Lantech QL-400 User manual

1
QL-400
Semi Automatic Stretch Wrap Machine
Manual
Serial Number: QM0056781

TABLE OF CONTENTS
2
1.0 Introduction.....................................................................................................................................5
1.1 Support..........................................................................................................................................6
2.0 Specifications...................................................................................................................................7
2.1 Machine Specifications.................................................................................................................8
2.2 Introduction to Load Guardian....................................................................................................10
3.0 Options...........................................................................................................................................11
4.0 Safety..............................................................................................................................................13
4.1 General Safety.............................................................................................................................13
4.2 Personnel Safety..........................................................................................................................13
4.3 Lockout/Tagout Procedures........................................................................................................14
4.4 Safety and Environmental Controls............................................................................................14
4.5 Warnings, Cautions and Notes....................................................................................................15
4.6 Pictograms...................................................................................................................................16
4.7 Residual Risk..............................................................................................................................18
5.0 Installation Instructions ...............................................................................................................19
5.1 Prepare the Area..........................................................................................................................19
5.2 Personnel, Equipment and Tools ................................................................................................20
5.3 Installation...................................................................................................................................21
6.0 Operator Instructions...................................................................................................................25
6.1 Sequence of Operation................................................................................................................26
6.2 Components ................................................................................................................................27
6.3 Assemblies..................................................................................................................................29
6.3.1 FDS and Counterweight......................................................................................................29
6.3.2 FDS Lift Drive....................................................................................................................29
6.3.3 EZ Thread Gate...................................................................................................................30
6.3.4 Pallet Grip...........................................................................................................................31
6.4 Controls.......................................................................................................................................32
6.4.1 Icon List..............................................................................................................................33
6.5 Operator Controls........................................................................................................................35
6.5.1 Select a Ready-to-Wrap Profile ..........................................................................................36
6.5.2 Create a Profile....................................................................................................................37
6.5.3 Home Menu ........................................................................................................................42
6.5.4 Manual Jog..........................................................................................................................43
6.5.5 Film Settings.......................................................................................................................43
6.5.6 Wrapper Settings.................................................................................................................44

TABLE OF CONTENTS
3
6.5.7 Film Calibration..................................................................................................................45
6.5.8 Wrap Apps Defaults............................................................................................................46
6.5.9 Options Defaults .................................................................................................................46
6.5.10 System.................................................................................................................................47
6.5.11 Service.................................................................................................................................47
6.5.12 Personalization....................................................................................................................48
6.5.13 User Access.........................................................................................................................48
6.5.14 Reports................................................................................................................................50
6.5.15 Help Menu ..........................................................................................................................55
6.5.16 Edit Profile..........................................................................................................................58
6.6 Initialize the Machine..................................................................................................................64
6.6.1 Lockout/Tagout Procedures................................................................................................64
6.6.2 How to Stop the Machine....................................................................................................64
6.6.3 Apply the Power to the Machine.........................................................................................64
6.7 Thread the Film...........................................................................................................................65
6.8 Operate the Machine...................................................................................................................66
6.8.1 Manual Override.................................................................................................................67
6.9 Film Roll is Empty......................................................................................................................68
6.10 Film Break Recovery..................................................................................................................68
7.0 Maintenance ..................................................................................................................................69
7.1 Daily and Weekly Maintenance..................................................................................................70
7.1.1 Pallet Grip...........................................................................................................................70
7.2 Monthly Maintenance.................................................................................................................70
7.3 Settings and Adjustments............................................................................................................71
7.3.1 FDS Up, Down Travel........................................................................................................71
7.3.2 Belt Slack Switch................................................................................................................72
7.3.3 Home Proximity Sensor for the Turntable..........................................................................73
7.3.4 Turntable Drive Belt ...........................................................................................................75
7.3.5 Load Height Sensor.............................................................................................................76
7.4 Variable Frequency Drives (VFD)..............................................................................................76
7.5 Standard Parts Replacement........................................................................................................77
7.5.1 FDS Lift Belt.......................................................................................................................77
7.5.2 FDS Lift Drive....................................................................................................................79
7.5.3 Turntable Drive Belt ...........................................................................................................80
7.5.4 Turntable Drive...................................................................................................................81

TABLE OF CONTENTS
4
7.6 Pallet Grip®................................................................................................................................82
7.6.1 Tilting Roller.......................................................................................................................82
7.6.2 Groove Roller......................................................................................................................83
8.0 Appendix........................................................................................................................................85
8.1 Glossary ......................................................................................................................................85
8.2 Warranty .....................................................................................................................................87
8.3 Wrap Problems............................................................................................................................88
8.3.1 Containment Force Variation..............................................................................................88
8.3.2 Product Crushes at the Edges of the Load ..........................................................................88
8.3.3 Product Crushes at the Top of the Load..............................................................................89
8.3.4 Excessive Film Breaks........................................................................................................89
8.3.5 Excessive Film Use.............................................................................................................90
8.3.6 Reduce, Eliminate the Film Tails........................................................................................90
8.3.7 Load Shifts in Shipment......................................................................................................91
8.3.8 Load Twists.........................................................................................................................91
8.3.9 The Load Slides off the Pallet.............................................................................................92
8.3.10 Increase the Throughput......................................................................................................92
8.3.11 Belt Slack Condition...........................................................................................................93
8.3.12 Wrap to Custom Height ......................................................................................................93
8.4 Wrap Quality...............................................................................................................................94
8.4.1 What is Load Guardian®? ..................................................................................................94
8.4.2 How to Select the Film for Your Load................................................................................94
8.4.3 How to Select the Correct Film...........................................................................................94
8.4.4 Find the Correct Pre-stretch................................................................................................95
8.4.5 What is Containment Force?...............................................................................................95
8.4.6 Set, Adjust the Tension on the Film....................................................................................96
8.5 Profile Build Descriptors ............................................................................................................96
8.5.1 Load Height ........................................................................................................................96
8.5.2 Load Shape..........................................................................................................................97
8.5.3 Pallet Fit..............................................................................................................................97
8.5.4 Wrap Height........................................................................................................................98
8.5.5 Wrap Apps..........................................................................................................................98
8.5.6 Profile Name.......................................................................................................................98
8.5.7 Profile Colors and Save.......................................................................................................99
9.0 Parts Lists and Drawings ...........................................................................................................101

INTRODUCTION
5
1.0 Introduction
Section 1 –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.
Section 2 –Specifications
Section 3 - Options
These sections contain data about your machine and special options.
This is important as you install and operate the machine.
Section 4 - Safety
This section points out the Warnings and Cautions to make sure that all personnel work
in a safe environment.
Section 5 –Installation
Section 6 –Operator Instructions
These sections tell you how to install and use the machine safely and efficiently.
Section 7 –Maintenance
This section tells you how to make sure that the machine stays at top performance.
Section 8 –Appendix
This section can include the CE –Declaration of Conformity, Glossary and Warranty
procedures.
Section 9 –Parts List and Drawings
This section includes the Bill of Materials (BOMs)
This manual helps you operate your machine safely and efficiently.
The value is to increase your productivity and decrease the packaging costs.

INTRODUCTION
6
1.1 Support
For support, use the phone and email data below:
LANTECH AFRICA & EUROPE –MALDEN NETHERLANDS
Phone
Email
Fax
Parts
[phone]
Parts
[email protected]
[phone]
Service
[phone]
Service
[email protected]
LANTECH ASIA PACIFIC –MELBOURNE AUSTRALIA
Phone
Email
Fax
[phone]
Parts
[email protected]
[phone]
Service
[email protected]
Support
[email protected]
LANTECH CHINA - SHANGHAI
Phone
Email
Parts
[phone]
Parts
[e-mail]
Service Hotline
[phone]
Service
[e-mail]
LANTECH NORTH & SOUTH AMERICA –LOUISVILLE KENTUCKY
Phone
Email
Fax
Parts
502-815-9101
Parts
[email protected]
502-267-8864
Service
502-815-9103
Service
[email protected]
Retrofits
502-815-9104
Retrofits
[email protected]

SPECIFICATIONS
7
2.0 Specifications
All Lantech® machines have a serial number tag in 1 of these locations:
On the Door of the Enclosure
On the Electrical Enclosure
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.

SPECIFICATIONS
8
2.1 Machine Specifications
QL-400
General
Dimensions
Standard Height
2032 mm (80”) Wrap Height
3023 mm L x 1702 mm W x 2337 mm H
(119" L x 67" W x 92" H)
Dimensions
Extended Height
2794 mm (110”) Wrap Height
3023 mm L x 1702 mm W x 3099 mm H
(119" L x 67" W x 122" H)
Weight with Pallet
671 kg (1480 lb)
Performance
Speed*
25 - 35 Loads/Hour
Minimum Load Dimensions
762 mm x 762 mm x 508 mm
(30” W x 30” L x 20” H)
Maximum Load Dimensions - Standard Height
Note: Maximum wrap height increases 254 mm
(10”) for 762 mm (30”) FDS option
2032 mm (80”) Wrap Height
1321 mm x 1321 mm x 2032 mm
(52” W x 52” L x 80” H)
Maximum Load Dimensions - Extended Height
2794 mm (110”) Wrap Height
1321 mm x 1321 mm x 2794 mm
52” W x 52” L x 110” H
Load Dimensions - Diagonal
1829 mm (72") Recommended
Maximum Load Weight
2268 kg (5000 lbs)
* Note: Changes to the load dimensions, wrap pattern and the steps to load, unload the turntable can change the
throughput.

SPECIFICATIONS
9
Turntable
Turntable Diameter
1651 mm (65”)
Turntable Speed
15 rpm
Turntable Height
70 mm (2 ¾”)
Turntable Bearing Support
1219 mm (48”) Diameter
Turntable Drive
1 hp (.75 kW) 230/460 VAC 1800 rpm 3 Phase, 50/60 Hz
TEFC
Motor - 40:1 Speed Reducer
Film Delivery System (FDS)
FDS Lift Drive
1/2 hp (.37 kW) 230/460 VAC 1800 rpm TEFC
37:1 Speed Reducer
24 VDC Brake
Film Pre-stretch
Power Roller Stretch Plus with EZ Thread and Pallet
Grip®
FDS Drive
1/2 hp (.37 kW) 230/460 VAC 3 Phase, 1800 rpm TEFC
Film Pre-stretch Percentage
250%
Film
All Commercial Grade Films (50 - 150 Gauge)
Standard Film Capacity
254 mm (10”) Diameter
508 mm (20”) Width (Standard)
762 mm (30”) Width (Optional)
Film Tension
Electronically controlled with Reduced Film Tension at the
start of the wrap cycle
Auto Film Cut-off
Automatically cuts the film at the end of the wrap cycle
Electrical Requirements
Electrical Supply
Dedicated, Grounded Electrical Supply
Do not use on GFCI circuit
Power - US
120 Volts, 20 Amps
Power - EU
220 Volts, 16 Amps
Controls
Single Board Computer with Touch Screen Interface
Communications
IP Address
192.168.139.128
Network Mask
255.255.255.0
Gateway IP
192.168.139.2
DNS
192.168.139.2
Warranty
5 Years

SPECIFICATIONS
10
2.2 Introduction to Load Guardian
Why is Load Guardian important?
Load Guardian is a control system that helps the Operator set the Wrap Profiles quickly and easily.
Containment Force is what holds the load together and is the number of layers of film multiplied by the
film tension.
Load Guardian:
•Holds the Containment Force set for the applicable Wrap Profile
•Decreases the Film Tension at the bottom of the load –to decrease Film Breaks
•Controls the position of the film to hold the set Containment Force
•Shows the Containment Force based on the settings for the Film Coverage
Load Guardian monitors and adjusts to changes in the film tension and the number of layers of film on
the load.
Load Guardian is what gives you Safe-to-Ship Loads.
How? Select or Create a Profile for each type of load.
There are 10 Ready-to-Wrap Profiles already set in your machine.
•Put a load on the turntable and see if you can identify your load in the Ready-to-Wrap Profile
selection
•If you can, select the Profile and Push Start
If you cannot identify your load in the Ready-to-Wrap selection, push Create New Profile.
Create the Profile for your load.
In minutes, you can create a Safe-to-Ship Load.
See Section 6.5.1 and 6.5.2 for detail of the pre-programmed Profiles and how to Create a Profile

OPTIONS
11
3.0 Options
This section includes the options that are not on the standard machine.

OPTIONS
12

SAFETY
13
4.0 Safety
This manual tells the operator and maintenance personnel how to safely install and operate the
machine. This section includes:
•General safety
•Personnel safety
•Lockout/Tagout Procedures
•Safety & Environmental Controls
•Warnings, Cautions and Notes
•Pictograms
•Residual Risk
4.1 General Safety
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.
4.2 Personnel Safety
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.
•Refer to the Installation section for personnel and tools to safely install the machine.

SAFETY
14
4.3 Lockout/Tagout Procedures
Lockout/Tagout Procedures
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
Automatic Machines
1. Disconnect the main power.
a. Move the Main Disconnect switch to the “Off” position.
b. Lock the Main Disconnect switch in the “Off” position.
2. Disconnect the main pneumatic supply.
a. Move the main pneumatic valve to the “Off” position.
b. Lock the main pneumatic valve in the “Off” position
Semi-Automatic Machines
1. Move the “Main Disconnect” switch to the “Off” position.
2. Lock the “Main Disconnect” switch in the “Off” position.
3. Disconnect the power cord from the electrical outlet.
4. Lock the power cord.
4.4 Safety and Environmental Controls
Safety and 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.

SAFETY
15
4.5 Warnings, Cautions and Notes
Warnings, Cautions and Notes
Warning
Tells the operator that there is a hazard that can cause a serious injury.
Caution
Tells the operator that there is a hazard that can cause:
•A minor injury
•Damage to the equipment, environment.
Note
Gives additional data that is helpful to the operator.

SAFETY
16
4.6 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.
Do Not Operate Without Guard in
Position
No Entry
Maximum Capacity
Do Not Step
Do Not Reach
Fire Can Occur
Chemical Waste
Environment
Important Note
Refer To Manual
Hot Surface
Electrical Warning
Explosion Warning
Release of Pressure
Electrical Shock Warning

SAFETY
17
Pull In Warning
Do Not Walk on Conveyor
Hit is Possible From Above
Machine Can Fall
Obey the Safety Instructions
Hit is Possible From The Side
Fall Warning
Do Not Reach
Cut Warning
Film Delivery System Warning
Crush Warning

SAFETY
18
4.7 Residual Risk
Residual Risk - There is a risk when you operate, repair this machine even when personnel obeys all
safety requirements.
Q Series®, S Series™, Lanringer and Ring Straddle
Risk:
There is a risk of shock when you perform a troubleshooting task with the power to the
machine “On”.
Make sure that only qualified personnel complete these tasks when the power to the machine
is “On”.
PPE
Use of PPE against injury is not applicable
Q Series® and S Series™
Risk:
The Film Delivery System (FDS) can fall during maintenance if you do not use sufficient
support to hold the FDS.
Make sure that the supports hold the FDS when you change, adjust, repair the lift motor or
belt.
PPE
Use of PPE against injury is not applicable
Q Series®
Risk:
The counterweight can fall during maintenance if you do not use sufficient support to hold it.
Install the FDS shipping brackets and the counterweight brackets before you change, adjust,
repair the lift motor or belt.
PPE
Use of PPE against injury is not applicable

INSTALLATION
19
5.0 Installation Instructions
Read the Installation section and do the steps in sequence.
Note: Illustrations are for reference only.
Note: Functions, descriptions and data can be different on your machine. Refer to Section 3 Options.
Note: Make sure that only qualified personnel complete the steps for Installation, Maintenance and
Troubleshooting.
WARNING
Obey all safety decal instructions and warnings.
CAUTION
Complete the installation before you apply the power to the machine.
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.
5.1 Prepare the Area
The space requirements can be different on each machine.
Refer to your machine dimensions when you prepare for the installation.
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 (¼”).
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

INSTALLATION
20
5.2 Personnel, Equipment and Tools
Standard Height
Personnel and Safety Equipment
•1 Forklift Operator
•1 Electrical/Mechanical Technician
Equipment
•Forklift with 2000 kg (4000 lb) capacity and 5 m (15’ ) lift
•1 Ladder
Tools
•Wrenches and Sockets (Metric and Standard)
Extended Height (Mast Ships in Horizontal Position)
Personnel and Safety Equipment
•2 Forklift Operators
•1 Mechanical Technician
•1 Electrical Technician
Equipment
•2 Forklifts with 2000 kg (4000 lb) capacity and 5 m (15’ ) lift
•1 Ladder
Tools
•Wrenches and Sockets (Metric and Standard)
•Allen wrenches (Metric and Standard)
•Torque wrench
•Straps, Chains