine the cause of failure and the subsequent inclusion of the replacement part under this warranty. Defective parts that have been disassembled or damaged during removal or otherwise tampered with will not be covered under this warranty.

Damage caused during transport is the responsibility of the carrier and is not covered under this warranty. All damages detected upon receipt of equipment should be reported immediately to the carrier and ARPAC® should be notified.

ARPAC ® shall under no circumstances be liable for any direct, indirect, incidental or consequential damages, losses or expenses arising in connection with the use of, or inability to use, our product(s) for any purpose whatsoever. Except as stated herein, ARPAC ® makes no other warranty, expressed or implied, nor does it assume or authorize anyone else to assume for it, any other obligation relating to our products or any other products. ARPAC ® makes no guarantee as to the appropriateness of equipment for particular purposes. Products serviced and/or parts replaced during this warranty period will carry the unexpired portion of the original warranty only. The sole obligation of ARPAC ® under this warranty will be to provide repairs to stretch wrapping components, or replacement parts, ex-works ARPAC ®.


ii-2

1-1

1Table of Contents

Record of RevisionsRevision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1List of Affected Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-1

Warranty InformationWarranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-1

Chapter 1 — Table of ContentsTable of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Chapter 2 — Safety2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12.2 Personnel Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12.3 Statement of Liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22.4 Safety Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . 2–2

Warning Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 Caution Statements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

Chapter 3 — Introduction3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13.2 Machine Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

3.2.1 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23.2.2 Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

3.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–33.4 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–43.5 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–43.6 Mechanical Sub-Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

3.6.1 Base Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–53.6.2 Turntable Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–63.6.3 Tower Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–93.6.4 FLM-SAVR® Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3–103.6.5 Dancer Bar Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11


1-2

Chapter 4 — Installation4.1 Machine Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–14.2 Optional Ramp Installation Instuctions. . . . . . . . . . . . . . . . . . . . . . 4–5

Chapter 5 — Operation5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–15.2 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–25.3 Main Control Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–55.4 Other Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

5.4.1 Swift Change Film Mandrel. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85.4.2 Wrap-N-Weigh® Operator Interface (Optional). . . . . . . . . . 5–9

5.5 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–105.6 Job Machine Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–155.7 Recovering From An Emergency Stop. . . . . . . . . . . . . . . . . . . . . . 5–165.8 Reloading Film Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17

Chapter 6— Periodic Maintenance6.1 Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16.2 Walk Around Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26.3 Cleaning External Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–36.4 Checking Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . 6–46.5 Cleaning Film Saver Pre-Stretch Rollers . . . . . . . . . . . . . . . . . . . . . 6–56.6 Cleaning Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–66.7 Greasing Center Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–76.8 Checking Turntable Drive Chain Tension. . . . . . . . . . . . . . . . . . . . 6–86.9 Checking Fasteners for Tightness. . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9

Chapter 7 — Inspection & Repair7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17.2 Fuse Inspection & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–27.3 Turntable Homing Switch Inpection & Repair. . . . . . . . . . . . . . . . 7–37.4 Turntable Roller Inspection & Repair . . . . . . . . . . . . . . . . . . . . . . . 7–57.5 Carriage Switch Inpection & Repair. . . . . . . . . . . . . . . . . . . . . . . . . 7–77.6 Film Saver Door Switch Inspection & Repair . . . . . . . . . . . . . . . . . 7–97.7 Main PCB Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–107.8 Display PCB Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11


1-3

Chapter 8 — Troubleshooting8.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–18.2 Troubleshooting Index & Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–28.3 Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7

Chapter 9 — Electrical Schematics9.1 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Chapter 10 — Service Information10.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–110.2 Field Service Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

10.2.1 Objective. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–110.2.3 Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–110.2.4 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–110.2.5 ARPAC Commitment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–210.2.6 Scheduling Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2

10.3 Installation Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–210.3.1 Objective. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–210.3.2 Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–210.3.4 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–210.3.5 ARPAC® Commitment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–310.3.6 Customer On-Site Preparation . . . . . . . . . . . . . . . . . . . . . . 10–310.3.7 Scheduling Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–410.8 Service Contact Information. . . . . . . . . . . . . . . . . . . . . . . . . . 10–4

Chapter 11 — Illustrated Parts List11.1 Ordering Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1

11.1.1 Replacement Parts Policy & Contact Information . . . . . . 11–111.2 How to Use This Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2

11.2.1 General Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–211.3 Commonly Ordered Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–211.4 Overall Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–411.5 Top Drive Tower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–611.6 Side Mounted Film Saver Assembly . . . . . . . . . . . . . . . . . . . . . . 11–811.7 Swift Change Film Support Roll Assembly . . . . . . . . . . . . . . . 11–1111.8 Base Assembly (4000lb Capacity, 59.5” Dia) . . . . . . . . . . . . . . 11–1211.9 Control Assembly (Part 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1411.10 Control Assembly (Part 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–16

Chapter 12 — Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1


1-4

2.1 Introduction 2-1

2Safety Information

2.1 IntroductionEvery effort has been made by Arpac to provide you with a safe machine. This section describes the safety precautions that should be taken when working with, on or around the equipment. It is essential that machine operators and maintenance personnel follow the safety information below.

2.2 Personnel Instructions

Warning

Make sure that you wear safety goggles and other personal protective equipment according to your company’s safety standards when operating this machine. You may get injured if you do not.

Warning

Make sure that all power is disconnected from machine and machine has stopped before servicing machine or clearing machine of jams. You may get seriously injured if you do not. Follow your company’s lock out/tag out procedures accordingly.

Interfacing Equipment

Observe all applicable codes when interfacing this equipment to other equipment. Specific attention must be paid to any PINCH POINTS that may be created.


2-2 2.3 Statement of Liability

2.3 Statement of LiabilityWhile this machine has been designed for safe operation, improper operation or carelessness may result in serious injury or damage to equipment. The manufacturer or its agents and representatives assume no responsibility for the following:

1 Injury or danger from improper use of the machine.

2 Problems or hazards resulting from failure to maintain the equipment as specified in this manual.

3 Equipment which has been tampered with or modified. Arpac is not liable for any damage or injury arising from failure to follow the instructions and procedures provided within this manual or associated informational material, or from user failure to use caution when installing, operating, adjusting, or servicing this machine. Arpac is not liable for damage or injury arising from the use of this product for any other use than that intended by the manufacturer.

2.4 Safety Conventions Used in this ManualSpecific safety information is listed in this manual in the form of WARNING and CAUTION statements. Pay close attention to these statements - they contain important information on avoiding potential hazards to you or the equipment.

Warning Statements• are used to indicate hazards or unsafe practices which COULD result

in severe personal injury or death.

• appear in bold type.

• have a triangular symbol with an exclamation point above the text.

• are preceded by the word Warning.

• are always found before the step or piece of information to which they refer to.

• look like the following example:

Warning

Make sure that all power is disconnected from machine and machine has stopped before servicing machine or clearing machine of jams. You may get seriously injured if you do not. Follow your company’s lock out/tag out procedures accordingly.


2.4 Safety Conventions Used in this Manual 2-3

Caution Statements• are used to indicate hazards or unsafe practices which could result in

minor personal injury or product or property damage.

• appear in bold type.

• have a triangular symbol with an exclamation point above the text.

• are preceded by the word Caution.

• are always found before the step or piece of information to which they refer to.

• look like the following example:

Caution

Remove shipping bolts before operating machine. Machine may get damaged if you do not.


2-4 2.4 Safety Conventions Used in this Manual


3Introduction

3.1 IntroductionThis manual provides installation, operation and service information for the Pro-Series LP Semi Automatic Stretch Wrapper. This manual also includes a spare parts list for the machine.

Figure 3-1. The Pro-Series LP Semi Automatic Stretch Wrapper

Carriage

Tower

TurntableTurntable

FLM-SAVR®

Control Panel

Drive Motor

Drive Motor

Drive Motor

FLM-SAVR®

BaseEZ-Load®


3-2 3.2 Machine Features

3.2 Machine FeaturesThe Arpac Pro-Series Semi-Automatic Stretch Wrapper is a rugged and durable semi-automatic wrapping machine that is easy to operate and maintain. The machine has the following features:

3.2.1 Standard Features• TOC feature (Top Over-Wrap Control)

• EZ-LOAD® Powered Pre-Stretch 150% - 300%

• Average cycle time 2 min (based on 3 bottom & 3 top wraps)

• Forklift portable

• Custom formed steel channel with steel tube reinforcement

• All welded steel construction

• Cycle pause control

• Turntable jog control

• Carriage pause control (banding)

• Electronic home position alignment

• Photo electric load height sensing

• Variable carriage speed

• Dual LED wrap counters

• Steel-It paint provides scratch resistant surfaces and prevents corrosion

• Anti-static pre-stretch rollers

• Corner compensation

• Maximum load weight 4000 lbs (1770 kg)

• Maximum load size -- 60” (152cm) Dia. x 83" (211cm) -- 60” (152cm) Dia. x 81" (206cm) W/ Scale

3.2.2 Optional Features • Extended base frames for additional turning clearance for oversized

pallets

• Tower height and turntable capacity upgrades

• Top platen device used to stabilize tall or light unstable loads for rotation

• Adjustable roping guide

• A variety of access ramps to assist loading of pallet


3.3 Dimensions 3-3

3.3 Dimensions

Figure 3-2. Dimensions


3-4 3.4 Specifications

3.4 Specifications

Table 3-1: Specifications

3.5 Abbreviations% Percent

° C Degree Celsius

cm Centimeter

° F Degree Fahrenheit

Kg Kilogram

Lb Pound

M Meter

max. Maximum

min. Minimum

mm Millimeter

UL Underwriters Laboratories

SpecificationsVoltage 120/240 VAC

Current 10 Amps/5Amps (Use Dedicated 20 Amp Circuit)

Frequency 60 Hz Single Phase

Max. Load 4000 lbs (1770 kg)

Max. Load Height 72” (183 cm)

Max. Load Diagonal Clearance 85” (216 cm)

Standard Turntable Size 60” (152.4 cm)

Max. Turntable Size 72” (183 cm)

Turntable Speed 0-12 RPM

Vertical Carriage Speed 0-21 FPM (0-6.4 MPM)

Relative Humidity Limits Transit/Storage 10% to 100% Operating10%-80% Non-Condensing

Atmospheric Limits 14.5 inHg to 30.74 inHg500 hPa to 1060 hPA

Weight 1485 lbs (657 kg)1,568 lbs (693 kg) With Scale Option

Certifications: UL

No user serviceable parts


3.6 Mechanical Sub-Assemblies 3-5

3.6 Mechanical Sub-AssembliesThis section gives a brief overview of the equipment and its functions under normal production conditions.

3.6.1 Base Sub AssemblyThe base is the frame weldment that supports the turntable and tower assemblies. All joints are of welded steel construction. The base also houses the drive components needed to rotate the turntable.

The turntable is in the home position when the machine is placed in the cycle mode. A proximity sensor is used to signal the machine’s controller that the turntable is in the correct position. A pallet is placed and centered on the turntable. A product detect photo eye detects the product. The operator affixes the leading end of the film to the pallet and presses cycle start push button. The turntable starts rotates the pallet until it is wrapped according to the wrap pattern selected. When the wrapping of the product is complete the turntable stops in its home position. The operator cuts the film, affixes the trailing end of the film to the pallet and removes it. Another pallet can now be wrapped.

Figure 3-3. The Pro-Series LP Stretch Wrapper Subassemblies

Tower

TurntableTurn Table Drive Motor

FLM-SAVR®

BaseEZ-Load®


3-6 3.6 Mechanical Sub-Assemblies

3.6.2 Turntable SubassemblyThe turntable is a steel platform mounted to a shaft on the base of the machine in front of the tower. It is independently driven by a chain and sprocket arrangement and rotates on casters which are mounted to the base of the machine. The purpose of the turntable is to support and rotate the product while it is being wrapped. The drive motor is mounted on the base housed by the tower.

The base drive motor rotates the turntable through a sprocket and chain drive. The magnet used to detect the position of the turntable is mounted to the main drive sprocket.

The main drive sprocket is mounted to a four-hole flanged bearing which is positioned on a shaft mounted to the base frame. The bearing has a set screw fastened to the shaft. This bearing supplies support to the center of the disc, it does not hold the sprocket down on the shaft; the weight of the turntable disc and gravity holds the sprocket on the shaft.

A series of heavy duty casters mounted to the base near the outer parameter of the turntable platforms support the outer portion of the platforms. A lubrication access hole is located near the center of the disc for lubrication of the main sprocket bearing.

Over time it is normal for roller chain to stretch. Refer to the maintenance section for Chain adjustment procedure

Caution

When moving the unit make sure the fork truck forks are fully inserted in the fork truck tubes. In the event the forks are positioned between the bottom of the disc and the base the disc will lift the sprocket off of the shaft possibly causing damage to the machine. The disc will have to be removed from the sprocket and the sprocket reinstalled onto the shaft.



Figure 3-4. Turntable Top View

Figure 3-5. Turntable Bottom View

Fork Truck Tubes

Main Bearing Access Hole

Turntable DiskMounting Screws

Turntable Disk

Drive Motor

Chain Tensioner

Proximity Sensor

Drive Sprocket

Main BearingPosition Magnet

Support Casters



3.6.3 Tower SubassemblyThe tower assembly is located opposite the turntable on the base of the machine. It provides the support for the film carriage motor and chain linkage as well as the film saver as it travels up and down while wrapping the pallet.

Figure 3-6. Tower Subassembly

Film Carriage Motor

Main Control/PowerSupply Junction Box

Tower

Film Carriage

Film Carriage

Drive Chain

Mounting Bracket



3.6.4 FLM-SAVR®Saver Sub AssemblyThe FLM-SAVR® is the mechanical assembly used to hold the film roll and distribute film to the product as the turntable rotates. This assembly consists of a film holder, dancer bar, film feed rollers and film guide rollers. The FLM-SAVR® is mounted to the film carriage bracket inside the tower.

The film carriage drive controls the vertical movement of the film saver. Depending on the wrap pattern selected, the film carriage ascends and descends the tower as the turntable rotates. The product load height photo eye is used to detect the top of the product. This photo eye signals the machine to start its over wrap cycle (controlled by the over wrap potentiometer). This allows the operator to wrap a portion of the top of the product.

Figure 3-7. FLM-SAVR® Sub Assembly

FLM-SAVR® Drive(Under Cover)

Film Guide Rollers

Film Holder

Load HeightPhoto Eye

Film Dancer Bar



3.6.5 Dancer Bar SubassemblyThe dancer bar assembly is made up of a series of film guide rollers, a stationary arm and a spring-loaded pivoting arm. The purpose of the dancer arm is to provide film to the machine that is under constant tension.

The dancer bar is connected to a direct-drive potentiometer that is used to signal the film feed motor. A demand for film is placed on the film feed system as the turntable rotates. Additional film is required when the product corners are wrapped. As the demand for film increases the dancer bar is pulled forward and adjusts the potentiometer. The speed of the motor increases its speed as a result and more film is fed to the product. This action is called corner compensation. As the dancer arm moves back the demand for film decreases and less film is distributed until it stops.

Figure 3-8. Dancer Bar Sub Assembly

Film Drive Rollers

Dancer Bar

Drive Roller Access Door

4.1 Machine Installation Instructions 4-1

4Installation

4.1 Machine Installation InstructionsTools Required:

• Adjustable-End Wrench• Diagonal Cutters• Forklift • Utility Knife

Procedure starts on next page.


4-2 4.1 Machine Installation Instructions

1 Cut and remove shipping strap (1 in Figure 4-1).

2 Remove cardboard (2).

3 Remove shrink wrap plastic (3) from around machine.

4 Remove manuals box (4) and unpack it.

5 Lift machine off of pallet by inserting forklift forks into lift holes (5) and raising forks.

6 Move machine to desired location. Be careful not to smash tower into overhead doors when moving under doors - keep elevation low.

Figure 4-1. Machine on Shipping Pallet (Typical)

1

2

5

4

3


4.1 Machine Installation Instructions 4-3

7 Remove two shipping bolts (1 in Figure 4-2).

Figure 4-2. Shipping Bolts

1


4-4 4.1 Machine Installation Instructions

8 Remove wire ties (1 in Figure 4-3) and unwind power cord.

9 Plug power cord into outlet. The outlet must have at least 10 amps of current for 120VAC or 5 amps for 240VAC.

10 If your machine came with an optional ramp, go to the next page. Otherwise, installation is complete.

Figure 4-3. Power Cord

1

2


4.2 Optional Ramp Installation 4-5

4.2 Optional Ramp Installation1 Cut and remove shipping straps (1 in Figure 4-1).

2 Remove cardboard (2).

Figure 4-4. Ramp on Pallet (Extended Ramp Shown)

Warning

Ramp is heavy. Two people are required to lift it. You may get injured if you try to lift it yourself.

3 Slide ramp up to turntable as shown below. Secure in place with floor anchors (1 in Figure 4-4).

Figure 4-5. Ramp Installed

1 2

1 (x4)


4-6 4.2 Optional Ramp Installation


5Operation

5.1 IntroductionThis chapter describes the following:

• How the machine generally works - a sequence of operation.

• What the controls of the machine do.

• How to set the controls and operate the machine.

• How to change film rolls.


5-2 5.2 Sequence of Operation

5.2 Sequence of OperationThis section describes the general operation of the machine.

Warning

Make sure that you thoroughly read ALL Sections of Chapter 5 before trying to operate the machine. You or other people may get severely injured if you do not.

1 The operator sets the machine’s controls to desired settings.

2 The machine is loaded with a pallet of product as shown below.

Figure 5-1. Machine Loaded with Product

3 The operator attaches the wrapping film to the corner of the pallet as shown below.

Figure 5-2. Film Attachment


5.2 Sequence of Operation 5-3

4 The operator then starts the machine.

5 The machine’s turntable starts to rotate and the film begins to wrap around the base of the product pallet as shown below.

Figure 5-3. Wrapping Film Around Base

6 After a preset number of layers of film have been wrapped around the base of the pallet, the FLM-SAVR® will begin moving up and wrapping film around the remaining height of the product on the pallet as shown below.

Figure 5-4. Wrapping Film Around Product


5-4 5.2 Sequence of Operation

7 When the FLM-SAVR® reaches the top of the product (as detected by a photosensor), it will wrap a preset number of layers of film around the top of the product.

8 The FLM-SAVR® will then begin lowering and wrap a second layer of film around the product as the turntable continues to turn.

9 When the FLM-SAVR® reaches its lowest (home) position, everything stops.

Figure 5-5. Final Position

10 The operator then cuts the film between the film saver and the pallet and manually pats the trailing edge of the film to the wrapped product pallet.

11 The wrapped pallet is unloaded from the machine.

12 Process repeats for the next loaded pallet.

Figure 5-6. Cutting and Patting Film


5.3 Main Control Panel Description 5-5

5.3 Main Control Panel DescriptionFigure 5-7 below shows the location of the main control panel. The paragraphs that follow describe each control.

Figure 5-7. Main Control Panel

1 EMERGENCY STOP PUSH-Pull Button - Pressing this button will immediately shut down all electrical devices, with the exception of the controller. The button must be pulled out before restarting the machine.

2 WRAP CYCLE STOP Push Button - Pressing this button interrupts the wrap cycle and resets the wrap counters. This control is located on the main control panel. To clear any fault code press this button and the Wrap Cycle Pause button simultaneously.

Caution

Pressing this button does not de-energize the machine or relieve pneumatic pressure.

15

13 12

9 8

7 6 5

4 3 2

1

14

10

11


5-6 5.3 Main Control Panel Description

3 WRAP CYCLE START Button - Pressing this push button starts the normal cycle of the machine. The machine will automatically stop when the pallet is completely wrapped.

4 WRAP CYCLE PAUSE Button - Pressing this button interrupts the normal cycle of the machine. It does not reset the machine as the cycle stop push button does. To resume the normal cycle of the machine at the point of interruption, press the wrap cycle start push button. This control is located on the main control panel. To clear any fault code press this button and the Wrap Cycle Stop button simultaneously.

5 TURNTABLE JOG, CARRIAGE PAUSE Selector Switch - The turntable jog/carriage pause selector switch allows the operator to manually control the turntable and the carriage. This control typically is used for maintenance or troubleshooting purposes.

• Turntable Jog: Operates the turntable when the machine is out of cycle. The turntable will turn in clockwise rotation for as long as this switch is held.

• Carriage Pause: Temporarily stops the carriage when the machine is in normal wrap cycle. The motion will stop for as long as the switch is held.

6 TURNTABLE JOG TO HOME Button- Pressing this button rotates the turntable in the clockwise rotation to the home position and then stops. This control typically is used for maintenance or troubleshooting purposes. This button is disabled in the cycle mode.

7 CARRIAGE LOWER/RAISE Switch - This switch allows the operator to manually control the position of the carriage. This control typically is used for maintenance or troubleshooting purposes. This switch is disabled when the machine is in the cycle mode.

• Carriage Lower: Lowers the carriage while the machine is out of cycle.

• Carriage Raise: Raises the carriage while the machine is out of cycle.

8 BASE WRAP and TOP WRAP COUNTER Displays - These displays have three functions:

• Prior to normal cycling of the machine, these displays show the number of times that the bottom and top of the pallet will be wrapped.

• During normal cycling of the machine, these displays show the number of times that the bottom and top of the pallet have been wrapped-in real time.

• When a fault condition occurs, such as the machine running out of film, these displays will show a fault condition number. This number can be cross reference to Chapter 8 “Troubleshooting” for information on how to resolve the problem.


5.3 Main Control Panel Description 5-7

9 BASE Wrap Button: This button is used to set the number of times the base of the pallet will be wrapped. Press the button repeatedly to increase the number as displayed in the base display above it. When the number reaches 9 it will start at 0 again.

10 TOP Wrap Button: This button is used to set the number of times the top of the pallet will be wrapped. Press the button repeatedly to increase the number as displayed in the top display above it. When the number reaches 9 it will start at 0 again.

11 TURNTABLE SPEED Knob - This knob adjusts the speed of the rotation of the turntable during the wrap cycle. It would be natural to think that the fastest speed is the best for production results. But be mindful that a faster speed may result in spinning loose or light products off of the pallet. For example, faster speeds are OK for bricks but not OK for cups of dried Asian noodle soup - which is very light.

12 CARRIAGE SPEED Knob - This knob adjusts the vertical travel speed of the film carriage while the machine is in the wrap cycle. As mentioned earlier, there are separate controls for setting the number of times the top and bottom of the pallet is wrapped. This control allows you to adjust the level of wrapping in the center portion of the pallet.

13 LOAD COMPRESSION Knob - This knob adjusts the amount of tension between the film saver and the product pallet. This, in turn, sets how tightly the product is compressed together. This control, much like the TURNTABLE SPEED Knob mentioned above, can affect the product positioning on the pallet. If the compression is too high and the product too light, then the product may be pulled or knocked off the pallet during the wrapping process. Conversely, if the compression is too low and the product too heavy, the product may shift during transit.

14 OVER WRAP Knob - This knob adjusts how far the film saver will continue to rise after reaching the top off the pallet load. This allows the formation of an overwrap film layer to seal the top level product downwards as shown in Figure 5-8 on the next page. If this knob is set to 0, the photosensor will be disabled and the film saver will continue to its highest possible position during the wrapping process - which could result in quite a mess.

15 Fuses: The fuses protect the machine’s wiring from short circuits. Only a service technician is allowed to service them.


5-8 5.4 Other Controls

Figure 5-8. Film Overwrap

5.4 Other Controls

5.4.1 Swift Change Film MandrelThe swift change film mandrel is designed for fast film loading. It also locks and supports the film roll on the machine.

Figure 5-9. Swift Change Mandrel

Overwrap


5.4 Other Controls 5-9

5.4.2 Wrap-N-Weigh® Operator Interface (Optional)The wrap-n-weigh® operator interface displays the weight of the pallet on the machine. Refer to the Pennsylvania Scale Manual for more information. The manual is included on the CD ROM that accompanies this manual.

Figure 5-10. Wrap & Weigh® Operator Interface


5-10 5.5 Operating Instructions

5.5 Operating InstructionsOperate the machine as follows:

Caution

Make sure that machine has been installed properly and shipping bolts are removed before operating machine. Machine will get damaged if you do not.

1 Do not load the machine with a pallet of material until told to do so in this procedure. The machine’s controls must be set and the machine set to its home position before it can be loaded.

Warning

Make sure all personnel are cleared away from machine, especially the machine’s turntable before turning the machine on. Injury may result if you do not.

2 Make sure the machine is plugged in.

3 Make sure the machine is loaded with film. If not, load a new film roll according to Section 5.8.

4 On the main control panel, pull out the EMERGENCY STOP button. This will turn the machine on as indicated by the displays lighting up.

5 Press and release the TURNTABLE JOG HOME button. If the turntable is not in its home position, it will automatically move to its home position. If the turntable is in its home position, nothing will happen - which is OK.

6 Turn and hold the CARRIAGE selector switch to the LOWER position until the film saver carriage moves to its lowest position. Then release the switch. If the carriage is already in it’s home position, nothing will happen - which is OK.

7 Press the BASE button repeatedly until the desired number of base wraps is set.

8 Press the TOP button repeatedly until the desired number of top wraps is set.

9 Set the TURNTABLE SPEED knob to 5.

10 Set the CARRIAGE SPEED knob to 5.

11 Set the LOAD COMPRESSION knob to 3.

12 Set the OVER WRAP knob to 5.


5.5 Operating Instructions 5-11

Figure 5-11. Control Panel

11

10

9

8 7

6 5

4

12



13 Place the pallet on the machine as shown below. The corners should be approximately positioned as shown - this allows for the proper attachment of the film.

Figure 5-12. Pallet Positioning

14 Pull the film out of the film saver and stick it to the bottom corner of the pallet as shown below. When you start to pull the film, it will automatically feed out.

Figure 5-13. Attaching Film



Warning

Make sure everyone is clear of machine before starting wrapping cycle. Also stay clear of the machine when it is wrapping the pallet. Injury may result if you do not.

Warning

Press the EMERGENCY STOP button to stop the machine if a hazard appears to personnel or the machine. Refer to Section 5.7 for information on recovering from an EMERGENCY STOP.

15 Press and release the WRAP CYCLE START button. The machine will automatically wrap the pallet.

16 Cut the trailing portion of the film with a knife or scissors as shown below and pat the film against the pallet. Go to the next page.

Figure 5-14. Cutting Trailing Film



17 Inspect the wrapped pallet and consider the following points:

• Was the bottom wrapping adequate? If not, change the BASE wrap count for the next pallet.

• Was the top wrapping adequate? If not, change the TOP wrap count for the next pallet.

• Did all the product stay on the pallet? If not, reduce TURNTABLE SPEED. Is so, you may want to consider increasing the speed to increase production.

• Did the mid-section of the pallet get wrapped well enough? If not, decrease the CARRIAGE SPEED. If it was too thick, increase the speed.

• Was the product wrapped too tight or too loose? Decrease or increase LOAD COMPRESSION accordingly.

Caution

It may take several hours before final film compression takes effect. Be careful not to apply too much initial compression pressure when wrapping light products. The final force of the film may crush the product.

• Was the overwrap too little or too much? Increase or decrease OVER WRAP accordingly.

18 Unload pallet.

19 Load and wrap another pallet.

20 If necessary, readjust settings. When you feel settings are correct, record them in the table on the next page for future reference.


5-16 5.6 Job Machine Settings

5.6 Job Machine Settings

Table 5-1: Job Machine Settings

Job Description or Customer Name

BA

SE Wrap #

TOP W

rap #

TUR

NTA

BLE SPEED

CA

RR

IAG

E SPEED

LOA

D C

AR

RIA

GE

OVER

WR

AP


5.7 Recovering From An Emergency Stop 5-17

5.7 Recovering From An Emergency StopIf the machine has been stopped using the EMERGENCY STOP button during the middle of a wrapping cycle, do the following steps to reset it.

1 Cut the film between the film saver and the pallet with a utility knife.

2 Stick the trailing end of the film to the pallet’s product.

3 Pull the EMERGENCY STOP button out.

4 If a digital error message code appears in the display, press the CYCLE STOP and CYCLE PAUSE buttons simultaneously to clear the display.

Warning

Make sure everyone is clear of machine before homing the turntable Injury may result if you do not.

5 Press and release the TURNTABLE JOG HOME button. The turntable will automatically return to its home position.

6 Turn and hold the CARRIAGE selector switch to the LOWER position until the film saver carriage moves to its lowest position. Then release the switch.

7 Reattach the film to the bottom of the pallet.

8 Press and release the WRAP CYCLE START button to restart the machine.


5-18 5.8 Reloading Film Roll

5.8 Reloading Film RollWhen the machine runs out of film, load a new film roll as follows:

Warning

Unplug the machine’s power cord before doing the following steps. You may get injured if you do not.

1 Unplug the machine’s power cord.

2 Pull out pin (1 in Figure 5-15) and rotate cap (2) back.

3 Remove spent film roll (3).

4 Insert new roll and close cap. Make sure the roll is oriented so that it unwinds in the direct shown in the film threading diagram.

Figure 5-15. Film Roll Reloading

Figure 5-16. Film Threading Diagram

1

3

2


5.8 Reloading Film Roll 5-19

5 Lift latch, turn it 1/4 turn counterclockwise and open film door as shown below.

Figure 5-17. Opening Film Door

6 Pull film over rollers as shown below.

Figure 5-18. Stretching Film Over Rollers


5-20 5.8 Reloading Film Roll

7 While holding onto film, firmly close door and secure with latch as shown below.

8 Plug machine’s power cord back in.

9 Resume production.

Figure 5-19. Closing Film Door

6.1 Periodic Maintenance Schedule 6-1

6Periodic Maintenance

6.1 Periodic Maintenance ScheduleRefer to the schedule below for information on when to perform periodic maintenance on the machine.

Note: Due to varying operating conditions, the procedures listed below may have to be performed at greater or lesser intervals. You may have to adjust intervals according to your machine’s performance.

When To Do It

What To Do Dai

ly

Wee

kly

Qua

rter

ly

Ever

y 6

Mon

ths

Refer to Section

Perform Walk Around Safety Inspection X 6.2

Clean External Surfaces X 6.3

Check Emergency Button For Proper Operation X 6.4

Clean Film Saver Pre-Stretch Rollers X 6.5

Clean Photo Sensor X 6.6

Lubricate Turntable Center Shaft Bearing X 6.7

Check Turntable Drive Chain Tension X 6.8

Check Fasteners for Tightness X 6.9

Table 6-1: Periodic Maintenance Schedule


6-2 6.2 Walk Around Safety Inspection

6.2 Walk Around Safety Inspection

Tools Required:

• None

Warning

Disconnect the machine’s power cord or shut off power supply to machine before servicing it. You can be severely injured if you do not.

At the beginning of each day, do a daily safety inspection of the machine and its surrounding area. Pick up any trash or obstacles around the machine. Wipe up any grease or spills.


6.3 Cleaning External Surfaces 6-3

6.3 Cleaning External Surfaces

Tools Required:

• Cleaning Wipes

• Warm Soapy Water

Warning


Use cleaning wipes and warm soapy water to clean external surfaces of the machine.


6-4 6.4 Check Emergency Stop Button

6.4 Check Emergency Stop Button With the machine cycling, press the Emergency Stop. The machine should stop immediately. Pull button back up to reset.


6.5 Cleaning Film Saver Pre-Stretch Rollers 6-5

6.5 Cleaning Film Saver Pre-Stretch RollersTools Required:

• Cleaning Wipes

• Isopropyl Alcohol

Warning


Caution

Do not use acetone to clean rollers or rollers will get damaged.

1 Pull latch (1 in Figure 6-1) out and turn it to open roller door (2).

2 Thoroughly clean rollers (3) with wipes and alcohol.

3 Close door.

Figure 6-1. Film Saver Stretch Rollers

1

23


6-6 6.6 Cleaning Photo Sensor

6.6 Cleaning Photo SensorTools Required:

• cleaning wipes

• window cleaning solution

Warning


1 Spray a small amount of window cleaning solution to face of photoeye (1 in Figure 6-2).

2 Dry photoeye with cleaning wipe.

Figure 6-2. Cleaning Photoeye

1


6.7 Greasing Center Shaft Bearing 6-7

6.7 Greasing Center Shaft BearingTools Required:

• cleaning wipes

• grease gun

Warning


1 Apply one pump of grease to grease fitting (1 in Figure 6-3).

2 Wipe fitting clean.

Figure 6-3. Grease Fitting

1


6-8 6.8 Checking Turntable Drive Chain Tension

6.8 Checking Turntable Drive Chain TensionTools Required:

• 3/8” hex wrench

• 1 1/16” closed end wrench

Warning


Caution

Do not overtighten chain. The machine may get damaged if you do.

1 Loosen bolt (1 in Figure 6-4).

2 Turn nut (2) until you begin to feel the resistance of the chain tightener against the chain. Then turn the nut another 30°.

3 While holding nut still, tighten bolt.

Figure 6-4. Tightening Turntable Drive Chain

1

2


6.9 Checking Fasteners for Tightness 6-9

6.9 Checking Fasteners for TightnessTools Required:

• adjustable-end wrench

• medium flat-tip screwdriver

• medium phillips-tip screwdriver

• set of hex wrenches

Warning


1 Check all exterior fasteners for tightness. Tighten as required.


6-10 6.9 Checking Fasteners for Tightness


7Inspection & Maintenance

7.1 IntroductionThis chapter covers various inspection and repair procedures for the machine.


7-2 7.2 Fuse Inspection & Replacement

7.2 Fuse Inspection & ReplacementTools Required: None

Warning


Caution

You must replace fuse with the exact same type of fuse or the machine may get damaged. All fuses must be quick-blow type.

1 Disconnect power from machine.

2 Turn fuse holder cap (1 in Fig. 7-1) counterclockwise and pull cap and fuse out of control panel.

3 Check if fuse filament is burned through. If required, replace fuse by pulling it out of cap and inserting new fuse.

4 Reinstall fuse cap and fuse into control panel.

Figure 7-1. Fuse Location

1

2A8A 8A 8A


7.3 Turntable Proximity Sensor Inspection & Repair 7-3

7.3 Turntable Proximity Sensor Inspection & RepairTools Required:

• Adjustable End Wrench

• Forklift Truck

• Lift Chain With Two Open Hooks

• Set of Hex Wrenches

• Two 3/8”-16 Eyebolts

Warning



2 Unscrew turntable mounting screws (1 in Fig. 7-2).

3 Screw eyebolts into lifting holes. (2).

4 Insert chain hooks into eyebolts.

5 Insert forklift fork under chain and lift turntable (3) off of machine. Set turntable aside.

Figure 7-2. Turntable Mounting Bolts

1

2 1

2

3


7-4 7.3 Turntable Proximity Sensor Inspection & Repair

6 Make sure that sensor (1 in Fig 7-3) is tight, mounted properly and is not damaged. Repair or replace as required.

7 Make sure that sensor magnet (2) is mounted properly and is not damaged. Repair or replace as required.

Figure 7-3. Turntable Home Switch and Magnet

1 2


7.4 Turntable Roller Inspection & Repair 7-5

7.4 Turntable Roller Inspection & RepairTools Required:

• Adjustable End Wrench

• Forklift Truck

• Lift Chain With Two Open Hooks

• Set of Hex Wrenches

• Two 3/8”-16 Eyebolts

Warning



2 Unscrew turntable mounting screws (1 in Fig. 7-4).

3 Screw eyebolts into lifting holes. (2).

4 Insert chain hooks into eyebolts.

5 Insert forklift fork under chain and lift turntable (3) off of machine. Set turntable aside.

Figure 7-4. Turntable Mounting Bolts

1

2 1

2

3


7-6 7.4 Turntable Roller Inspection & Repair

6 Make sure that rollers (1 in Fig 7-5) are not damaged or obstructed. Repair or replace as required.

Figure 7-5. Turntable Rollers

1 (x6)


7.5 Carriage Switch Inspection & Repair 7-7

7.5 Carriage Switch Inspection & Repair

Tools Required:

• 1/2” Open-Wrench

Warning



2 Make sure that switches (1 in Fig 7-6) are tight, mounted properly and not damaged. Repair or replace as required.

3 Make sure that lower switch magnet (2) is mounted properly and is not damaged. Repair or replace as required. Go to the next step.

Figure 7-6. Carriage Switch Location

1 2


7-8 7.5 Carriage Switch Inspection & Repair

4 Make sure that upper switch magnet (1 in Fig. 7-7) is mounted properly and is not damaged. Repair or replace as required.

Figure 7-7. Upper Magnet Location

1


7.6 Film Saver Door Switch Inspection & Repair 7-9

7.6 Film Saver Door Switch Inspection & Repair

Tools Required:

• 1/2” Open-Wrench

Warning



2 Make sure that switch (1 in Fig 7-8) is tight, mounted properly and not damaged. Repair or replace as required.

3 Make sure that switch magnet (2) is mounted properly and is not damaged. Repair or replace as required.

Figure 7-8. Film Saver Door Switch Location

1

2


7-10 7.7 Main PCB Replacement

7.7 Main PCB ReplacementTools Required:

• Medium Flat-Tip Screwdriver

• Medium Phillips Screwdriver

Warning



2 Disconnect all connectors from PCB (1 in Fig. 7-9).

3 Unscrew mounting screws (2) and remove board (3).

4 Reverse steps to reassmble.

Figure 7-9. Main PCB

1 (x6)2 (Type)3


8Troubleshooting

8.1 IntroductionThis chapter is divided into two sections.

The first section is a group of troubleshooting charts that will guide you through many of the problems that may occur with the machine.

The second section is made up of figures that show the actual location of components on the machine as referenced in the schematics in Chapter 9. These can be used together with the schematics for further troubleshooting of the machine.


8-2 8.2 Troubleshooting Index & Charts

8.2 Troubleshooting Index & ChartsUse the following troubleshooting index and troubleshooting charts as an aid in solving your machine’s malfunction. Possible fault codes that may accompany a fault will appear in the display on the machine’s control panel.

NOTE: To clear a fault code, press the CYCLE STOP and CYCLE PAUSE buttons simultaneously.

Table 8-1: Troubleshooting Index

Problem PossibleFaultCode

Refer to Page:

Machine does not turn on. None 8-3Turntable does not rotate. 11 & 17 8-3Turntable will not stop rotating. 17 8-4Film carriage does not rise. 11,12,14 &

158-4

Film carriage is at top position and will not lower.

11,12,14 & 16

8-5

Film does not feed during wrap cycle. 13 8-6Machine will not start 10 8-6Machine stops during mid-cycle. 13 8-6


8.2 Troubleshooting Index & Charts 8-3

Problem Possible Cause RemedyMachine does not turn on.

Machine is not plugged in.

Make sure machine is plugged in.

Emergency stop button is pressed.

Pull button out before restarting machine.

Source Breaker is not turned on or fuse is blown.

Make sure that breaker at power source is turned on (or wall fuse has not blown).

Control panel fuse is blown.

Check and, if necessary, replace fuse according to Section “7.2 Fuse Inspection & Replacement” on page 7-2.

If fuse blows again quickly, replace main control PCB according to Section “7.7 Main PCB Replacement” on page 7-10.

Turntable does not rotate.

Possible Fault Codes 11, 13 & 17

Film saver door is open. Make sure that film saver door is closed.

Film has broken or has run out.

Reattach or reload film according to Section “5.8 Reloading Film Roll” on page 5-18.

Turntable speed is set too low.

Increase setting on TURNTABLE SPEED knob on main control panel.

Turntable not in home position.

Press TURNTABLE JOG HOME button on main control panel to send turntable to its home position.

Continued...



Turntable does not rotate.

(Cont.)

Turntable fuse is blown. Check and, if necessary, replace fuse according to “7.2 Fuse Inspection & Replacement” on page 7-2.

Turntable is blocked by an obstruction.

Inspect turntable for damage or obstructions according to Section “7.4 Turntable Roller Inspection & Repair” on page 7-5.

Film saver door switch has failed.

Inspect film saver door switch according to Section “7.6 Film Saver Door Switch Inspection & Repair” on page 7-9.

Turntable will not stop rotating.

Fault code 10 displayed.

Turntable proximity sensor has failed.

Inspect sensor according to Section “7.3 Turntable Proximity Sensor Inspection & Repair” on page 7-3.

Film carriage does not rise.

Possible Fault Codes 11,12,14 & 15

Carriage Speed is too low. Increase setting on CARRIAGE SPEED knob on main control panel.

Turntable not in home position.

Press TURNTABLE JOG HOME button on main control panel until turntable is in its home position.

Carriage is blocked by an obstruction.

Check for and remove any obstructions.

Carriage fuse is blown. Check and, if necessary, replace fuse according to Section “7.2 Fuse Inspection & Replacement” on page 7-2.

Continued...

Problem Possible Cause Remedy


8.2 Troubleshooting Index & Charts 8-5

Film carriage does not rise.

(cont.)

Photo Sensor is dirty or misaligned.

Clean photo sensor according to Section “6.6 Cleaning Photo Sensor” on page 6-6.

Also make sure that eye is properly mounted and aligned.

Carriage upper or lower limit switch is faulty.

Inspect and, if necessary, repair switches according to Section “7.5 Carriage Switch Inspection & Repair” on page 7-7.

Film carriage is at it’s top position and does not lower.

Possible Fault Codes 11,12,14 & 16

Emergency stop button is pressed.

Pull button out before restarting machine.

Carriage is blocked by an obstruction.

Check for and remove any obstructions.

Carriage fuse is blown. Check and, if necessary, replace fuse according to “7.2 Fuse Inspection & Replacement” on page 7-2.

Photo sensor is dirty or misaligned.

Clean photo sensor according to Section “6.6 Cleaning Photo Sensor” on page 6-6.

Also make sure that sensor is properly mounted and not obstructed when it rises above top of pallet.

Continued...Carriage upper limit switch is faulty.

Inspect and, if necessary, repair switch according to Section “7.5 Carriage Switch Inspection & Repair” on page 7-7.




Film does not feed during wrap cycle.


LOAD COMPRESSION knob set too high.

Lower knob setting.

Film saver fuse is blown. Check and, if necessary, replace fuse according to Section “7.2 Fuse Inspection & Replacement” on page 7-2.

Film saver switch is bad. Check switch LS4 for proper operation. Refer to Figure 8-3 on page 8-8 for location of switch.

Machine will not start.


Film saver door is open. Close door.

Door switch is faulty. Inspect and, if necessary,

repair switch according to Section “7.6 Film Saver Door Switch Inspection & Repair” on page 7-9.

Machine stops during wrap cycle.


Film has run out. Load new film according to Section “5.8 Reloading Film Roll” on page 5-18.

Dancer bar switch is faulty.

Check switch LS4 for proper operation. Refer to Figure 8-3 on page 8-8 for location of switch.



8.3 Component Location 8-7

8.3 Component LocationThe schematic diagrams in Chapter 9 can be used be used to troubleshoot electrical problems with the machine. The schematics cover most of the electrical components in the machine. Figures 8-1 through 8-6 show photos of the components listed on the schematics. This allows you to identify the location of the components and translate the fault isolation logic of the schematics into actual testing of components for failure.

Figure 8-1. Control Box

PCB2

FC2

PCB3

FC1

PCB4

P3

P2

P1

PCB1

P5

P6

SCR2

SCR3

SCR1

P4


8-8 8.3 Component Location

Figure 8-2. Turntable Home Limit Switch

Figure 8-3. Dancer Switch and Dancer Potentiometer

LS1Turntable Home Magnet

P1Dancer

LS4

SW


8.3 Component Location 8-9

Figure 8-4. Carriage Limit Switches

LS2

LS3

Lower Magnet

Upper Magnet


8-10 8.3 Component Location

Figure 8-5. Motors and Load Height Photo Sensor

Figure 8-6. Film Saver Door Switch and Magnet

Film SaverMotor

CarriageMotor

TurntableMotor

Load HeightPhoto Sensor

LS4

Magnet

9.1 Electrical Schematics 9-1

9Diagrams & Electrical Schematics

9.1 Electrical SchematicsThis chapter contains the electrical schematics for the Pro-Series LP.

Refer to Section “8.3 Component Location” on page 8-7 to see the actual view of the components referenced in the schematics.

Drawing Number Drawing Description # Sheets

PRO-1 Electrical Wiring Diagram 1

PRO-2 PCB Layouts 1

PRO-3 Electrical Wiring Diagram (Split Frame Option) 1

PRO-4 Split Frame Connection Diagram 1

Table 9-1: List of Schematics


9-2 9.1 Electrical Schematics


10Service Information

10.1 IntroductionThis section contains an overview of ARPAC®’s field service policies.

10.2 Field Service Policy

10.2.1 ObjectiveTo furnish our customer with prompt, competent, and complete service so they can operate at optimum efficiency.

10.2.3 Service PersonnelARPAC®’s field technicians are experienced in the servicing of ARPAC® equipment, are qualified to instruct customer’s personnel in correct operation and maintenance procedures of ARPAC® equipment. ARPAC® Field Service Technicians are fully supported by factory and all Engineering Departments.

10.2.4 TrainingThe Arpac Group is pleased to provide free lifetime access to Arpac University’s regularly scheduled technical training courses for customers purchasing a packaging machine from Arpac or its distributors.

These technical training courses will focus on theory of operation, machine setup and operation, preventive maintenance and long-term care. Many specific machine courses are available on Arpac bundler, horizontal, corrugated, and stretch wrapping machines. These regularly scheduled 1 day or 2 day courses are held approximately every 12 weeks at the Arpac University and Demo Room located near O’Hare airport in Chicago. Class demand will influence the frequency of these class offerings.

For further information or a current technical training calendar and agenda, contact Arpac’s training department at 847-678-9034 ext 4088.

Custom machine specific training courses can be developed for delivery at your location or at Arpac. For further information and a quotation, contact Arpac’s training department.


10-2 10.3 Installation Policy

10.2.5 ARPAC Commitment• Be readily available to communicate with the customer(s).

• Service Technicians available for supervision and instruction of personnel at prevailing rates and expenses.

• Upon arrival of the ARPAC® Service Technician, he should be able to commence immediately, minimize “downtime” of your production facilities and commence training of your personnel.

10.2.6 Scheduling ServiceAt least 10-days advance notice is required for scheduling personnel. Emergencies will be handled as quickly as possible. If assistance is required during installation or operation of the system or if you need information pertaining to system-related problems not covered by this manual, please contact ARPAC® Service Dept. (telephone (800) 237-0725).

10.3 Installation Policy

10.3.1 ObjectiveTo furnish our customer with prompt, competent, and complete service so they can operate at optimum efficiency. Failure to use factory trained personnel for initial machine start-up may void the warranty.

10.3.2 Service PersonnelARPAC®’s field technicians are experienced in the servicing of ARPAC equipment, and are qualified to instruct customer’s personnel in the correct operation and maintenance procedures of ARPAC® equipment. ARPAC® Field Service Technicians are fully supported by factory and all Engineering Departments.

10.3.4 TrainingARPAC® personnel are available for ARPAC® equipment training, either on site hands-on, or in a classroom environment supported by visual aids and literature to be administered under separate purchase order.

The Arpac Group is also pleased to provide free lifetime access to Arpac University’s regularly scheduled technical training courses for customers purchasing a packaging machine from Arpac or its distributors.

These technical training courses will focus on theory of operation, machine setup and operation, preventive maintenance and long-term care. Many specific machine courses are available on Arpac bundler, horizontal, corrugated, and stretch wrapping machines.


10.3 Installation Policy 10-3

These regularly scheduled 1 day or 2 day courses are held approximately every 12 weeks at the Arpac University and Demo Room located near O’Hare airport in Chicago. Class demand will influence the frequency of these class offerings.

For further information or a current technical training calendar and agenda, contact Arpac’s training department at 847-678-9034 ext 4088.

Custom machine specific training courses can be developed for delivery at your location or at Arpac. For further information and a quotation, contact Arpac’s training department.

10.3.5 ARPAC® Commitment• To furnish equipment per quotation.

• Be readily available to communicate with the customer(s) to facilitate start-up.

• Service Technicians available for start-up supervision and instruction of personnel at prevailing rates and expenses.

• Upon arrival of the ARPAC® Service Technician, he should be able to commence immediately, minimize “downtime” of your production facilities and commence training of your personnel.

10.3.6 Customer On-Site Preparation• Unload, unpack, and inspect the equipment for any freight damage

(apparent or hidden). If there is any damage, the Bill of Lading will need to be signed, noting the damage. You will then need to file all the necessary freight claims with the appropriate carrier. All shipments are freight collect and you are responsible for any damages in transit.

• Remove all interfering equipment and clear area where equipment is to be installed.

• Assemble/erect subject equipment.

• Lag system to floor.

• Furnish all electrical wiring and connections per system requirements.

• Furnish any air and/or gas lines and connections if required.

• Integrate with any existing up and/or down stream equipment.

• Provide qualified technicians, operators, and maintenance personnel to start-up system.


10-4 10.3 Installation Policy

10.3.7 Scheduling ServiceIf assistance is required during installation or operation of the system or if you need information pertaining to system-related problems not covered by this manual, please contact ARPAC® Service Dept. (telephone (800) 237-0725).

10.8 Service Contact InformationContact information for service is listed below. Please have your machine’s model number and serial number ready when calling. Also have a Purchase Order number when calling.

ARPAC Parts Contact InformationPhone: (847) 678-9034Fax: (847) 678-210924 Hour Emergency Service: (800) [email protected] for service Monday through Friday,7:00 AM to 6:00 PM (Central Time)

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Affordable Automation Phone (479) 675-0079 After hours (479) 883-9496

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11.1 Ordering Parts 11-1

11Illustrated Parts List

11.1 Ordering PartsFor your convenience, replacement parts and accessories can be ordered from ARPAC® by fax 24 hours a day. Please have the following information available to ensure quick, easy, and accurate service.

• Your name and telephone number

• Your P.O. (Purchase Order) number

• Your preferred method of delivery

11.1.1 Replacement Parts Policy & Contact InformationShould a replacement part be needed, ARPAC®’s return material authorization policy must be adhered to. ARPAC® will not distribute equipment or parts without a purchase order from an authorized ARPAC® distributor. This procedure includes warranty and non-warranty replacement parts. A return authorization will be issued at that time, and credit will not be issued until the suspect part has been received and inspected. Call ARPAC® sales for the distributor in your area at (847) 678-9034.

Phone: (847) 678-9034Fax: (847) 678-210924 Hour Emergency Service: (800) [email protected] for service Monday through Friday,7:00 AM to 6:00 PM (Central Time)


11-2 11.2 How to Use This Parts List

11.2 How to Use This Parts List

11.2.1 General Part NumbersThis chapter contains all part numbers necessary to order Pro Series LP replacement parts and assemblies.

This illustrated parts breakdown is presented in disassembled order. Detail parts are shown below their respective upper level assemblies whenever possible.

The parts lists follow the illustration for a particular assembly and represent components of that assembly. The number listed in the quantity column is the number of the specific part required to complete the assembly and may not reflect the quantity needed for the entire system.

The lists are divided into four columns. The item/index numbers refer to the identification number located on the drawing. The part number is the Arpac part number, used to identify the part for ordering. The part description column lists each part name, and the quantity column lists the quantity of that part used in that particular assembly.

Illustrations are shown before the parts list for each assembly.

11.3 Commonly Ordered PartsPart Description Part number

Motor Drive Assembly 205132Magnet, Rectangular Pressure Sensitive Adhesive 822976.Fuse, Glass AGC 8 Amp/250VAC 804998.231Fuse-Glass AGC 2 Amp/250VAC 803998.226Link, Connecting, #40 800502.Link, Connecting, Offset #40 800523.Link, Connecting, #50 800505.Link, Connecting, Offset #50 800522.Caster Wheel Assembly 205114.000APro-Series LP Installation, Operation & Service Man-ual

100003.251

Table 11-1: Commonly Ordered Parts


11.3 Commonly Ordered Parts 11-3

Page Intentionally Blank


11-4 11.4 Overall Assembly

11.4 Overall Assembly

Figure 11-1. Overall Assembly

1

13

4

2 & 3


11.4 Overall Assembly 11-5

Fig ref. Part number Description Qty

1 229987.000A Top Drive Tower Assembly (See Section “11.5 Top Drive Tower Assembly” on page 11-6 for break-down of assembly)

1

2 224855.000C Side Mounted Film Saver Assem-bly (See Section “11.6 Side Mounted Film Saver Assembly” on page 11-8 for breakdown of assem-bly)

1

3 224911. Swift Change Film Roll Support Assembly (See Section “11.7 Swift Change Film Support Roll Assem-bly” on page 11-11 for breakdown of assembly)

1

4 236010. Base Assembly (See Section “11.8 Base Assembly (4000lb Capacity, 59.5” Dia)” on page 11-12 for breakdown of assembly)

1

5 221410 Parts Kit, 200% Stretch, Film Saver 1

6 235230 Kit, Paint, Steel It, Semi-Auto 1

12 206456 Kit, Fuse, SW Pro-Series 1

13 243372 Pro-Series Control Assembly (See Section “11.9 Control Assembly (Part 1)” on page 11-14 and Sec-tion “11.10 Control Assembly (Part 2)” on page 11-16 for breakdown of assemblies)

1

Table 11-2: Overall Assembly


11-6 11.5 Top Drive Tower Assembly

11.5 Top Drive Tower Assembly

Figure 11-2. EZ/Pro Top Drive Tower Assembly

17,25

7 244

2221

2315

51612

13

9

6 18,914

3

2


11.5 Top Drive Tower Assembly 11-7


1 229994. Weldment, Carriage 1

2 229988. Weldment, Tower 1

3 202169.002 Shaft, 0.625”, Tapped 1/4’-20, 7.640” Long

1

4 229997. Cover, Top 1

5 229989. Drive Shaft 1

6 229634. Plastic Guide 1

7 800562. Collar, Shaft, Set Screw, 3/4” 2

8 204835. Coupling, Chain Adjustment 1

9 221607. Bracket, Magnet, Tower, Right 1

10 238493. Plate, Cover, Plexiglass 1

11 823638. Flange, Extended Output Gearbox 1

12 230030. Tape, Slit 2

13 821786. Gearbox, Worm 1

14 823673. Motor, 1/3 H.P. 1

15 821168. Sprocket 1

16 802744. Bearing, Flange 1

17 800906. Sprocket 1

18 823533. Chain, Roller #40, 312 Pitches 156” 1

19 800502. Link, #40 1

20 804994.913 Connector, Strain Relief 1

21 820234. Wheel, Caster 4

22 800325.016 Bolt, Shoulder, 5/8” Dia. X 1 3/4” 4

23 820598. Nut, Hex, 1/2”-13, Nylon Jam 4

24 807258. Washer, Oilite 1

25 800560 Collar, Shaft, Set Screw, 5/8” 2

26 822425 Tape, Double Sided, 3/4” .07”

27 800275.071 Washer, Flat 5/8” X 1 1/4” X 14 ga. 4

Table 11-3: Top Drive Tower Assembly


11-8 11.6 Side Mounted Film Saver Assembly

11.6 Side Mounted Film Saver Assembly

Figure 11-3. EZ/Pro Side Mounted Film Saver Assembly

26 32

2116

43

1715,24,2718

3166

45

20

30

6

28

1210

19

2

25

11,35

4

47

23

529,46

22,542953

13

5

42,43

348

142

50,5187


11.6 Side Mounted Film Saver Assembly 11-9

Fig ref. Part number Description Qty1 224978. Spacer, Idler Sprocket 12 224903. Shaft, Roller 43 800912. Sprocket 14 823674. Motor, 1/2 H.P. 15 214611.003A Roller Assembly 16 820115. Bearing Flange Rad 17 821470. Bearing Flange 18 101412. Stop Lever, Transfer Rack Film 29 804007.165 Photo Sensor 1

10 820086. Bearing Flange Black 411 224913. Plate, Dancer Bar 212 224856. Weldment, Roller Cage, 20” Film 113 800324.003 Bolt, Shoulder, 1/2 Dia. X 1/2” Lng 214 241144. Motor Mounting Ring Spacer 115 820126. Bushing, Oilite 216 821152 Sprocket 117 214477 Weldment, Pot Mounting Bracket 118 800561 Collar, Shaft Set Screw 119 214611.002A Roller Assembly 520 822924. Latch, Lift & Turn Compression 121 218352 Gear, Spur 122 825104. Spring, Compression 123 211969.000A Shaft, Dancer 124 804998.351 Pot, 10K Ohm 125 224866 Weldment, Film Saver Frame 126 821477 Pulley, Timing 127 820827 Gear, Spur 128 230209 Pulley, Timing 129 823049 Belt, Timing 130 211973.000C Weldment, Final, Roller 231 214480. Bracket, Microswtch Mounting 132 224905.001 Guard, Film Saver, Right Hand 133 804998.553 Switch-Limit 134 800292.019 Washer, Lock Split 5/8” 135 800317.010 Pin, Roll 3/16” Dia X 1 Lg 237 800275.065 Washer, #8 Flat 2

Table 11-4: EZ/Pro Side Mounted Film Saver Assembly (1 of 2)


11-10 11.6 Side Mounted Film Saver Assembly

Fig ref. Part number Description Qty38 800328.006 Socket Head Screw 1/4”-20 X 3/4” 139 800341.005 Screw, Set, 10-32 X 1/2” 240 800328.013 Socket Head Screw 1/4”-20 X 1 1/4 141 800325.003 Shoulder Bolt 142 804006.121 Proximity Sensor 143 822976. Magnet .5”44 800267.003 Flat Head Screw 1/4-20 X 1/2 SS 245 224903.001 Roller Shaft 146 224955. Plate, Mounting 147 224977. Spacer, Pulley 148 229619 Spacer, Mounting Cover 149 800292.005 Washer, 1/4” Split Lock 1050 800246.040 Socket Head Screw 10-32 X 5.5” 151 237929. Clevis, Spring 152 237928 Retainer, Spring 153 237930.001 Weldment, Spring Mounting

Bracket1

54 825143. Bushing, Oilite 355 800322.003 Shoulder Bolt, 5/16” X 5/8” Lg 156 800321.002 Shoulder Bolt, 1/4” X 3/8” Lg 157 815213. Washer, Oilite 258 811314. Washer, Oilite 259 800292.012 Washer, 3/8” Split Lock 860 817011.002 Washer, 5/16” External Lock 161 800238.009 Binder Head Screw, 10-32 X 1 1/2” 162 800238.005 Binder Head Screw, 10-32 X 3/4” 463 800282.012 Hex Head Bolt, 3/8”-16 X 1 1/4” 464 800282.006 Hex Head Bolt, 3/8”-16 X 3/4” 465 800278.011 Hex Head Bolt, 1/4”-20 X 1/2” 1066 800275.023 Washer, Flat 1/2” Hardened 267 800292.001 Washer, #10 Split Lock 968 800290.006 Nut, Hex 1/4”-20 169 800307.003 Screw, Pan Head, 6-32” X 1” 270 800238.002 Binder Head Screw, 10-32 X 3/8” 5

Table 11-5: EZ/Pro Side Mounted Film Saver Assembly (2 of 2)


11.7 Swift Change Film Support Roll Assembly 11-11

11.7 Swift Change Film Support Roll Assembly

Figure 11-4. Swift Change Film Support Roll Assembly

Table 11-6: Swift Change Film Support Roll Assembly


1 224906. Lift Bar 1

2 224907. Weldment, Top Mounting Bracket 1

3 224911. Plate, Core Bearing 1

4 224617. Thrust Bearing 2

5 810565. Plunger, Index 1

6 214497.002 Weldment, Film Holder 1

7 800324.007 Bolt, Shoulder, 1/2” Dia X 3/4” Long 1

8 801031. Spring, Compression 1

9 800324.10 Bolt, Shoulder, 1/2” Dia. X 1 1/4” 1

10 810743.001 Nut, Acorn, 3/8”-16 1

11 822974. Clevis Pin 1

12 800328.032 Socket Head ap Screw 1/4-20X 1/4 1

13 823229. Nut, 3/8”-24 Hex Jam 1

3

4

5,13

1

11

2

6

104

18

9

7

12


11-12 11.8 Base Assembly (4000lb Capacity, 59.5” Dia)

11.8 Base Assembly (4000lb Capacity, 59.5” Dia)

Figure 11-5. Base Assembly (4000lb Capacity, 59.5” Dia)

11

17

102

7

6,15,16

43312,32

13,14

5

1

19, 35

8


11.8 Base Assembly (4000lb Capacity, 59.5” Dia) 11-13


1 233032. Weldment Base 1

2 823639. Gearbox 1

4 234814. Weldment, Drive Sprocket 1

5 229964. Turntable, 59.5” Dia 1

6 823617. Chain, Roller, #50 230 Pitches, 143.75” lg

1

7 823678. Sprocket 1

8 800905. Sprocket 1

9 224963. Plate, Mounting Take Up 1

10 823674. Motor, 1/2 H.P. 1

11 205939 Roller Assembly 6

12 820091. Bearing Flange 1

13 224967. Bracket, Prox Switch Mounting 1

14 804006.121 Proximity Sensor 1

15 800505. Link, #50 1

16 800522. Link, #50 Offset 1

17 804998.092 Cord Connector 1

18 800282.006 Hex Head Cap Screw 3/8-16 X 3/4” 4

19 800282.018 Hex Head Cap Screw 3/8-16 X 2” 2

20 800284.005 Hex Head Cap Screw 1/2-13X1/1/4 4

21 800271.003 Flat Head Cap Screw 3/8-16X3/4” 4

22 825309. Key, Tapered, 3/16” Sq X 1 1/2” 1

26 808036. Nut, Hex, 10-24 2

27 800275.014 Washer, Flat 3/8” 2

29 800292.012 Washer, Split Lock 3/8” 6

30 800292.017 Washer, Split Lock 1/2” 4

32 802207. Grease Fitting, 90Deg, 1/4-28 Tapered

1

33 822976. Magnet 1

34 822957. Socket Head Cap Screw 7/16-20X2 1

35 807279 Tensioner, Spring, Rotary 1

Table 11-7: Base Assembly (4000lb Capacity, 59.5” Dia)


11-14 11.9 Control Assembly (Part 1)

11.9 Control Assembly (Part 1)

Figure 11-6. Control Assembly (Part 1)

19

20

1415

16

14

22

24

28

24

21

8

23

13


11.9 Control Assembly (Part 1) 11-15

Fig ref. Part number Description Qty8 230027. Plate, Electrical Panel 1

13 804998.226 Fuse, Glass AGC, 2 Amp 250VAC 114 804998.231 Fuse, Glass AGC, 8 Amp 250VAC 316 804998.313 Knob 419 804004.128 Push Button, Blue 120 804004.127 Push Button, Green 121 804004.121 Push Button, Red 122 804004.122 Push Button, Yellow 123 804004.126 Push Button, Mushroom Head 124 804021.030 Selector Switch 228 800308.007 Screw, Pan Head, 8-32 X 1” 6

Table 11-8: Control Assembly


11-16 11.10 Control Assembly (Part 2)

11.10 Control Assembly (Part 2)

Figure 11-7. Control Assembly (Part 2)

39

5,40

35

32

27

38

4

315

9

6

1

7

2

34

37

17,18

11

26


11-17

Fig ref. Part number Description Qty1 204792. Cable, Ribbon, 16 Pin 12 204796.000A Cable, Ribbon, 34 Pin 13 204802. Fuse Cable Assembly 14 205099. Delay Card Assembly - Photo Eye 15 218899.030 PCB Assembly 16 205882 Switch Board PCB Assembly 17 208885. Display Board PCB Assembly 111 804998.024 Connector, 15-Pin 112 804998.072 Contact Block 115 804998.241 Fuse-Holder 30A/250V, 1.25 FU 417 804998.515 Spacer, Nylon 1118 804998.516 Spacer, Nylon Tube 1125 820330. Contact Block 1026 820331. Center Shield 127 800308.003 Screw, Pan Head, 8-32 X 1/2” 428 800308.007 Screw, Pan Head, 8-32 X 1” 532 205132. Motor Drive Assembly 334 229881. Control Panel Cover 135 229880. Electrical Enclosure 137 205905 Power Cord Assembly 138 804998.703 Terminal Strip - 12 Position 139 804032.005 Ground Kit Hardware 140 804020.007 Suppressor, Varistor 1

Table 11-9: Control Assembly


11-18


12-1

Notes

Pro-SeriesLP Installation, Operation & Service Manual

12-2

Notes


12-3

Notes

Pro-SeriesLP Installation, Operation & Service Manual

12-4

Notes