COUSINS 3300-CTA Instructions for use

INSTRUCTION
&
MAINTENANCE
MANUAL
MODEL 3300-CTA
CONVEYORIZED
PLATFORM AUTOMATIC
STRETCH-WRAPPING
SYSTEM
& OPTIONS
COUSINS PACKAGING INC.
6450 Northam Drive, Mississauga, Ontario L4V 1H9 Canada
Phone: [phone] Fax: [phone]
www.cousinspackaging.com

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RAPIDCHECKLIST
Hereisasimpleandhelpfulprocedureforstartingthemachine,butwealsorecommendthatthe
manualbethoroughlyreviewedbyaqualifiedservicetechnician.

STEPSMANUALSECTION
FORREFERENCE
Removepackagingmaterialsandinspectfordamage.Havethedriver
acknowledgeanydamagebeforesigningacceptance.
IMPORTANT,youareresponsibleforanyfreightdamage
claimswiththecarrier.
Section4:2
Foramachinewithanextendedtower,refertothemanualforassembly
instructions.Section4:3
Installblueplasticcovertothetopofthetower.Section4:5Item1
Plugthemachinetoastandard115Voutlet.A14gaugeextensioncordsmay
beusedtemporarily.Section4:6
Manuallyjogtheturntableandfilmcarriagetocheckforbindingorunusual
noise.Section4:5Item8
Manuallylowerandraisethefilmcarriagetocheckforbinding.Thefilm
carriageMUSToperatebetweenitsupperandlowerlimits
Section5:2:3:2
Section5:2:3:3
Loadarolloffilmandthreaditaccordingtothethreadingdiagramlocatedon
thetopoffilmcarriage.Remembertorestorepowerbypressingthe“Power
On/Reset”push‐buttononthecontrolpanel.
Section6:2
Bringatestloadtothemachine…
Attachthefilmtotheload.
Section6:1
Section6:3
SetForce‐to‐Loadto0…
Setthetop&bottomwrapcountsto2…
Setthefilmcarriageraiseandlowerspeedsto3
Section5:1:7
Section5:2:7
Section5:1:5&
5:1:6
PresstheCycleStartbutton…
IncreaseordecreaseForce‐to‐Loaduntildesiredtensionisachieved…
Increaseordecreasespiralspeedsuntildesiredoverlapisachieved…
Increaseordecreasetopandbottomwrapcountsaccordingly.
Section5:1:4
Section5:1:7
Section5:1:5&
5:1:6
Section5:2:6
Reviewtheinstructionsinthemanualtomodifyotherwrappingparameters.Section5:2:6

NOTE:Foralltrouble‐shootingissues,refertothe “Trouble‐ShootingGuide”sectioninthemanual

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TABLE OF CONTENTS
1:0 BEFORE STARTING THE MACHINE.........................................................9
2:0 SPECIFIC CAUTIONS AND WARNINGS.................................................11
3:0 MACHINE DESCRIPTION ........................................................................13
3:1 Machine Specifications........................................................................ 14
3:2 Conveyor Specifications...................................................................... 15
4:0 INSTALLATION........................................................................................17
4:1 Moving the Machine ............................................................................. 17
4:2 Unpacking and Inspection................................................................... 17
4:3 Extended Tower Assembly (Optional)................................................ 18
4:3:1 Fold-Down Tower Assembly..........................................................18
4:3:2 Tower Guard Removal / Installation............................................... 19
4:4 Installing the Machine.......................................................................... 19
4:5 Pre-Operation Check and Final Assembly ......................................... 20
4:6 General Power Requirements.............................................................. 22
5:0 SET-UP AND OPERATING PROCEDURES ............................................23
5:1 Operating Controls - Control Panel Door........................................... 23
5:1:1 Main Disconnect Switch................................................................. 24
5:1:2 Emergency Stop Push-Pull Button................................................. 24
5:1:3 Power On / Reset Push-button......................................................24
5:1:4 Wrap Cycle Start Push-Button.......................................................25
5:1:5 Carriage Raise Speed Control Potentiometer................................25
5:1:6 Carriage Lower Speed Control Potentiometer............................... 25
5:1:7 Force to Load Control Potentiometer.............................................25
5:1:8 Eject Load Push-Button (Basic 2-Station system only)..................26
5:1:9 Infeed Conveyor Jog Push-Button (Multi-Station System)............. 26
5:1:10 Turntable Conveyor Jog Push-Button (Multi-Station System)........ 27
5:1:11 Outfeed Conveyor Jog Push-Button (Multi-Station System).......... 27
5:1:12 Control Mode Manual / Auto Push-Button (Optional).....................27
5:2 Operator Interface Panel (HMI)............................................................ 28
5:2:1 Control Power Disabled Screen.....................................................28
5:2:2 Start-up Splash Screen..................................................................29
5:2:3 Manual Functions #1 Screen......................................................... 29
5:2:3:1 Turntable Jog Button..................................................................30
5:2:3:2 Film Carriage Raise Button ........................................................30
5:2:3:3 Film Carriage Lower Button........................................................30
5:2:4 Manual Functions #2 Screen......................................................... 30
5:2:4:1 Film Clamp Open / Close Button................................................ 31
5:2:4:2 Cut / Wipe Arm Advance Button................................................. 31
5:2:4:3 Cut / Wipe Arm Retract Button................................................... 31

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5:2:5 Conveyor Manual Functions Screen (Optional)..............................32
5:2:5:1 Conveyor Manual Reverse Button ..............................................32
5:2:6 Machine Settings Screens..............................................................33
5:2:7 Wrap Count Settings Screen..........................................................33
5:2:7:1 Top Wrap Revolutions Preset Display.........................................34
5:2:7:2 Base Wrap Revolutions Preset Display.......................................34
5:2:8 Photo-Eye Settings Screen ............................................................35
5:2:8:1 Auto Load Height Photo-eye Off/On Button ................................35
5:2:8:2 Top of Load Film Overlap Display...............................................36
5:2:9 Clamp Open Height Screen............................................................37
5:2:9:1 Clamp Open Height Display........................................................37
5:2:10 Film Force Settings Screen............................................................38
5:2:10:1 Reduced Bottom Film Force Button ..........................................39
5:2:11 Low Load Settings Screen..............................................................39
5:2:11:1 Enable Low Load Wrap Button..................................................40
5:2:12 Conveyor Settings Screen (Optional).............................................40
5:2:12:1 Infeed Conveyor Auto Start Button (Optional)...........................41
5:2:12:2 Seconds Infeed Start Delay Display (Optional).........................41
5:3 Operating Controls - Inside Control Panel..........................................42
5:3:1 PLC Analog Trim-pots....................................................................42
5:3:1:1 Analog Trim-pot #V0 ...................................................................42
5:3:1:2 Analog Trim-pot #V1 – Decel (Delay) Timer...............................43
5:4 Wireless Remote Control......................................................................43
5:4:1 Wireless Remote Start Push-Button...............................................44
5:4:1:1 Basic 2-stage System .................................................................44
5:4:1:2 Multi-stage System with Optional Powered Infeed Conveyor......44
5:4:2 Wireless Remote E-Stop Push-Button............................................44
5:5 Remote Start / Stop Pendant (Optional)..............................................44
5:5:1 Remote Start Push-Button..............................................................45
5:5:1:1 Basic 2-stage System .................................................................45
5:5:1:2 Multi-stage System with Optional Powered Infeed Conveyor......45
5:5:2 Remote Stop Push-Button..............................................................45
5:6 Remote Lanyard Start Switch (Optional).............................................45
5:7 Machine Status Indicator Beacon........................................................46
5:7:1 Machine Ready (Green) Status Indicator Beacon..........................46
5:7:2 Machine Busy (Red) Status Indicator Beacon................................46
5:8 Super Rapid Thread II™ Prestretch Door Safety Switch ...................47
5:9 Turntable Speed Adjustment (Optional)..............................................47
5:9:1 Turntable Start Speed Setting........................................................48
5:9:2 Turntable Run (Fast) Speed Setting...............................................48
5:9:3 Turntable Slow Speed Setting........................................................48
5:10 Film Carriage Speed Set-Up.................................................................49
5:10:1 Carriage Raise Speed....................................................................49
5:10:2 Carriage Lower Speed....................................................................49
5:11 Film Carriage Limit Switch Striker Adjustment ..................................49

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5:12 Auto Load Height Sensing Photo-Eye Adjustment............................ 50
5:13 Film Carriage Safety Switch ................................................................ 50
6:0 WRAPPING A LOAD................................................................................53
6:1 Placing the Load onto the Turntable Conveyor................................. 53
6:2 Threading the Super Rapid Thread II™ Prestretch............................ 54
6:3 Attaching the Film to the Film Clamp ................................................. 57
6:4 Starting the Wrap Cycle (Initial Set-up) .............................................. 57
6:5 Wrap Cycle Sequence of Operation.................................................... 58
6:5:1 Automatic Wrap Cycle Sequence.................................................. 58
6:5:2 Film Fault Reset Sequence ...........................................................59
6:6 Re-Wrapping the Load ......................................................................... 60
6:7 Removing the Wrapped Load.............................................................. 60
7:0 REMEDIAL ADJUSTMENT ......................................................................63
7:1 Turntable Soft-Start.............................................................................. 63
7:2 Load Toppling or Sliding ..................................................................... 63
7:3 Film Tearing & Puncturing................................................................... 63
7:4 Film Roping Roller................................................................................ 65
7:5 Uneven Top Surfaces........................................................................... 65
7:6 Auto Load Height Photo-Eye False Signals ....................................... 66
7:7 Top Sheet Application.......................................................................... 66
7:8 Reinforcing Band Application ............................................................. 67
7:9 Film Clamp............................................................................................ 68
8:0 MAINTENANCE REQUIREMENTS ..........................................................69
8:1 Lubrication............................................................................................ 69
8:2 Maintenance Frequency Recommendations...................................... 69
9:0 MAINTENANCE AND ADJUSTMENTS....................................................71
9:1 Film Carriage Lift Chain Adjustment .................................................. 71
9:2 Turntable Removal & Installation........................................................ 72
9:2:1 Turntable Conveyor Removal........................................................ 73
9:3 Turntable Drive Chain Adjustment...................................................... 74
9:4 Turntable Support Wheels................................................................... 75
9:5 Film Carriage Limit Switch Lever Arm Adjustment ........................... 75
9:6 Auto Load Height Sensing Photo-Eye Adjustments.......................... 75
9:7 Variable Frequency Drives................................................................... 76
9:8 Turntable Positive Alignment Set-Up and Adjustment...................... 77
9:9 Turntable Home Position Proximity Sensor Adjustment .................. 78
9:10 Dancer Proximity Sensor Installation & Adjustment......................... 78
9:11 Ni-Chrome Film Cutter Hot-Wire Installation...................................... 80
9:12 Film Cut / Wipe Arm Adjustment......................................................... 82
9:13 Film Carriage Safety Switch Adjustment............................................ 84
9:14 Prestretch Roller Cleaning Procedure................................................ 86

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10:0 TROUBLE-SHOOTING.......................................................................... 87
10:1 Trouble-shooting Operator Interface Fault Messages .......................87
10:1:1 Film Fault........................................................................................88
10:1:2 Film Carriage Safety Switch Tripped Fault.....................................89
10:1:3 Film Cut/Wipe Arm Watchdog Timer Fault.....................................90
10:1:4 Film Carriage Height Sensor Fault .................................................91
10:1:5 Variable Frequency Drive Fault......................................................92
10:1:6 Wrap Cycle Watchdog Timer Fault.................................................93
10:2 Trouble-Shooting Guide .......................................................................94
11:0 PARTS LISTS...................................................................................... 107
12:0 COMPONENT MANUALS
13:0 MECHANICAL DRAWINGS
14:0 ELECTRICAL DRAWINGS
15:0 VFD PARAMETERS
16:0 PLC SOFTWARE PROGRAM
17:0 SUPPLEMENTS

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1:0 BEFORE STARTING THE MACHINE
Please refer to the following checklist before calling your Cousins Packaging
distributor or the factory for start-up assistance. This will prevent confusion and
additional expense during the start-up process.
1. Check for any freight damage, (hidden or apparent) and if found report it
to the carrier. It is the responsibility of the consignee to report any
damage incurred during shipment.
2. Uncrate and assemble the machine. If the machine is equipped with an
extended tower, erect the tower according to the instructions in Section
4:3.
3. Set the machine in place, and ensure that it is level. After leveling, lag it
to the floor.
4. Before operating the machine, remove any Styrofoam, strapping, or
shipping blocks from beneath the film carriage that may be present.
5. Actuate the Film Carriage Descent Obstruction Plate upwards and then
release, to ensure that the plate mechanism and safety switch assembly
are functioning freely. If the Descent Obstruction Plate becomes
jammed in the recessed position, the film carriage lower function
will become inoperable.
6. If the machine is being used in conjunction with a gravity exit conveyor,
ensure that the conveyor is correctly aligned with the turntable conveyor
and a minimum 1/2" gap is present between the turntable and the first full
length roller on the gravity conveyor. Mount the gravity conveyor photo-
eye to the conveyor in the indicated location. After leveling the conveyor,
lag it to the floor.
7. Connect the incoming electrical power supply and verify that the voltage
is correct, (refer to Section 4:6). Do not connect or attempt to operate
the machine without supplying proper and consistent electrical
input. Potential damage may occur that will void warranty.
8. Ensure that the limit switches mounted on the film carriage operate
between the Upper and Lower Limit Switch Strikers. These strikers are
the adjustable button-head screw and bar assemblies mounted to a rail
on the side of the tower. These strikers define the maximum travel of the
carriage. WITHOUT THESE STRIKERS AT THE TOP AND BOTTOM
TO TELL THE CARRIAGE TO STOP, THE CARRIAGE WILL OVER-

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RUN ITS SAFE OPERATING RANGE, POTENTIALLY CAUSING
SERIOUS DAMAGE!
9. During the winter months, gear-reducer lubricants will thicken when
exposed to cold weather during shipment. Allow the machine to warm up
to room temperature for 8 hours (minimum) before attempting to operate
the machine. FAILURE TO DO THIS MAY RESULT IN BLOWN FUSES
OR MOTOR V/F DRIVE FAILURE!
10. If the machine is to be loaded and / or unloaded by fork-lift truck, it is
strongly recommended that fork-lift truck floor stops be installed to
prevent the lift truck from colliding with the conveyors.
11. READ THE MANUAL!