GLOBAL INDUSTRIAL 238509 Fully Automatic Low Profile Pallet Wrapper User Manual

GLOBAL INDUSTRIAL 238509 Fully Automatic Low Profile Pallet Wrapper User

Manual

Machine Dimension

1. System Specification

Machine Dimension

(See Figure 1)

Specification

• 120V 60HZ Single-Phase
• Power Supply: 1000W
• Air: 6-0.7Mpa

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

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 Once an object is detected underneath the moving film carriage, the machine will stop.
• The machine is equipped with automatic film attaching and cutting It can feed and cut the film automatically, no operator required.
• The interval between 2 wrapping operations is required to more than 3

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
• Do not immerse in
• To Reduce the Risk of Electric Shock and Injury to Persons, Disconnect from Power Supply Before Servicing and
• To provide continued protection against risk of electric shock, connect to properly grounded outlets
• 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

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.

Machine Set-up

1. Place the crated machine close to the designated wrap 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
3. Check all internal connections to ensure there is no loose/disconnected electrical
4. Connect the motor wiring and sensor leads according to the corresponding wire
5. If the OPTIONAL ramp ( Model NO: 412410) is purchased: Select a ramp position illustrated 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)

 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)

Connect to the power supply and perform a ground test before using the machine.

Control Panel Buttons

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

Operator Controls

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.

Clamp Close

Manually close or open the film clamp device. When this button is pushed, the button will turn green and display as “Clamp Open”. Push the button again, the clamp will open.

Swing Arm Out/Swing Arm Back

Manually operate the swing arm to move closer and further from the pallet.

Electromagnet ON

Manually release film tension from the film carriage. When this button is pushed, the button will turn green.

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.

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.

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 &11))
To return to the main menu, press the EXIT button.

 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 film clamp and leave 50-100mm longer than the clamp (See Figure 14)
4. Turn the emergency stop switch clockwise and turn the power

Machine Operation

Trial run-Normal System Start-Up:

1. Place the Packaged pallet on the machine turntable until the positioning stopping plate touch.
2. Turn the power on
3. Thread the film as instructed and attach it to the film
4. Adjust the sensitivity of the photo The machine is adjusted to the factory setting before delivery.
5. Push “Start” button on control panel or “ON” on remote controller to initiate
6. Push” E-Stop” or “OFF” on the remote controller to stop machine

NOTE: It is recommended to perform a trial run in order to become familiar with the various parameters, adjustments, and speed controls.

Emergency Stop Condition.

1. In the event of an emergency, press the STOP This cancels the current wrapping cycle and immediately stops the system. Figure 15 will display on the screen.
2. Correct the
3. Turn the STOP button clockwise to reset the stop button and perform the normal system start-up

NOTE: If the weight of the package exceeds 1,100lbs, turn the turntable adjustment knob M1 counterclockwise prior to pressing the emergency stop button.

Operation

1. Load the film roll in the film carriage and thread the film according to Figure 13
2. Turn the power
3. Attach the film to film clamp according to Figure 14
4. Adjust the sensitivity of the photo The machine is adjusted to the factory setting before delivery.
5. Adjust the parameter according to the packing
6. Trial run: Place the packaged pallet, used for a trial run, on the machine 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 users is familiar with the various parameters and adjustments, the user is ready to operate the machine.

Maintenance & Troubleshooting

CAUTION! All machine maintenance work must be performed with the power supply disconnected.

1. Keep the machine 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 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.

OPERATING

ISSUES

| CAUSES| RECOMMENDATIONS
---|---|---

The machine is not powering on

| Main power is turned off| Check the power going into the machine.

Verify that switch is turned on.

Wrong parameter setting| Reset parameter
PLC Failure|

Replace PLC

No display on PLC screen
Breaker Failure| Replace Breaker

Turntable does not run

| Pallet overweight| Reduce the pallet weight
Chain falls off| Check the chain transmission mechanism (loosen the chassis screws, remove the turntable cover and check whether the

chain and tension are abnormal.

Loose Chain

Inverter failure or damage

| 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.

Film Carriage malfunction

| Limit switch failure or damage| Overhaul or replace the limit switch
Photocell failure or damage| Overhaul or replace the photocell
Loose chain or interference| Overhaul the vertical lifting chain system

 | PLC Failure|

Replace the PLC

---|---|---
Carriage Up/Down button is

unresponsive

Inverter failure or damage| Troubleshoot and   replace   inverter   if

damaged

Motor Failure| Overhaul the lifting motor
The bottom safety plate is stuck| Overhaul if the safety plate is stuck or the

safety switch is damaged

Film clamping failure

| Air supply is not enough or

disconnected

| Overhaul if the air tube is leaking and

make sure the air supply is 0.6MPa

Clamp rubber falls off or damage| Fasten or replace rubber
Magnetic valve or cylinder failure| Replace magnetic valve or cylinder

Film Breaks

| Clamping is not tight enough| Refer to previous troubleshoot
The position of Roll making roller

falls off the position

| Adjust and fasten the roller
Film is too thin or insufficient

quality

| Replace film roll（Thickness≥20um）
Film clamp does

not open

| Clamping sensor does not detect

signal

| Overhaul the sensor cable or replace

clamping sensor

Turntable does

not stop

| Home position sensor does not

detect signal

| Overhaul the sensor cable or replace

home position sensor

Components & Parts

Turntable

No| Part No| Description| QTY
1| XT4505-DM-0100| Turntable Base| 1
2| XT45N-0101-1-V1| Hinge fixing base| 1
3| 10000000697| Tension pulley bracket| 1
4| XT4505-0129-V1| Tension pulley:12B-Z11| 1
5| XT8020-0614| Plastic Spacer155| 1
6| XT4505-DM-0126| Protection Cover| 1
7| 10000000486G| Motor chain pulley: 12B, 14 teeth| 1
8| XT8020-0506| Plain roller| 4
9| 30 CV-32-750-30| Vertical Gear motor 0.75KW| 1
10| XT4505-DM-0102| Motor cover| 1
11| 10000000510-DM-HJ| Disc| 1
12| XT4505-DM01-09| Round Cover| 1
13| 10010000617| Turntable roller| 12
14| GB/T1243| Chain 12B-190 keys with joint| 1
15| KSL06-M6| L type rotating joint φ6-M6| 1
16| GB/T276| Bearing 6205-2RS| 1
17| 10000000548| Chain noise reducer| 3
18| 10000000688| Contacting plate holder| 2
19| GB/T5783-2000| Hex bolt M860| 2
20| 10000000693-DM| Center turntable pulley:12B-Z50| 1
21| PL-05N NPN Type| Approximate Switch| 2
22| XT45N-0110| Switch holder| 2
23| FPC6-M5| Welding plate| 1
24| XT4505-DM01-02| Bracket| 2
25| XT4505-DM01-01| Positioning stopper plate| 1
26| XT4505-DM01.01| Clamping unit| 1
27| XT4505-DM01-08| Clamping cover| 1
28| XT4505-DM01.02| Film cutting unit| 1
29| XT4505-DM-0126-1| Protection cover A| 1
30| XT4505-0138-CN82| Motor bottom cover| 1

Film Attach Unit

Film Cutting Unit

Film Attaching & Cutting Unit

No| Part No| Description| QTY
1| XT4505-DM02-01| Film cutting holder| 1
2| BM530-02-D9| Magnetic valve| 1
3| PU322-02-S9| Magnetic valve| 1
4| AFC20001| Pneumatic combination parts| 1
5| HSV08| Manual valve| 1
6| FPC 8-02| Screw| 1
7| XT4505-DM02-05| Film breaker base cover| 1
8| XT4505-DM02-13| Cylinder holder| 1
9| SC40175SCA| Cylinder 40175| 1
10| XT4505-DM02-03| Roller holder| 1
11| W550T2mm-L520mm| Wiping PVC belt| 1
12| XT4505-DM02-04| Wiping belt cover| 1
13| XT4505-DM02-08| Heating element copper joint A| 1
14| XT4505-DM02-09| Heating element tension spring| 2
15| XT4505-DM02-12| Bakelite sleeve| 2
16| XT4505-DM02-07| Heating element base| 2
17| 20600000153-V1| Tension roller| 1
18| Φ1700| Heating element| 1
19| XT4505-DM02-11| Copper joint B| 1
20| M1245| Hex Bolt     M1245| 1
21| SC-40-U| Fish eye joint PHS12| 1
22| XT4505-DM02-02| Rotating arm welding parts| 1
23| M12| Hex Bolt     M12| 1
24| UCP204| Bearing| 2
25| XT4505-DM01-05| Clamping arm base| 2
26| 10| Shaft Ring| 4
27| M6*12-N| Screw| 2
28| MB1012| Oil free bearing| 4
29| XT4505-DM01-02| Clamping arm unit A| 1
30| XT4505-DM02-1| Clamping rubber| 2
31| XT4505-DM01-04| Clamping arm rotating arm shaft| 2
32| XT4505-DM01-03| Clamping arm unit B| 1
33| XT4505-DM01-07| Connection pole| 2
34| APDCL-32-B50-Y| Cylinder| 1
35| XT4505-DM01-06| Cylinder Base| 2
36| APCCL-32-B50-Y| Cylinder| 1
37| M6| Hex fasten bolt| 2

Film Carriage

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 6625| 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 L218W12T2mm| 1
16| XT45Z-03-V1| Top film carriage cover| 1
17| XT45Z-09| Shaft lock ring| 1
18| 10000000046| Tension friction wheel| 1
19| XT4505-DM03-01| Guiding plate, A| 1
20| XT4505-DM03-04| Belt bracket B| 1
21| XT4505-DM03-03| Belt bracket A| 1
22| ZYE1-1564Z| Electromagnet| 1
23| TD98-03-39| Spring| 1
24| M440| Cross head screw| 1
25| M535| Hexagon socket cap head screw| 1
26| XT4505-DM03-03| Guiding plate B| 1
27| FR-2MX| Photocell| 1
28| M820| Star knob| 1
29| XT45M-14| Guide roller| 2
30| XT45Z-16| Switch install plate| 1
31| KW3-0Z-2| Micro switch with Wheel| 1
32| QB/T3876| Hinge:5038| 2
33| XT45Z-15-V3| Safety plate| 1

Tower and Lift

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| 2
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 6625| 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 B414| Lifting reduction motor| 1
34| XT4505S-01-20| Lifting Pulley Cover| 1

Electrical Components

Electrical Diagram

Read More About This Manual & Download PDF:

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>