Professional Documents
Culture Documents
Q-300XT/Q-400XT
Semi Automatic Stretch Wrapper
Machine Manual
Serial Number: QX011598
1
Table of Contents
2
Table of Contents
7.1.1 XT Cut and Clamp ............................................................................................... 54
7.1.2 Pallet Grip ............................................................................................................ 55
7.2 Monthly Maintenance .................................................................................................... 55
7.3 Settings and Adjustments ............................................................................................... 56
7.3.1 FDS Up, Down Travel Proximity Sensor ............................................................... 56
7.3.2 Belt Slack Switch ................................................................................................ 58
7.3.3 Turntable Home Proximity Sensor ......................................................................... 59
7.3.4 Turntable Drive Belt ............................................................................................... 61
7.3.5 Lantech Intelli-sensor .......................................................................................... 62
7.3.6 Load Cell ................................................................................................................. 63
7.4 Motor Control Boards .................................................................................................... 65
7.4.1 FDS Lift Motor ....................................................................................................... 65
7.4.2 Turntable ................................................................................................................. 66
7.4.3 Power Roller Stretch Plus ....................................................................................... 67
7.5 Potentiometer Settings.................................................................................................... 68
7.5.1 Film Delivery System ............................................................................................. 68
7.5.2 Turntable ................................................................................................................. 69
7.6 Film Delivery System..................................................................................................... 71
7.6.1 Power Roller Stretch Plus ....................................................................................... 71
7.7 Standard Parts Replacement ........................................................................................... 74
7.7.1 FDS Lift Belt........................................................................................................... 74
7.7.2 FDS Lift Drive ........................................................................................................ 76
7.7.3 Turntable Drive Belt ............................................................................................... 77
7.7.4 Turntable Drive ....................................................................................................... 78
7.8 Pallet Grip ................................................................................................................... 79
7.8.1 Pivoting Roller ........................................................................................................ 79
7.8.2 Groove Roller.......................................................................................................... 80
7.9 XT Cut and Clamp ...................................................................................................... 81
7.9.1 Turntable Clamp Actuator Proximity Sensor ................................................................. 81
7.9.2 XT Actuator Tab ..................................................................................................... 83
8.0 Troubleshooting ............................................................................................................... 85
8.1 General Data ................................................................................................................... 85
8.2 Film Delivery System..................................................................................................... 86
3
Table of Contents
8.3 Turntable ........................................................................................................................ 89
8.4 Pallet Grip ................................................................................................................... 91
8.5 XT Cut and Clamp ...................................................................................................... 92
9.0 Appendix ........................................................................................................................... 95
9.1 Glossary.......................................................................................................................... 95
9.2 Warranty ......................................................................................................................... 97
10.0 Parts Lists and Drawings ................................................................................................ 99
4
INTRODUCTION
1.0 Introduction
This manual tells the operator and maintenance personnel how to safely install and operate the
machine. The function of the manual is to make sure that the operator and maintenance personnel
have complete instructions.
1. Introduction
2. Specifications
3. Options
4. Safety
5. Installation
6. Operator Instructions
7. Maintenance
8. Troubleshooting
9. Appendix
10. Parts List and Drawings
The Specifications and Options sections contain data about your machine and special options.
This is important as you install and operate the machine.
The Safety section points out the Warnings and Cautions to make sure that all personnel work in
a safe environment.
The Installation and Operator Instructions sections tell you how to install and use the machine
safely and efficiently.
The Maintenance and the Troubleshooting sections tell you how to make sure that the machine
stays at top performance.
The Appendix section can include the CE Declaration of Conformity, Glossary and Warranty
procedures.
This manual helps you operate your machine safely and efficiently. The value is to increase your
productivity and decrease the packaging costs.
5
INTRODUCTION
1.1 Support
For support, use the phone and email data below:
6
SPECIFICATIONS
2.0 Specifications
All Lantech machines have a serial number tag in 1 of these locations:
Figure 2-1
Figure 2-2
Note:
The exposed metal parts on all Stretch Wrap Machines have a heavy Rust Preventative applied before
shipment.
You can use Mineral Spirits or a similar cleaner to remove it.
If you remove it, make sure that you apply a light Rust Preventative to the exposed metal before you
operate the machine.
7
SPECIFICATIONS
2.1 Machine Specifications
General Q300XT Q400XT
2032 mm (80) Wrap Height
Dimensions 3023 mm L x 1702 mm W x 2337 mm H
Standard Height (119" L x 67" W x 92" H) X X
680 kg (1500 lb) X
Weight with Pallet 694 kg (1530 lb) X
Performance
Speed* Loads/Hour 30-40 30-40
762 mm x 762 mm x 508 mm
Minimum Load Dimensions
(30 W x 30 L x 20 H) X X
2032 mm (80) Wrap Height
Maximum Load Dimensions - Standard Height
1321 mm x 1321 mm x 2032 mm
Note: Maximum wrap height increases 254
mm (10) for 762 mm (30) FDS option (52 W x 52 L x 80 H) X X
2794 mm (110) Wrap Height
Maximum Load Dimensions - Extended Height
1321 mm x 1321 mm x 2794 mm
52 W x 52 L x 110 H X X
Load Dimensions - Diagonal 1753 mm (69") Recommended X X
8
SPECIFICATIONS
Q300XT Q400XT
Turntable
Turntable Dimensions 1651 mm (65) Diameter X X
Turntable Speed 12 rpm X X
Turntable Height 70 mm (2 ) X X
Turntable Bearing Support 1219 mm (48) Diameter X X
HP (.56 kW) 90 VDC 1750 RPM
TEFC
Motor - 40:1 Speed Reducer X
1 HP (.75 kW) 90 VDC 1750 RPM
Turntable Drive TEFC Motor - 30:1 Speed Reducer X
Film Delivery System (FDS)
Gearmotor 1/5 HP (.15 kW) 90 VDC
FDS Lift Drive 2250 RPM 45:1 50 RPM Output TENV X X
Power Roller Stretch Plus with EZ
Thread X
Power Roller Stretch Plus with EZ
Thread and Pallet Grip X
HP (.37 kW) 90 VDC 1750 RPM
FDS Drive TENV Motor X X
Standard Film Pre-Stretch 200% 250%
All Commercial Grade Films 50-150
Film Gauge X X
254 mm (10) Diameter
508 mm (20) Width (Standard)
Standard Film Capacity 762 mm (30) Width (Optional) X X
Electronically controlled with Reduced
Wrap Force Wrap Force at the start of the wrap cycle X X
Pallet Grip Option X
Electrical Requirements
Electrical Supply Dedicated, Grounded Electrical Supply X X
Power - US 120 Volts, 20 Amps X X
Power - EU 220 Volts, 16 Amps X X
Controls Microcontroller X
Microcontroller in NEMA 12 Enclosure X
Warranty 5 Years X X
9
SPECIFICATIONS
10
OPTIONS
3.0 Options
This section includes the options that are not on the standard machine.
11
OPTIONS
General
Infrared Device
Line of Sight Operation
Immune to Interference
The Range of Operation is 9 m (30)
There are 2 steps to start the wrap sequence. This makes sure that the machine does not start
accidentally.
The Start button overrides the remote transmitter.
Remote Transmitter
3 channel selections
Start Button
Stop Button This is not an Emergency Stop.
Low Battery Indicator
9-Volt Alkaline Battery
Remote holder
All remote transmitters can stop
a machine with the remote
option.
Only the transmitter that arms
the receiver can control the start
of the machine. The special
code for each transmitter makes
sure that the remote does not
start the incorrect machine.
2 aiming features Figure 3.3 - Remote Aiming Features
Receiver
The beeper and visual alarms when the remote start is Armed. The volume control is
adjustable (Rotating shutter on the beeper).
3 channel selections (Dip Switch settings Default is Channel 1).
The receiver includes a label with the correct channel number for the correct machine, to
help the operator.
Adjustable Arming time (Dip switch settings Default is 8 seconds.
The remote stops the machine if the operator uses the remote or the lanyard (if applicable) to
start the machine.
12
OPTIONS
Installation
1. Attach the receiver to the top of the mast on the turntable side.
2. Make sure that the receiver sensor points to the turntable.
3. Put the cable through the hole in the mast and install the quick
connect into the receiver
4. Attach the number labels on the receiver to show the channel
settings.
Note: You can use the remote for multiple machines.
The channels must be different if the machines are less than 9 m
(30) of each other.
Refer to the channel settings.
5. Install the battery in the transmitter and replace the cover. Make
sure that the tab pushes forward and the cover is tight.
6. Attach the transmitter holder to the loading device (i.e. forklift).
Clean the surface and attach with the adhesive; or Figure 3.4 - Receiver Mount
Figure 3.5
13
OPTIONS
Line Of Sight Operation
18'
Make sure that the receiver sensor is in the (5.5m)
transmitter.
(7m)
Part tolerances
Condition of the lens on the 32'
transmitter and receiver (9.8m)
Sequence of Operation
This sequence of operation refers to the
remote start sequence only. Refer to section
6 for the Sequence of Operation for the
machine. Figure 3.6 - Line Of Sight Area
Functions
Channel (Blue 1-2-3) Use these buttons to make the selection of the
channel for the correct machine (Arm receiver unit).
Start (Green) Use this button to start the wrap sequence. Figure 3.7 - Remote
Stop (Red) Use this button to stop the wrap sequence.
To start the machine after a Stop, Arm the receiver and push the start button.
The Manual functions are off. To turn these functions on, push the E-stop, then reset
it.
14
OPTIONS
Receiver Settings
The remote start receiver includes the switch settings for the Channels and Arm times. The
receiver is in the enclosure.
Figure 3.8
1 Channel Settings
2 Arm Time Settings
Channel Settings
The Channel setting on the receiver includes 4 switches. Use these switches to engage 1 of the 3
channels. The default setting is for Channel 1.
Note: You can use the remote for multiple machines. The channels must be different if the
machines are less than 9 m (30) of each other. Refer to the channel settings.
15
OPTIONS
Arm Time Settings
The Arm time setting on the receiver includes 7 switches.
Use these to set the time that the receiver engages to start the machine from the remote
transmitter.
If the time setting releases, you must arm the receiver to start the machine.
If the beacon illuminates and the alarm sounds, the receiver unit is Armed. The default time to
arm the receiver is 8 seconds.
16
OPTIONS
Troubleshooting
Problem Possible Cause Solution
Use the remote to Arm and start
the machine.
The manual functions are The remote transmitter stopped the Push the Start button on the
1
not available. machine. control console.
Push then Reset the E-stop to
engage the Manual Functions.
Examine the power cord and make
sure that it connects into the correct
receptacle.
No power at machine. Reset the Emergency Stop.
Examine, replace the main fuses.
Examine the power receptacle for
power.
Make sure that the cable for the
The cable connection to the receiver
quick connect attaches at the
is not correct.
receiver.
Examine the power source and
The transmitter does not No power at receiver unit. make sure that it applies the power
Arm the receiver. to the receiver.
17
OPTIONS
18
SAFETY
4.0 Safety
This manual tells the operator and maintenance personnel how to safely install and operate the
machine. The section includes:
General safety
Personnel safety
Safety & Environmental Controls
Warnings, Cautions and Notes
General Safety
Read the manual to install, operate, and repair the machine safely.
Obey all safety decals.
Obey all warnings to prevent an injury to personnel.
Obey all cautions to prevent damage to the machine.
Obey all Lockout/Tagout procedures before you change, adjust, repair a part.
Refer to the adjustment data to prevent a safety hazard.
Personnel Safety
To prevent an injury and safety risk, do not install, operate, repair the machine while
influenced by drugs, alcohol, medication.
A part that moves can catch loose clothing, long hair, jewelry and cause injury to
personnel.
Data on Personal Protective Equipment (PPE) is in the Installation section of this manual.
Refer to the Installation section for personnel and tools to safely install the machine.
19
SAFETY
Safety & Environmental Controls
Make sure that you recycle all waste.
Release all chemical waste to a certified Waste Processing Company only.
To decommission the machine, the owner of the machine and all auxiliary equipment,
must:
Obey applicable environmental regulations and discard electrical components safely.
Obey all applicable environmental, plant, and industrial safety regulations.
This applies to local, regional, and federal controls, and includes all OSHA and CE
regulations.
Lockout/Tagout
Obey these procedures to prevent an injury from unexpected energizing, start-up, release of
stored energy.
This applies to local, regional, and federal controls, and includes the current controls for:
Australia OSHA Prevention of Unexpected Startup
Europe CE Machinery Directive Isolation of Energy Sources
USA OSHA Control of Hazardous Energy
20
SAFETY
4.1 Pictograms
The pictograms tell personnel of possible dangerous areas around the machine. Obey all
pictograms and safety decals.
Some of the pictograms in the list below do not apply to your machine.
Electrical Warning
Hot Surface
Explosion Warning
Pull In Warning
21
SAFETY
Do Not Reach
22
INSTALLATION
CAUTION
Obey the torque specifications to prevent damage to the fasteners. Too much
torque can cause the fasteners to loosen.
Note:
The exposed metal parts on all Stretch Wrap Machines have a heavy Rust Preventative applied before
shipment. You can use Mineral Spirits or a similar cleaner to remove it.
If you remove it, make sure that you apply a light Rust Preventative to the exposed metal before you
operate the machine.
Location:
Make sure that the mast has a clearance of a minimum of 762 mm (30) to the nearest
blockage.
A flat and level floor no more than 6 mm ().
Make sure that the floor can hold the weight of:
The machine
The maximum load weight
Forklift
Pallet Jack
Other equipment in the area
Personnel
23
INSTALLATION
5.2 Personnel, Equipment and Tools
Standard Height
Personnel
1 Forklift Operator
1 Electrical/Mechanical Technician
Equipment
1 Forklift
1 Ladder
Tools
Wrenches And Sockets (Metric and Standard)
Extended Height
(Mast Shipped In Horizontal Position)
Personnel
2 Forklift Operators
1 Mechanical Technician
1 Electrical Technician
Equipment
2 Forklifts
1 Ladder
Tools
Wrenches and Sockets (Metric and Standard)
Allen wrenches (Metric and Standard)
Torque Wrench
Straps, Chains
24
INSTALLATION
5.3 Installation
Standard Height Mast
The Mast is in the up position
Step 1
Remove the protective materials.
Step 2
Remove the bolts, brackets and boards that
hold the machine and the components to the
skid.
Step 3
Put the forks of the forklift into the loops in
the aft of the machine. Figure 5.1
Step 4
Slowly lift the machine and set it in position.
CAUTION
Do not lift a machine with an extended length base or larger turntable with the
fork loops.
Figure 5.2
25
INSTALLATION
Step 5
Remove the FDS shipping bracket from the mast (Figure
5-3).
1. Remove the M10 nut that holds the bracket to the
base.
2. Remove the M8 bolt and nut that hold the bracket to
the FDS.
Step 6
The counterweight is in the access panel on the mast.
There are 2 brackets that hold the counterweight in
position (Figure 5-4).
1. Remove the (2) M10 bolts.
2. Remove the brackets.
Step 7
Stow the shipping brackets and the counterweight Figure 5.3
brackets in the mast.
CAUTION
Before you move the machine to a different location, install the shipping and
counterweight brackets.
Figure 5.4
Step 8
Connect the power cord to the dedicated, grounded electrical supply.
Note: The machine has a 3.6 m (12) power cord with a 20-amp plug. Use a 20-amp receptacle.
Do not use an extension cord.
26
INSTALLATION
Step 9
There is a lanyard that adds the option for a remote start. The lanyard includes a ring on the arm
of the switch.
1. Connect the lanyard cord (cord not included) to the ring.
2. Use the pulleys to thread the cord on the ceiling.
3. Make sure that the forklift is clear of the load to operate the lanyard.
Figure 5.5
27
INSTALLATION
28
OPERATOR INSTRUCTIONS
6.0 Operator Instructions
Note: Illustrations are for reference only.
Note: Functions, descriptions and data can be different on your machine. Refer to Section 3,
Options.
Note: It is important to know all components. This includes how to thread the film and operate
the controls.
Note: Some machines have a remote Emergency Stop. It is important to know the location of
all E-stops before you operate the machine.
WARNING
Obey all Lockout/Tagout procedures before you change, adjust, repair a part.
WARNING
Obey all safety decal instructions and warnings.
WARNING
Do not make a change to this machine without approval from Lantech. It can
cause a safety hazard and cancel the warranty.
CAUTION
Do not use a sharp object that can cause damage to the roller to remove the film
that is wound onto the pre-stretch roller.
CAUTION
Do not let a heavy load stay on the turntable for extended periods of time. This
can cause damage to the turntable.
29
OPERATOR INSTRUCTIONS
6.1 Sequence of Operation
The sequence of operation starts with a load on the turntable.
1. Push the Film Assist button.
2. Pull the film and attach it to the load.
3. Push the Start button.
4. The turntable turns and the FDS moves up. The speed of the FDS is set on the control
console.
5. The film pre-stretches and is applied to the load.
6. The load height sensor senses the top of the load and the FDS stops to apply the top wrap.
Q300XT
7. On the first full revolution of the turntable during the top wraps:
a. The turntable speed decreases to the Home speed.
b. The XT Cut and Clamp engages to release the beginning film tail.
c. The turntable speed increases.
8. The FDS completes the top wraps.
9. The FDS lowers to the bottom of the load and stops to apply the bottom wrap.
10. The turntable speed decreases to the Home speed.
11. The XT unit clamps and cuts the film.
12. The XT retracts as the turntable moves to the home position.
13. The operator removes the load from the turntable.
Q400XT
7. The FDS lowers to wrap the bottom of the load.
8. Pallet Grip engages and makes a cable of film on the bottom edge of the film.
9. The pivoting roller engages and attaches the film cable to the pallet.
10. On the last revolution of the bottom wraps, the XT unit engages to clamp and cut the film.
11. At the end of the wrap cycle, the FDS raises and disengages the Pallet Grip.
30
OPERATOR INSTRUCTIONS
6.2 Components
Q300XT and Q400XT
6
3
7 2
4
Figure 6.1
1 Mast
2 Film Delivery System (FDS)
3 Turntable
4 XT Cut and Clamp
5 XT Actuator
6 Controls
7 Roper
31
OPERATOR INSTRUCTIONS
Turntable
2 3
4
5
Figure 6.2
1 Turntable Top
2 Urethane Ring
3 Drive Ring with Home Proximity Actuator
Bearing Support Ring with Home Position Proximity
4
sensors
5 Center Bearing
32
OPERATOR INSTRUCTIONS
6.3 Assemblies
6.3.1 FDS and Counterweight
Figure 6.3
1 FDS Lift Drive
2 Turntable Drive (Base)
FDS Up Travel proximity sensor (Down Travel
3
sensor not shown)
4 FDS Belt Slack switch
33
OPERATOR INSTRUCTIONS
6.3.3 EZ Thread Gate
The gate opens to 2 positions.
Figure 6.4
Figure 6.5
34
OPERATOR INSTRUCTIONS
6.3.4 Pallet Grip
Standard on Q400 XT
Option on Q300XT
Figure 6.7
35
OPERATOR INSTRUCTIONS
Film Tail Elimination
Use the Configuration Setup to engage this option (Configuration Bit C-17).
1. The wrap cycle starts and the FDS is at the bottom of the load.
2. The Pallet Grip engages.
3. The FDS moves to the top of the load to apply the top wraps.
4. The turntable speed decreases and the XT Cut and Clamp engages to release the beginning
of the film tail.
5. The FDS applies the top wraps and moves to the bottom of the load to apply the bottom
wraps.
6. The film cable assembly engages to make a cable of film on the bottom edge of the film.
7. The pivoting roller engages to apply the film cable to the pallet.
8. As the FDS applies the bottom wraps, the beginning of the film tail wraps before the film
clamp and cut sequence.
Figure 6.8
36
OPERATOR INSTRUCTIONS
6.4 Controls
The Controls are on the side of the mast.
The Emergency Stop (E-stop)
Power On button (illuminates)
Mode and Fault Indicators (LEDs)
Potentiometers for Turntable rotation, FDS speed control
and Wrap Force
Touch pad
Figure 6.9
37
OPERATOR INSTRUCTIONS
2 6
3 1 7
4 8
5 9
10 11
12
13
14 15
16 23 30
17 24 31
18 25 32
19 26 33
20 27 34
21 28 35
22 29 36
37
38
Figure 6.10
38
OPERATOR INSTRUCTIONS
6.4.1 Mode and Fault Indicators
1 Power On The illuminated green button applies the control power to the machine.
2 Cycle Pause The wrap cycle is paused.
3 Not Used
4 Turntable 2 (Option) The second turntable is On (dual turntable option).
5 Power On The Control Power is On.
6 Band Mode The Band mode is On.
7 Film Break There is a film break.
8 One-Way Wrap The option for One-Way Wrap is On.
9 Top Sheet Cycle (Option) The Top Sheet Cycle is On.
The indicator shows the number of wraps to be applied to the top of the
10 Top Wrap Count
load. Wrap counts increment from 1 9.
The indicator shows the number of wraps to be applied to the bottom
Bottom Wrap Count of the load. Wrap counts increment from 1 9.
11
The indicator shows how much wrap force is applied to the load. It
12 Wrap Force Display
shows the lbs. of force.
Potentiometers
13 Wrap Force The potentiometer sets the wrap force applied to the load.
The potentiometer increases, decreases the speed of the turntable. The
14 Turntable Speed
maximum speed is 12 rpm.
The potentiometer increases, decreases the up and down travel speed
15 FDS Speed
of the FDS
Touch Pad Controls - Do not use a pointed object on the touch pads. Use only your finger.
16 Jog (Turntable) This turns the turntable.
This automatically sets the turntable and the FDS to the home position.
17 Home The turntable turns at low speed and stops at the home position. The
FDS lowers to the home position.
18 Not Used
19 Turntable 2 (Option) This controls the second turntable on a dual turntable system.
20 Not Used
21 Not Used
22 Not Used
23 Platen Up (Option) This control lifts the top platen arm.
24 Platen Down (Option) This control lowers the top platen arm.
25 One-Way Wrap (Option) The One-Way Wrap is On.
This control pauses the wrap cycle. Push it a second time to continue
26 Cycle Pause
the wrap cycle.
39
OPERATOR INSTRUCTIONS
This control releases the film from the FDS. The film releases for
27 Film Assist
approximately 5 seconds.
28 Not Used
The Top Sheet Cycle is On.
29 Top Sheet Cycle (Option)
Push the control again to continue the wrap cycle.
This control moves the FDS in the up direction. It stops at the Up
30 FDS Up
Travel proximity sensor.
This control moves the FDS in the down direction. It stops at the
31 FDS Down
Down Travel proximity sensor.
32 Presets This control gives access to the microcontroller functions.
This control sets the number of film bands to the load and then
33 Band
continues the wrap cycle.
34 Not Used
35 Not Used
36 Not Used
37 Start This starts the wrap cycle.
A red spring-loaded button that stops the operation of the machine.
38 The Emergency Stop
To release, twist the E-stop.
40
OPERATOR INSTRUCTIONS
6.4.2 Presets
Preset Mode
The Preset Mode gives access to
timers and counters.
Figure 6.11
41
OPERATOR INSTRUCTIONS
Adjust the values of the Presets to tune the machine.
1. Push the Presets button for the Preset Mode.
2. Push the Bottom Wrap Count for the correct count.
Push the button to move through the presets.
Preset Number
Appears Here
P 1
.
Preset Value
1.5 Appears Here
Figure 6.12
42
OPERATOR INSTRUCTIONS
The Microcontroller holds the Settings.
To adjust:
1. Push the Presets button to get access to the Preset Mode.
2. Push and hold the Start button.
3. Continue to hold the Start button and push the Top Wrap Count button.
4. Release the Start button and the Top Wrap Count button.
After 2 seconds, the machine goes into the Manual Mode and the Factory Settings are set.
A decal in the access door includes the instructions to change the Presets. The decal includes the
Preset number, a description, the factory setting, and a space to record the values.
43
OPERATOR INSTRUCTIONS
P. 5. This sets how long the turntable turns before the FDS continues the wrap cycle after a 10 seconds
film break occurs.
This is applicable when the wrap cycle continues from the point of the film break.
Turntable Deceleration during Top Wraps for Film Tail Elimination
P.6.
This sets when the turntable speed decreases to minimum speed to release the film tail 8.0 seconds
from the clamp. This is for the Early Release option.
Top Platen Ascent Timer
P.7.
This sets how long the Top Platen continues at the end of the wrap cycle. This is Not used
applicable only with the Top Platen option.
Backup Timer on Reverse 90 XT Turntable
P.8.
This sets the time that the turntable turns in the opposite direction to an alternative stop 5.0 seconds
position.
The Number Of Multiple Wrap Cycles To Be Applied To the Load
P.9. Not used
This sets the number of wrap cycles. This preset is only available with the Multiple
Wraps option.
44
OPERATOR INSTRUCTIONS
6.4.3 Configurations
The Configuration Mode gives access to the options in the microcontroller.
45
OPERATOR INSTRUCTIONS
Boards for the FDS Lift:
46
OPERATOR INSTRUCTIONS
47
OPERATOR INSTRUCTIONS
6.5 Initialize the Machine
CAUTION
Before you initialize the machine, read How to Stop the Machine.
48
OPERATOR INSTRUCTIONS
6.6 Thread the Film
WARNING
Obey all safety decal instructions and warnings.
Make sure that the film roll is in the correct position. Refer to the illustration below.
Figure 6.13
1 Push the E-stop
2 Open the EZ Thread Gate
3 Thread the film between the Mast and the Top Guard and between the Rollers
4 Close the Gate
5 The Tackifier is on this Side
49
OPERATOR INSTRUCTIONS
The standard film roll measures 254 mm (10) in diameter and 508 mm (20) in width.
Thread the Film
1. If your machine has Pallet Grip, move the FDS up until the cabling assembly and the angled
roller disengage.
2. Push the E-stop.
3. Look for damage on the film roll. Step 6
4. Put the film roll on the film post.
5. Release the latch on the EZ Thread gate.
6. Pull out 914 1219 mm (3 - 4) of film and
twist it into a rope.
7. Refer to the diagram and thread the film.
8. Close the gate. The film must be loose to
make sure that it does not break.
9. Twist the E-stop to release it.
10. Push the Power On button.
11. Push the Film Assist button.
12. Pull the film and attach it to the load, skid.
Step 8
50
OPERATOR INSTRUCTIONS
6.7 Operate the Machine
1. Twist the E-stop to release it.
2. Push the Power On button.
3. Push the Film Assist button.
4. Pull the film and attach it to the load.
5. Push the Start button.
6. Remove the load from the turntable at the end of the cycle.
51
OPERATOR INSTRUCTIONS
52
MAINTENANCE
7.0 Maintenance
Note: Illustrations are for reference only.
Note: Functions, descriptions and data can be different on your machine. Refer to section 3 for
options.
Note: Some machines have a remote Emergency Stop. It is important to know the location of
all E-stops before you operate the machine.
WARNING
Obey all Lockout/Tagout procedures before you change, adjust, repair a part.
WARNING
Obey all safety decal instructions and warnings.
WARNING
Do not make a change to this machine without approval from Lantech. It can
cause a safety hazard and cancel the warranty.
53
MAINTENANCE
7.1.1 XT Cut and Clamp
Look for, remove the debris (film pieces, wood chips) from around the XT unit.
Move the XT unit to the up position to remove the debris. (Figure 7.2).
Figure 7.1
Figure 7.2
54
MAINTENANCE
7.1.2 Pallet Grip
Standard on Q400 XT
Option on Q300XT
Remove the debris from in and around the
Pallet Grip.
Make sure that the pivoting roller moves freely
and retracts fully.
Examine the groove roller and make sure that it
turns freely.
Make sure that the film moves over the groove
in the groove roller as the load wraps.
55
MAINTENANCE
7.3 Settings and Adjustments
7.3.1 FDS Up, Down Travel Proximity Sensor
Installed Alternative
Factory Setting Setting Setting Notes
FDS Up Travel proximity
sensor 89 mm (3 )
Adjust to limit up travel.
FDS Down Travel proximity 19 mm (3/4)
sensor Standard
Measure from the bottom of the 38 mm (1-1/2")
proximity sensor to the base of w/Bottom Safety
the mast. Sensor
3
89mm 3/4 1 1/2
OR
19mm 38mm
56
MAINTENANCE
FDS Up, Down Travel Adjustment
There are 2 proximity sensors to control the up, down travel of the FDS. The sensors are in the
mast and start when the FDS travels up and down. Get access to the sensors through the door on
the aft of the mast.
57
MAINTENANCE
7.3.2 Belt Slack Switch
The Belt Slack switch senses a fault in the FDS down travel.
You can install, adjust the switch through the top door of the mast. It is on the bottom side of the
top cap.
Note: Before you adjust the switch install the FDS shipping bracket to remove the tension from
the belt.
Figure 7.6
Figure 7.7
58
MAINTENANCE
7.3.3 Turntable Home Proximity Sensor
5/16
8mm
Figure 7.8
59
MAINTENANCE
Turntable Home Proximity Sensor
The turntable uses a proximity sensor to see when the turntable is in the home position. The
sensor is below the turntable top and sees an actuator tab on the drive ring.
1. Push the E-stop and disconnect the power.
2. Remove the turntable tensioner guard and loosen the drive belt tension.
3. Remove the turntable top.
a. Install (2) 3/8x16 eyebolts into the holes on the turntable top.
a. Remove the (4) M8 flat head screws from the middle of the turntable.
b. Attach a strap, chain to the turntable top and to the forklift.
c. Set the turntable top safely out of the work area.
WARNING
Use caution when the turntable top is off. There are moving parts that can
cause an injury.
60
MAINTENANCE
7.3.4 Turntable Drive Belt
Adjust the tension on the turntable drive belt.
1. Remove the cover from the belt tensioner.
2. Make sure that the belt is installed correctly.
3. Loosen the 10 mm locknut until the plate
moves freely.
4. Put a 3/8 torque wrench with a short
extension into 3/8 square opening on the pivot
plate.
5. Torque counterclockwise to 68 N-m (50 lb-ft). Figure 7.10 10 mm Locknut
Tighten the flange locknut by hand as you set
the torque.
6. Use the torque wrench to tighten the 10 mm
locknut on the plate to 52 N-m (39 lb-ft).
7. Replace the cover.
3
1
2
1
2
61
MAINTENANCE
7.3.5 Lantech Intelli-sensor
62
MAINTENANCE
7.3.6 Load Cell
Figure 7.14
Figure 7.15
63
MAINTENANCE
Calibrate the Load Cell Amplifier Board
WARNING
Obey all Lockout/Tagout procedures before you change, adjust, repair a part.
2. Record the current position of jumper J4 on the motor control board. Move it to the CAL
position.
3. Make sure that the jumper J1 is set to STD.
Note: The 20 CAL and 30 CAL jumper settings, potentiometers do not apply.
4. Attach the voltmeter positive lead to load cell output (TP-Load Cell In) and negative lead to
circuit common (TP-C).
5. Apply the power and push the Power On button.
Calibration - These steps make sure that the load cell senses the force on the load.
6. Make sure that there is no pressure on the load cell and the voltmeter shows 0 VDC. If a
voltage is more than 0, adjust the Zero Offset potentiometer to 0 VDC.
7. Thread the film and use a force gauge to apply 2.3 kg (5 lbs) of force to the film.
8. Make sure that the voltmeter shows 1 VDC at load cell output. If the voltage is negative,
turn the load cell 180.
To adjust:
9. Turn the GAIN CAL potentiometer clockwise to increase and counterclockwise to
decrease the output. The GAIN CAL is on the FDS in the small junction box.
10. Complete the calibration at 2.3 kg (5 lbs) and increase the force to 4.5 kg (10 lbs). Make sure
that the voltage is 2 VDC at load cell output.
11. Disconnect the power.
12. Remove the voltmeter leads from the circuit. Refer to the position of jumper J4 in step 2 and
move it to the original position.
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MAINTENANCE
7.4 Motor Control Boards
7.4.1 FDS Lift Motor
Factory Installed Alternative
Notes
Settings Setting Setting
DB Dead Band 35%
RESP Response 50%
IR Internal Resistance
35%
Compensation
RCL Reverse Current Limit 60%
FCL Forward Current Limit 60%
MAX Maximum Speed 65% (90VDC)
FACC Forward Acceleration 20%
RACC Reverse Acceleration 20%
Jumpers
2.5 amp - 20
J2 Current Limit
5 amp - 30
J3 Armature Voltage A90
J4 Reference Voltage 15 V
J5 SPD/TRQ SPD
50%
25% 75%
0% 100%
Figure 7.16
65
MAINTENANCE
7.4.2 Turntable
Factory Installed Alternative
Notes
Setting Setting Setting
DB Dead Band 35%
RESP Response
50%
IR Internal Resistance Compensation
35%
RCL Reverse Current Limit
25%
FCL Forward Current Limit
60%
MAX Maximum Speed 65% = 12 RPM
90 VDC
FACC Forward Acceleration
45%
RACC Reverse Acceleration
10%
MIN Minimum Speed 20% = 16-17
VDC
Jumpers
ARM Armature Voltage A90
CL Current Limit 7.5 Amps
50%
25% 75%
0% 100%
Figure 7.17
66
MAINTENANCE
7.4.3 Power Roller Stretch Plus
Factory Installed Alternative
Notes
Setting Setting Setting
KP 50%
TCI 50%
KD 25%
Cur. Lim. (Current Limit) 60%
Set Pt. Cal 10 VDC
Meter Cal Adjustment
Jumper J1A/J1B 115V/230V
Jumper J2 XT
Jumper J3 6 Amps Or
Motor
Nameplate
Amp Rating
Jumper J4 2.5 LBS.
Load Cell Amplifier Board Jumper J1 STD
50%
25% 75%
0% 100%
Figure 7.18
67
MAINTENANCE
7.5 Potentiometer Settings
7.5.1 Film Delivery System
Dead Band (DB) Keeps the motor in position.
If Dead Band is set too low, a small output voltage can cause the motor to move.
If the motor continues to move down, (drift):
1. Turn the potentiometer counterclockwise until the motor stops.
2. Measure the voltage between the M1 and M2 terminals to make sure that the output is 0
VDC.
Response (RESP) Dynamic Response Control - This potentiometer sets the response of the
control board. If the potentiometer is set too high, it can cause the control board to operate
incorrectly.
Internal Resistance Compensation - This controls how the motor control board measures the
differences between a load and a no-load condition. This is a factory setting.
If you replace the FDS motor, see the steps below.
1. Move the FDS up at low speed with a full film roll.
2. Attach the film to the load and make sure that you maximize the force-to-load.
3. If the motor surges, turn the potentiometer clockwise.
Reverse Current Limit (RCL) Controls the maximum current to the FDS lift motor when it
moves up.
Forward Current Limit (FCL) Controls the maximum current (amperage) to the FDS drive
when it moves down.
Maximum Speed (MAX) Controls the maximum speed of the FDS in the down direction.
1. Turn the FDS Speed knob clockwise.
2. Adjust the voltage to 90 VDC.
3. Measure the voltage across the M1 and M2 terminals.
Forward Acceleration (FACC) Controls the FDS rate of acceleration in the down direction.
Adjust counterclockwise to decrease the time.
Adjust clockwise to increase the time.
Reverse Acceleration (RACC) Controls the FDS rate of acceleration in the up direction.
Adjust counterclockwise to decrease the time.
Adjust clockwise to increase the time.
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MAINTENANCE
7.5.2 Turntable
Dead Band (DB) Keeps the motor in position.
If Dead Band is set too low, a small output voltage can cause the motor to move.
If the motor continues to move down, (drift):
1. Turn the potentiometer counterclockwise until the motor stops.
2. Measure the voltage between the M1 and M2 terminals to make sure that the output is 0
VDC.
Response (RESP) Dynamic Response Control - This potentiometer sets the response of the
control board. If the potentiometer is set too high, it can cause the control board to operate
incorrectly.
Internal Resistance Compensation - This controls how the motor control board measures the
differences between a load and a no-load condition. This is a factory setting.
If you replace the turntable motor, see the steps below.
1. Operate the turntable at low speed with a full film roll.
2. Attach the film to the load and make sure that you maximize the force-to-load.
3. If the motor surges, turn the potentiometer clockwise.
Reverse Current Limit (RCL) Controls the maximum current to the turntable. The RCL sets
the current available to the motor to decrease the speed at the end of the wrap cycle.
Forward Current Limit (FCL) Controls the maximum current (amperage) to the turntable
drive when it accelerates.
Minimum Speed (Min) Controls the speed that the turntable turns during Home speed at the
end of the cycle.
1. Push the Turntable Jog button to move the turntable off the Home position.
2. Push the Home button.
3. Adjust the MIN potentiometer to get 16 VDC at terminals M1 and M2.
69
MAINTENANCE
Forward Acceleration (FACC) Controls the turntable rate of acceleration.
Adjust counterclockwise to decrease the time.
Adjust clockwise to increase the time.
70
MAINTENANCE
7.6 Film Delivery System
7.6.1 Power Roller Stretch Plus
KD Sets the time for the pre-stretch to adjust to a film demand. (Example a load corner).
Set it fully counterclockwise to minimize the effect of this potentiometer.
KP Sets the level of response of the pre-stretch to a film demand. (Example a load corner).
Set Pt. Cal - Adjusts the reference voltage for the drive board.
1. Connect a digital voltmeter (DVM) to TP-C (NEG) and to terminal TB2 pin 3 (POS).
2. Push the Film Assist button to engage the drive board for approximately 7 seconds.
3. Adjust the potentiometer to 10 VDC.
TCI Sets the time for the pre-stretch to adjust to a film demand, such as a load corner.
71
MAINTENANCE
Power Roller Stretch Plus
The load cell amplifier board is on the FDS in the small junction box.
The load cell motor control board is in the control panel.
Examine the jumpers on the amplifier board and the load cell. Make sure that they are in the
correct position.
50%
25% 75%
0% 100%
KP - 50%
TCI - 50%
KD - 25%
Cur. Lim. - 60% PH-A PH-B
Set Pt. Cal. - 10 VDC) +15V RED
GRN +15V
Meter Cal. - 5 lbs. = 50 Millivolts, 10 lbs. = 100 Millivolts WHT COM COM BLK
BLK -15V
SH SH
COM
RED -IN WHT
J1 +IN GRN
30 CAL
AMPS
LBS 20 CAL
2.5/4.5/6.4/CAL TP
STD
XT/STD 6/8/11 A3-14
KP
J2 J3 J4
TP-C
Jumpers:
TCI
J1A/J1B - 115V/230 VAC
TP L.C. In
J2 - STD
KD
J3 - 6 Amps
TP Meter Out
J4 - 2.5 Lbs.
Cur.
Lim.
GAIN ZERO 30 20
J1A J1B CAL OFFSET CAL CAL
115V/230V 230V/115V
Figure 7.19
72
MAINTENANCE
Power Roller Stretch Plus
The steps below make sure that the motor control board adjusts to the changes of force that is
applied to the load during the wrap cycle.
73
MAINTENANCE
7.7 Standard Parts Replacement
7.7.1 FDS Lift Belt
1. Move the FDS to the correct position to install the
shipping brackets.
2. Push the E-stop.
3. Install the FDS shipping bracket and the
counterweight brackets. Refer to the Installation
Instructions.
4. Reset the E-stop.
5. Push the Power On button.
6. Move the FDS down until the Belt Slack switch
engages and the belt is slack.
Figure 7.20
7. Push the E-stop and disconnect the power.
8. Before you remove the lift belt, look at the routing of the belt and the rollers in the mast.
9. Remove the cotter pins from the shaft at the top cap of the mast.
10. Remove the belt from the shaft.
11. Remove the belt from around the rollers in the mast down to the FDS lift drive.
12. Unwind the belt from the drum. Count the number of revolutions.
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MAINTENANCE
13. Attach the belt to the drum.
a. Put the belt through the slot on the drum.
b. Put the metal pin into a
pocket at the end of the
belt.
c. Remove the pin from
the pocket of the belt.
d. Pull the belt out of the
slot in the drum.
14. Put the new belt through
the slot in the drum.
Make sure that the open
Figure 7.21
end of the pocket points to
the drum.
Put the pin in the pocket of the belt.
This holds the pin in the pocket while you
tighten the belt on the drum.
15. Wind the belt around the drum the same
number of revolutions recorded in step 12.
This helps align the belt when it is
installed and attached to the top cap.
16. Install the belt
a. Over the rollers at the top of the mast, and
b. Below the roller on the FDS. Figure 7.22
c. Attach to the shaft on the top cap. 1 Counterweight Roller and Belt
d. Replace the cotter pins in the shaft. 2 FDS Lift Belt and Rollers
17. Complete the belt installation, and apply the power to the machine.
To tighten the belt, move the FDS up at the minimum speed.
18. Remove the FDS shipping bracket and counterweight supports and stow in the mast.
19. Apply the power to the machine.
20. Push the FDS Up and Down buttons to make sure that the belt is aligned.
75
MAINTENANCE
7.7.2 FDS Lift Drive
1. Push the FDS Up, Down buttons to move it to the
correct height to install the shipping brackets.
2. Push the E-stop.
Figure 7.24
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MAINTENANCE
7.7.3 Turntable Drive Belt
1. Push the E-stop and disconnect the power.
2. Install (2) 3/8-16 eyebolts into the holes on the turntable top.
3. Attach a strap, chain in the eyebolts and attach to the forklift.
4. Remove the (4) M8 flat head screws from the middle of the turntable.
5. Remove the turntable top.
6. Remove the tensioner cover.
3
1
2
1
2
77
MAINTENANCE
7.7.4 Turntable Drive
1. Push the E-stop and disconnect the power.
2. Open and remove the access door. Remove the
panels on the mast to get access to the drive.
3. Disconnect the motor wires.
4. Remove the cover from the belt tensioner.
5. Retract the tensioner.
a. Use a 3/8 drive ratchet and short extension,
small flat blade screwdriver and a small Phillips
screwdriver.
b. Put the 3/8 drive extension into the square
opening on the arm and turn counterclockwise.
c. Put the flathead screwdriver into the slot on the
tensioner cam and turn clockwise.
Figure 7.27
d. Turn the arm clockwise to release the tension on
the belt.
e. Put the Phillips screwdriver into the hole on the plate to hold the assembly in position.
6. Install (2) 3/8-16 eyebolts in the holes in the turntable top.
7. Remove the (4) M8 flat head screws near the center of the turntable and lift the top.
8. Attach a strap, chain in the eyebolts and attach to the forklift.
9. Remove the bolts and remove the drive.
10. Remove the brackets from the drive and attach to the replacement unit.
11. Attach the drive and connect the wires.
12. Attach the drive belt on the drive ring and then on the pulley.
13. Remove the screwdriver to release the tensioner.
14. Attach the turntable top to the drive ring on the turntable base.
15. Apply an anti-seize compound to the M8 screws before you attach to the turntable top.
16. Torque to 24 N-m (18 lb-ft).
17. Refer to the procedures for tension setup.
18. Replace the tensioner cover.
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MAINTENANCE
7.8 Pallet Grip
7.8.1 Pivoting Roller
Factory Installed Alternative
Notes
Setting Setting Setting
The pivoting roller and the
groove roller set the height
of the film cable on the 62
pallet.
1. Adjust the actuator to increase, decrease the angle of the roller when it is engaged.
2. Increase the movement of the roller to lower the position of the cable on the pallet. The
standard adjustment for the roller is 62 from floor level.
3. Loosen the bolts to adjust.
62
79
MAINTENANCE
7.8.2 Groove Roller
Factory Installed Alternative
Notes
Setting Setting Setting
The pivoting roller and the
groove roller set the height of 203mm
the film cable on the pallet. (8)
Adjust the groove roller to increase, decrease the quantity of the film to make the cable.
To adjust:
1. Fully engage the pivoting roller and loosen the 2 bolts on the groove
2. Adjust the roller.
The standard adjustment for a standard height 127 mm (5) pallet:
203 mm (8) from the floor to the top of the groove in the guide roller.
203mm
8
Figure 7.30
80
MAINTENANCE
1/8
3mm
Figure 7.31
81
MAINTENANCE
Turntable Clamp Actuator Proximity Sensor
The turntable uses a proximity sensor to sense when the turntable is at the clamp actuator
position. The sensor is below the turntable top and sees an actuator tab on the drive ring.
To adjust the sensor:
1. Push the E-stop and disconnect the machine.
2. Remove the turntable tensioner guard and loosen the tension on the drive belt.
3. Remove the turntable top.
a. Install (2) 3/8x16 eyebolts into the holes on the turntable top.
b. Remove the (4) M8 flat head screws from the middle of the turntable.
c. Attach a strap, chain to the turntable top and to the forklift.
d. Set the turntable top safely out of the work area.
WARNING
Use caution when the turntable top is off. There are moving parts that can
cause an injury.
82
MAINTENANCE
7.9.2 XT Actuator Tab
Factory Installed Alternative
Setting Setting Setting Notes
13mm
2
1
51m
25mm m
83
MAINTENANCE
84
TROUBLESHOOTING
8.0 Troubleshooting
This section tells some of the problems that can occur.
Refer to the electrical and mechanical drawings.
Refer to the Maintenance section for adjustments.
Refer to Section 1.1 for Lantech support.
3 The FDS does not apply The photoelectric sensor for the load Use the Film Height Above Load
the film to the top of the height sensor is not set correctly. gauge and adjust the sensor.
load.
85
TROUBLESHOOTING
8.2 Film Delivery System
86
TROUBLESHOOTING
The FDS down speed is set too low (two Adjust the speed.
speed FDS option includes second speed
potentiometer).
The top wrap counter does not operate Examine the Turntable Home
correctly. proximity sensor (PLS-1) input for
function.
11 The FDS does not move
down during the wrap The Down Travel proximity sensor does Examine, replace the sensor. (PLS-
cycle. not operate correctly. 107)
Examine the cable for damage.
Make sure that the cable connects
with the sensor.
The Belt Slack switch does not operate Examine, replace the sensor (LS4)
correctly.
87
TROUBLESHOOTING
88
TROUBLESHOOTING
8.3 Turntable
89
TROUBLESHOOTING
90
TROUBLESHOOTING
8.4 Pallet Grip
62
91
TROUBLESHOOTING
8.5 XT Cut and Clamp
92
TROUBLESHOOTING
93
TROUBLESHOOTING
94
APPENDIX - GLOSSARY
9.0 Appendix
CE Declaration of Conformity
Glossary
Warranty
9.1 Glossary
Auto Film Cut-off- This is an option that automatically cuts the film at the end of the wrap
cycle.
Banding This set the number of wraps that the FDS applies to the load then continues the wrap
cycle.
Bottom Wrap - This sets the number of wraps for the bottom of the load. The settings are from 1
to 9.
Dual Turntable - This option adds a second turntable. The operator can put a load on 1 turntable
while the other load is in the wrap cycle.
EZ Thread - This is a standard option on the Film Delivery System that makes it easy to thread
the film.
Emergency Stop - The Emergency Stop is a red button that safely stops the machine in an
emergency condition.
Film Delivery System (FDS) - This is the Electrical/Mechanical assembly that applies the film to
the load.
Initialize - This sets the safety circuits and puts all components in the start position.
Lockout/Tagout - These procedures make sure that the machine is off and not started up before
you complete the maintenance and repair work.
Mast The upright that holds the FDS and the control panel.
One-way Wrap - This option applies 1 layer of film to the load and wraps in only 1 direction.
Pallet Grip This option locks the load to the pallet. This is an option on the Q300 and
Q300XT. It is standard on the Q400 and Q400XT.
Pre-Stretch - A procedure that extends the length of the film before the FDS applies it to the load.
95
APPENDIX - GLOSSARY
Presets - Presets are adjustable timers and counters that control the machine operation.
Top Platen - This is a device that holds a load during the wrap cycle.
Top Sheet - This option lets the operator apply a sheet of film on top of the load during the wrap
cycle.
Top Wrap - This sets the number of wraps for the top of the load. The settings are from 1 to 9.
Turntable Top - This is a circular plate that holds the load and turns during the wrap cycle.
96
WARRANTY
9.2 Warranty
All Lantech machines include a warranty against a defect in:
Material
Design
Manufacturing
Lantech has the option to repair, replace the machine, part if:
Lantech is the manufacturer, vendor of the part
The part is defective
Lantech knows about the defect before the warranty period ends
Unless Lantech agrees in writing, this warranty does not include the requirements for federal,
local, safety, environmental regulations and standards.
European standards:
Supply of machine with Orgalime General Conditions
97
WARRANTY
98
PARTS LIST and DRAWINGS
10.0 Parts Lists and Drawings
How to Use This Section
This section helps the operator and maintenance personnel find the parts and assemblies. The
drawings follow each parts list.
99
PARTS LIST and DRAWINGS
100