User Manual for GLOBAL INDUSTRIAL models including: 238508 Semi Automatic Stretch Wrap Machine, 238508, Semi Automatic Stretch Wrap Machine, Stretch Wrap Machine, Wrap Machine
Global Industrial Semi-Automatic Stretch Wrap Machine, 112" Wrap Height | 238508 - GLOBALindustrial.ca
Global Industrial™ Semi-Automatic Stretch Wrap Machine, 112" Wrap Height
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DocumentDocumentSemi-Auto Low Profile Pallet Wrapper User Manual Model NO: 238508 Content 1. System Specification ...................................................................................................................................... 1 2. System Set-up................................................................................................................................................. 3 2.1 Machine Set-up .................................................................................................................................... 4 2.2 Installation............................................................................................................................................ 5 3. Control Panel Buttons .................................................................................................................................... 7 4. Operator Controls .......................................................................................................................................... 9 4.1 Manual ................................................................................................................................................. 9 4.2 Auto....................................................................................................................................................10 4.3 Input & Output (I/O) .......................................................................................................................... 11 4.4 Film Loading ....................................................................................................................................... 12 4.5 Machine Operation ............................................................................................................................ 13 5.Maintenance & Troubleshooting .................................................................................................................. 15 6.Components & Parts ..................................................................................................................................... 17 Machine Dimension Figure 1 1. System Specification Machine Dimension (See Figure 1) Length Width Height Turntable Diameter Turntable Height from Floor Wrapping Height Operation Space Maximum Load Size Electrical Specification 120V 60HZ Single-Phase Power Supply: 1000W 96.5" 59" 89.4" 59" 5.12" 112" 97" x 60" x 112" 52" x 52" x 112" Turntable System 13RPM turntable maximum speed 4400 lbs turntable maximum load capacity 1-13 rounds/minute Clockwise rotating turntable direction Film Delivery System Infinite/Manual Tension Adjustment 10" Diameter Roll Capacity 3" inner film roll diameter 20" Roll width Capacity 1 Machine Features Programmable logic controller (PLC) user interface 6 Modes: that's 5 automatic modes+1 manual mode The film carriage adopts close loop self-adjusting technology, to ensure each package is evenly wrapped Allowable package weight (22lbs-4400labs) SAFETY: The machine has an emergency stop button & sensor underneath the film carriage. Once an object is detected underneath the moving film carriage, the machine will stop. The interval between 2 wrapping operations is required to more than 3 minutes. . CAUTION! When servicing drive and controllers, they may be exposed components with housing or protrusions at or above the line potential. Extreme case should be taken to protect against shock. The user is responsible for conforming to all applicable code requirements with respect to grounding requirements. Do NOT use extension cords to operate the equipment. Disconnect AC input power when the machine is not in use and before checking components, performing maintenance, cleaning up and. Do NOT connect or disconnect wires and connectors while power is applied to the circuit. Always plug into a grounded outlet with the rated voltage. Loose clothing must NOT be worn while the machine is in operation. Stay clear of moving parts while the machine is running. For industrial and indoor use only. Do not immerse in water. To Reduce the Risk of Electric Shock and Injury to Persons, Disconnect from Power Supply Before Servicing and Opening. To provide continued protection against risk of electric shock, connect to properly grounded outlets only. Any servicing should be performed by an authorized service representative AND that the product has no user serviceable parts. The door lock can only be opened by authorized service personnel. 2 2. System Set-up Machine Placement Place the semi-automatic Stretch Wrap Machine close to an area where you will be wrapping your pallet loads. Refer to figure 2 to insure the machine meets the minimum clearance space requirements. Make sure that there is sufficient room to load/unload the machine and that you do not stretch the wiring cable. Remember, you will need to provide electrical service to 120 VAC, 9.1-AMP outlet. (see Figure 2) Floor Weight Bearing Tolerance The floor must be able to bear the weight of the machine, the weight of the maximum load, pus a safety factor. The floor must also be able to tolerate the stress of the machine operation. If the truck will operate on the same weight bearing area, add the weight of the trucks to the weight bearing stress tolerance requirement. Figure 2 3 2.1 Machine Set-up 1. Place the crated machine close to the designated wrap area. Remove all shipping fasteners holding the machine to the pallet. The machine may be crated with the tower tilted down the motor cover front carriage roller removed for shipping purpose. 2. Place forks of the forklift through the tubes provided at the rear base of the module, remove the machine from crate and place it at the designated wrap area. 3. Check all internal connections to ensure there is no loose/disconnected electrical wiring. 4. Connect the motor wiring and sensor leads according to the corresponding wire numbers. 5. If the OPTIONAL ramp (Model NO: 241021) is purchased: Select a ramp position illustrated below. The ramp can be positioned anywhere in a 180 rotation around the front of the turntable. There should be a 1/4" gap between the turntable and the ramp. The ramp should be fully supported by the floor. (See Figure 3) Figure 3 4 2.2 Installation NOTE: Installation requires two people Be careful when standing on the turntable during the installation, as it may turn when rotational force is applied. 1. Raise the tower upright safely with two people. 2. Tighten the screws between the tower and the turntable base (See Figure 4) 3. Screw the film carriage into the post (See Figure 5) 4. Connect to the power supply and perform a ground test before using the machine. Figure 4 Screw the set of (4) screws, washers, and lock washers through the tower and into the turntable base securely. (M10 x 20 screw) Screw the set of (2) screws connecting the tower and turntable (M8 x 10 screw) 5 Mount the film carriage onto the post by fastening a set of (2) screws. (M8 x 20 screw) Figure 5 6 3. Control Panel Buttons Figure 6 7 Speed Controller by M1, M2 knob M1: Control the speed of the turntable motor. The speed range 1-10 rpm. M2: Control the lifting motor speed Start Button has three functions The start of the automatic mode starts Resume after emergency stop Use/Cancel the central reinforcement Emergency Stop Button Press the emergency stop button to stop the machine immediately. Press the button when any emergency occurred during the packaging process. Turn the emergency stop button clockwise to reset the emergency stop button. Power Switch OFF, Power off the machine ON, Power on the machine 8 4. Operator Controls Figure 7 Main Menu Display 4.1 Manual Press the manual interface button in the main menu to display the manual operation. (See Figure 8) Carriage up/Carriage down Manually operate the carriage to move up or down. When this function is pushed, the button will turn green. To pause the operation, simply push the button again. This button may be used in conjunction with the turntable start button. Turntable Start The turntable Start button allows you to manually operate the turntable. When this button is pushed, the button will turn green. Pushing the button again will stop the turntable. The button may be used in conjunction with Carriage up/down button. Reset Push the Reset button to reset the system operation. The Turntable will return to its home position and the carriage will lower to the initial position. 9 Figure 8 Manual Display 4.2 Auto Press the AUTO button in the main menu to set parameters though the interface shown in figure 9. The parameters can be set according to the following packaging requirements: Bottom laps, Top laps, lifting time, strengthening laps, film cutting time and electric eye delay. Press the white box to set each parameter through the pop-up numerical keyboard followed by pressing the Enter button. Once the parameters are set, click the "Save" button on the screen to store the parameters for assigned group number. A total of five sets of parameters can be stored. To use any of the saved parameters, select the group number. (See Figure 9) NOTE: The parameters and function settings cannot be changed when the machine is running. Figure 9 Auto Display 10 4.3 Input & Output (I/O) You can check the status of all sensors and switches on the I/O interface shown in Figure 10. This display can be used for routine maintenance on the machine. (See Figure 10)) To return to the main menu, press the EXIT button. Figure 10 I/O display 11 4.4 Film Loading Be sure EMERGENCY STOP is pushed in before threading the film and pulled out when the film is threaded. 1. Load the film roll in the film carriage (See Figure 12) 2. Follow the film feed diagram and thread the film all the way through the rollers (See Figure 13) 3. Attach the film securely to the pallet. Tying the end of the film in a knot often helps secure the film to the pallet. 4. Turn the emergency stop switch clockwise and turn the power on. Figure 12 Figure 13 12 4.5 Machine Operation Trial run-Normal System Start-Up: 1. Place the Packaged pallet on the machine turntable until touch the positioning stopping plate. 2. Thread the film as instructed and attach it to the product. 3. Turn the power on. 4. Adjust the sensitivity of the photo switch. The machine is adjusted to the factory setting before delivery. 5. Select either Manual or Auto mode to achieve the user's packaging requirement. 6. Press the START button to initiate cycle. NOTE: It is recommended to tray a trail run to become familiar with the various parameters, adjustments, and speed controls. Emergency Stop Condition. 1. In the event of an emergency, press the STOP button. This cancels the current wrapping cycle and immediately stops the system. Figure 15 will display on the screen. 2. Correct the problem 3. Turn the STOP button clockwise to reset the stop button and perform the normal system start-up procedure. NOTE: If the weight of the package exceeds 1,100lbs, turn the turntable adjustment knob M1 counterclockwise prior to pressing the emergency stop button. Figure 15 13 Operation 1. Load the film roll in the film carriage and thread the film according to Figure 13 2. Turn the power on. 3. Adjust the sensitivity of the photo switch. The machine is adjusted to the factory setting before delivery. 4. Adjust the parameter according to the packing requirements. 5. Trial run: Place the packaged pallet, used for a trial run, on the machine turntable. Adjust M1 & M2 speed-controlled knobs to the desired speed. Packaging operation can be adjusted by the multiple parameters to achieve the user's packaging requirement. Once the user is familiar with the various parameters and adjustments, the user is ready to operate the machine. 14 5.Maintenance & Troubleshooting CAUTION! All machine maintenance work must be performed with the power supply disconnected. 1. Keep the machine clean. Use a dry cloth and cleaning agent to clean the machine. Do not use solvent water to clean the machine to prevent rusting. 2. Regularly perform maintenance on the machine every 3-6 months; Frequency varies with the machine usage. Check for internal dust build up. Check the tightness of the chain and lubricate the chain in routine maintenance inspections. WARNING! Make sure that only qualified personnel perform inspection, troubleshooting and part replacement. CAUTION! Disconnect all power, including external control power that may be present before serving the frequency drive controllers. 15 OPERATING ISSUES CAUSES Main power is turned off The machine is not powering on Wrong parameter setting PLC Failure No display on PLC screen Breaker Failure Pallet overweight Chain falls off Turntable does not run Loose Chain Inverter failure or damage Film Carriage malfunction Limit switch failure or damage Photocell failure or damage Loose chain or interference PLC Failure Carriage Up/Down button is unresponsive Inverter failure or damage Motor Failure The bottom safety plate is stuck RECOMMENDATIONS Check the power going into the machine. Verify that switch is turned on. Reset parameter Replace PLC Replace Breaker Reduce the pallet weight Check the chain transmission mechanism (loosen the chassis screws, remove the turntable cover and check whether the chain and tension are abnormal. The output protection of the inverter will flash the fault code on the inverter. Look up the corresponding fault code and troubleshoot method. Replace inverter if damaged. Overhaul or replace the limit switch Overhaul or replace the photocell Overhaul the vertical lifting chain system Replace the PLC Troubleshoot and replace inverter if damaged Overhaul the lifting motor Overhaul if the safety plate is stuck or the safety switch is damaged 16 6.Components & Parts Turntable Figure 16 17 No Part No 1 XT4505-0100-V1 2 XT45N-0101-1 3 10000000698-V1 4 XT4505-0129-V1 5 XT8020-0614 6 XT4505-0126-V2 7 10000000486G 8 XT8020-0506 9 CV-32-750-30S-UL 10 XT4505-0102-V1 11 10000000510-V2 12 GB/T825-1988 13 10010000617 14 10000000548 15 GB/T1243 -1997 16 10000000688 17 GB/T5783-2000 18 GB/T276-1994 19 10000000693 20 PL-05N NPN Type 21 XT45N-0110 22 XT4505-0138 Turntable Description QTY Turntable Base 1 Hinge fixing base 1 Tension pulley bracket 1 Tension pulley:12B-Z11 1 Plastic Spacer15*5 1 Protection Cover 1 Motor chain pulley : 12B, 14 teeth 1 Plain roller 1 Vertical Gear motor 0.75KW 1 Motor cover 1 Disc 1 Ring Screw M10 1 Turntable roller 12 Chain noise reducer 3 Chain 12B-190 keys with joint 1 Contacting plate holder 1 Hex bolt M8*60 1 Bearing 6205-2Z 1 Center turntable pulley:12B-Z50 1 Approximate Switch 1 Approximate Switch Holder 1 Motor bottom cover 1 18 Film Carriage 17 18 16 19 15 20 13 14 12 21 11 10 9 7 22 8 6 5 4 3 23 2 24 1 25 26 Figure 18 19 Film Carriage No Part No Description QTY 1 XT45Z-02-V2 Bottom fixed plate assembly 1 2 XT45M-19 Film roll: Welding assembly 1 3 10000000033 Film roll: bottom seat 1 4 10000000035-V1 Spring Plate 1 5 10000000030 Spring 1 6 20545000404-V1 Lock Ring 1 7 10000000034 Film roll: Top seat 1 8 XT45Z-06-V1 Rubber roller unit 1 9 GB/T1096 Plain key 6*6*25 1 10 GB/T276 Deep groove bearing 2 11 XT45M-12-V3 Rubber roller bearing seat 2 12 XT4508A-0205 Lock Sleeve 1 13 XT45Z-01-V2 Film carriage top plate 1 14 XT45Z-11-V1 Brake shaft 1 15 XT45Z-11-1 Rubber belt L218*W12*T2mm 1 16 XT45Z-03-V1 Top film carriage cover 1 17 XT45Z-09 Shaft lock ring 1 18 10000000046 Tension friction wheel 1 19 XT45Z-10-V1 Belt Holder 1 20 FR-2MX Photocell 1 21 M8*20 Star knob 1 22 XT45M-14 Guide roller 2 23 XT45Z-16 Switch install plate 1 24 KW3-0Z-2 Micro switch with Wheel 1 25 QB/T3876 Hinge:50*38 2 26 XT45Z-15-V3 Safety plate 1 20 Tower and Lift 5 6 7 8 9 10 11 12 3 2 1 33 32 31 30 28 29 27 13 14 15 21 26 16 34 17 18 25 19 20 21 22 23 24 Figure 19 21 Tower and lift Assembly No Part No Description QTY 1 XT45O5-0201-V2 Tower body 1 2 Z15G 1703 15A Door safety switch 1 3 XT45O5-0206 Z type holder 1 4 XT4505-0204 Tower body top cover 1 5 XT45O5-0203 Tower body top protection plate 1 6 XT4515-02-002 Door 1 7 Latch 2 8 DOP-107BV Delta Touch Screen 1 9 NRV228P-B472-4.7K + MF-A03 Potentiometer + Knob 3 10 HBDS1-AWY-11 Start Button 1 11 K22-81R Emergency stop switch 1 12 ULW26GS-20/04-1 Power switch 1 13 10000000549 Lifting motor chain wheel:08B 14 teeth 2 14 08B P12.7 Chain 08B(P12.7),314 joints 2 15 GB/T893.1 D35 Locking ring 35 2 16 GB/T276 Bearing:6202-ZZ 2 17 XT4505S-0113 Chain wheel:08B 14 teeth 2 18 XT4505S-0110-V2 Electrical housing 1 19 XT4505S-0115-V2 L Channel bracket 1 20 XT4505S-0105 Electrical component storage 1 21 XT4505-0119-CN82 Bottom limit switch seat 2 22 XCM2145L1 Limit switch 2 23 XT4505S-010702-V4 Inner tower assembly 1 24 XT4505S-0104 Guide rail 2 25 XT4505S-0103G Sliding block 4 26 XT4505S-0102-V1 Driven shaft 1 27 XT4505S-0109-V1 Connection board assembly 1 28 XT4505S-0111 Screw 4 29 GB/T1095 Key 6*6*25 2 30 XT4505S-0101 Driving shaft 1 31 XT4505S-0108 Top lifting board 1 32 XT4505S-010701 Motor Seat 1 33 NMRV050-60-T712-4 B14 Lifting reduction motor 1 34 XT4505S-01-20 Lifting pulley cover 1 22 Electrical Components Figure 20 23 No Part No Description QTY QF1 Circuit Breaker QF2 Circuit Breaker KM0 Contactor NB1-63 2P C16A6KAR 1 NB1-63 1P C2A6KAR 1 LC1D18BD 18A 24VDC 1 PO Power Switch LRS-50-24 1 INV1 Turntable inverter GD20-0R7G-S12-UL 1 INV2 Lift inverter GD20-0R4G-S12-UL 1 PLC Delta PLC DVP24ES200R 1 TB1 Connector TD1520 1 TB2 Connector TD1520 1 HMI Touch screen DOP-107BV 1 RP1 Potentiometer NRV228P-B472-4.7K 1 RP2 Potentiometer NRV228P-B472-4.7K 1 TA1 Start Button HBDS1-AWY-11 1 TB0 Emergency button K22-81R 1 QS1 Power isolation switch ULW26GS-20/04-1 1 Scale Printer Scale Printer PS--FSK-TN-UL-01 1 PS--FSK-TN-UL-02 1 24 25 V1+ V1- Y3 Y2 Y1 Y0 V1- V+ V- PE + - PE COM1 HMI Turntable Run Turntable Low Speed Carriage Up Carriage Down KM0 AC Y4 Contactor Y7 Y6 Y5 Y4 C1 Y3 Y2 Y1 Y0 DC OUT COM1 +24V 24G C0 PLC X11 X12 X13 X14 X15 X16 X17 X2 X3 X4 X5 X6 X7 X10 X1 X0 S/S L N PE X0 Door Switch X0 Anticollision Limit 1 GK1 X1 Counter Sensor GK0 X2 Height Check Sensor V- V- X5 X6 X7 X10 Carriage Up Limit 1 Carriage Down Limit 1 Start Emergency X11 X12 X13 X14 V1Carriage Up Limit 2 Carriage Down Limit 2 1# Inverter Alarm 2# Inverter Alarm V+ V+ Electrical Diagram L2 N2 PE V+ QS1 L0 N0 PE L1 QF1 L2 N1 N2 L2 KM0 L4 L2 L3 L2 N2 120VAC P0 24VDC PE V1+ V- V- X13 V- Y0 Y1 L3 N2 V- X14 V- Y2 Y3 L4 N2 R0C R0A COM S1 S2 L N INV1 1# INVERTER0.75KW 10V AI2 GND U/T1 V/T2 W/T3 R0C R0A COM S1 S2 L N INV2 2# INVERTER0.4KW 10V AI2 GND U/T1 V/T2 W/T3 41 42 43 U1 V1 W1 44 45 46 U2 V2 W2 QF2 V+ V- V+ V+ V+ V+ V- V- V- V- X0 X0 X1 X2 TB1 X5 X6 X7 X10 X11 X12 TB2 RP1/5K M1 PE Turntable motor/750W RP2/5K M2 PE Carriage motor/370W W1 V1 U1 PE L2 L2 N2 N2 L1 N1 L0 N0 PE 26Microsoft Word 2019