Orion H77-17 User manual

MODEL H77-17
SERIAL # 2004-8899999
2270 Industrial boul. , Montreal (Laval), Canada, H7S 1P9
Tel.: [phone], Fax: [phone]

INSTRUCTION
MANUAL
FOR ALL INQUIRIES
PLEASE CONTACT
OUR LOCAL DISTRIBUTOR
FOR NORTH AMERICA ONLY
1-800-333-6556

Thank you for choosing ORION stretch-wrapping
equipment. It is a wise choice, which will benefit your company
now and in the future.
ORION uses a unique combination of functional, rugged
steel structure and sophisticated control systems to offer
equipment high in durability and low in maintenance
requirements. Our advance control systems mean that Orion
equipment can be operated safely and efficiently without the
need for special operator expertise.
Please read this manual carefully and keep it handy.
Following these simple operating instructions will insure the
safe and efficient performance of this machine while simple
maintenance procedures will guarantee a long and productive
life of the equipment.

Notice:
Our manual covers standard features of the machine. Certain
options may not be fully covered due to their unique application.
In order to acquire more information about custom made features of
your machine and to provide quicker service, the following information is
required when making an inquiry:
1)Model
2)Serial Number
3)Subassembly ( see PART LIST )
SAFETY:
ORION'S stretch wrappers should be operated with caution and common
sense as any other industrial equipment. To prevent injury and/or electrical
shocks, careful operation of the machine and awareness of its many automatic
functions is required.
NOTE: All electrical power and compressed air must to be disconnected
prior to all inspection, maintenance or repair work.
ORION PACKAGING INC.

ORION PACKAGING SYSTEMS INC.
SEMI-AUTOMATIC SPECIFICATIONS -EFFECTIVE SEPTEMBER 1st, 2000
REVISED APRIL 2001
ORION EPICSERIES MODEL H-77
Spiral Semi-Automatic Medium Duty High Profile
Maximum Load Size 55”W x 55”L x 82”H
Weight Capacity 4,000 Ibs. Dynamic, 8,000 Ibs. Static
Utilities 115/1/60 15 Amp Service
Turntable 48”x48” Structural Steel Plate Turntable with Welded Steel Skirt
Dura-GlideTurntable Support System
Quiet in Operation, Maintenance Free
Turntable Drive 0-12 RPM Variable Turntable Speed
Variable Speed Drive Motor
Electronically Adjustable Acceleration/Deceleration (Soft Start)
Direct Heavy Duty Chain & Sprocket Drive
Positive Alignment Feature
Control Features CSA Approved, NEMA 12 Control Panel
State-of-the-Art Logic Control
User Friendly Microprocessor with Micro-Switch Keypad
Revo-LogicExact Wrap Counting Technology
Electronic Film Tension Control Adjustment on the Panel
Separate Top / Bottom Wrap Count Selectors with LED Count Display
Variable Speed Film Carriage Up/Down Control
Film Carriage Raise/Lower Switch (Manual)
Photocell for Automatic Load Height Detection
Turntable Jog Pushbutton
Film Delivery 20” Insta-Thread LT Powered Pre-Stretch Film Delivery System
200% Pre-Stretch Ratio
Easy & Safe to Operate Self-Threading Carriage Design
Electronic Film Tension Control Adjustment on the Panel
Variable Speed Film Output (Non-Wearing Sensor)
Heavy Duty Chain & Sprocket Ratio Control
Adjustable Film Roping Bar on Chassis for Stronger Interlocking of Load and Pallet
Film Carriage Elevator Drive Heavy Duty ANSI Chain Carriage Lift
Variable Speed Drive Motor
Multi-Point UHMW Precision Carriage Guidance System
Structural Features 100% Structural Steel Construction Throughout
Easy Access to All Components
Open Mechanical Design for Ease of Maintenance
Forklift Portable Base Design
Structural Steel Tube Mast
Hinged Mast for Ease of Shipping, Portability
Estimated Shipping Weight 1,100 Ibs.
Visit our Distributor Support Website at www.support.orionpackaging.com

MACHINE UNLOADING
INSPECTION & INSTALLATION
UNLOADING
Machine can be easily unloaded and transported by a forklift with a minimum capacity of
2500 lbs.
1. Carefully insert the forks into the lifting tubes to the maximum possible depth. Depending
on the model, a forklift access may be either at the turntable end of the machine frame, the
tower end or both. In case of the mongoose machine enter the forks under the frame or
insert the forks in the tube brackets welded to the top of the machine.
2. Lift the machine (or other part of system) only to the necessary height to move it with no
bouncing or friction on the floor.
3. Sit the machine down assuring uniform contact with the floor, which is necessary to
ensure correct and smooth operation.
INSPECTION
1. Remove all packing and supporting additions -these may include the blocks under the
carriage and the restraining bar over the table.
NOTE: when removing the stretchwrap film covering the machine, care must be taken not
to cut any of the electrical wires and/ or polyurethane covering on the film carriage rollers.
2. Perform a visual inspection of the electrical and mechanical parts for loosened joints and /
or broken connections. Any suspected shipping damage must be reported immediately to
the freight carrier. Any transport damage cannot be claimed to Orion Packaging Inc.
Items that are vulnerable to damage and must be inspected are as follows:
-Motors and transmissions
-Junction boxes
-Electrical conduits
-Proximity and limit switches
-Photocells
3. Check under the turntable to ensure that there is no crippling of the movable parts i.e.
casters, center axle or drive assembly.
4.Verify the following:
-Turntable or rotary arm drive system to confirm that the reducer to drive the chain is snug
and properly aligned.
-Verify the wires tight conduits for crushed sections or loose fittings.
-Verify the film carriage to be sure that it is correctly aligned with the tower
-Verify the tension on the lift chain.
-Verify all the dials and knobs on the control panel for smooth action.

MACHINE OPERATION
Before Starting Machine Operation
Verify that the machine is properly connected to the electrical source. The electrical
requirements depend on the machine type and features. For this information, please see the
machine electrical diagram provided with the machine operation manual. The control panel
layout for the machine is shown on the drawing.
CAUTION: Before preceding the machine operation familiarize yourself with the
EMERGENCY-STOP button and all functions, switches and pushbuttons.
POWER SWITCH
Located on the panel door or side of the panel box, the lockable power switch has two
settings:
ON - connects a power source to the machine
OFF - disconnects the power source.
START AND EMERGENCY STOP SWITCHES
The START switch is used to start the cycle once the load is on the turntable. The cycle
may be stopped on by pressing the STOP button (may also be used for the choosing the
range of counts of the top and bottom wraps - see TOP WRAPS and BOTTOM WRAPS).
NOTICE: In case of emergency, the push-pull STOP button interrupts the entire machine
electrical circuits. To continue the cycle the STOP push button should be pulled out and
START button pressed for the machine restarting. Double pressing of the push – pull STOP
button will reset the machine program and machine will be ready to apply the wrapping
cycle from its beginning.
WRAP PATTERN SELECTOR SWITCH “SPIRAL” UP / UP/DOWN
The Pattern Selector Switch “ SPIRAL” positions:
UP - When the UP position has been selected machine will first wrap bottom of load
applying selected number of bottom wraps. The film carriage will then move to the top of
load and stop. Selected number of top wraps will then be applied, after which the turntable
will slow down and stop in home position. Wrap pattern “SPIRAL UP ONLY” has been
completed.
UP/DOWN - This Selection has two Sub-Modes, programmable to enable the machine to
perform the two different wrap patterns (Bottom Wraps First and Top Wraps First).
BOTTOM WRAPS FIRST - When this Sub-Mode has been selected machine will first wrap
bottom of load applying selected number of bottom wraps. The film carriage will then move
to top of load and stop. Selected number of top wraps will then be applied. The film carriage
will move down to bottom position, after which the turntable will slow down and stop in home
position.

TOP WRAPS FIRST - When this Sub-Mode has been selected film carriage will move to top
of load and stop. Selected number of top wraps will be applied. The film carriage will then
move to bottom of the load and stop. Selected number of bottom wraps will then be applied.
The film carriage will be in bottom position; turntable will slow down and stop in home
position.
Machine is shipped pre-programmed in TOP WRAPS FIRST Sub-Mode, in order to change
Sub-Mode from TOP WRAPS FIRST to BOTTOM WRAPS FIRST see instructions below.
Before proceeding ensure that machine is in MANUAL, STANDBY MODE (machine is
powered on and all machine manual functions are enabled)
- Press the STOP (Red) Button
- To Re-program machine to BOTTOM WRAPS FIRST Sub-Mode, switch and hold
“Carriage Raise/Lower” Selector Switch in LOWER position and maintain for
Approximately 12 seconds.
- Pull the STOP (Red) push-button out.
- Perform standard machine reset procedure by double push-pull operation of the red
Mushroom stop button.
- At this point machine is ready and BOTTOM WRAPS FlRST Sub-Mode is now
Activated.
To Re-program machine to TOP WRAPS FIRST Sub-Mode follow procedures above, with
the exception of step 2. Switch and hold ‘Carriage Raise/Lower” Selector Switch in RAISE
position. At this point machine is ready and TOP WRAPS FIRST Sub--Mode is now
activated.
CARRIAGE CONTROL SWITCH
The CARRIAGE CONTROL switch is a three-position switch with the following settings:
RAISE - raises the carriage until the top limit switch on the tower is activated.
LOWER - lowers the carriage until the bottom limit switch on the tower is activated.
The switch is normally positioned in the middle where the carriage remains stationary.
Turning the switch to the RAISE or LOWER will activate the carriage to move in the
respective direction.
TURNTABLE JOG & REINFORCE WRAP
The turntable jog switch will rotate the turntable low speed when the switch positioned on
the TOWER / TURNTABLE JOG. When the switch is released, the turntable (rotary tower)
will stop. The switch is inoperative during the wrap cycle. When the same switch is
positioned on the REINFORCE WRAP the carriage will be stationary until the switch is
released.
PHOTOCELL ON/OFF SWITCH
The photocell switch has two settings:
ON - when turned ON, the photocell instructs the carriage to stop and begin the top wrap
sequence once the top of the load is reached. The carriage will always stop at the top of the
load regardless of its height. The photoswitch position on the track can be adjusted in order
to make the carriage pass the top of the load and overlap the top.
OFF - when turned OFF, the photocell is inoperative and the carriage will stop when the top
limit switch has been activated.

FILM TENSION
Film tension may be adjusted using the film tension control knob. It has a range of tension
from 0 to 10 (0 to 4 the low range, 4 to 8 the most useful range for most of the films used by
our customers, 8 to 10 as a very high range which may break some films).
CARRIAGE SPEED
The carriage speed potentiometer control can be used to control the amount of overlap the
film will have during the wrap. The potentiometer has settings from 0 to 10, the higher
settings being the fastest. High settings mean less film overlap because of faster carriage
speed and low settings mean more film overlap because of lower carriage speed.
TOP WRAPS 1,2,3...9
Three-position switch controls the number of wraps that may be applied on the top of the
load. The machine is preset RANGE # 1 (top wraps: 1 or 2 or 3). To change the values of
wrap see TOP & BOTTOM WRAP COUNTS CHANGE.
BOTTOM WRAPS 1,2,3...9
Three-position switch controls the number of wraps that may be applied on the bottom of the
load. The machine is preset with RANGE # 1 (bottom wraps: 1 or 2 or 3) which may be
applied. To change the values of wrap see TOP & BOTTOM WRAP COUNTS CHANGE.
TOP & BOTTOM WRAP COUNTS CHANGE
The Top & Bottom Wrap Selector Switches have three (3) ranges of wrap counts and
operate independently of each other.
Range #1 Wrap values of 1 - 2 - 3
Range #2 Wrap values of 4 - 5 - 6
Range #3 Wrap values of 7 - 8 – 9
For the selection of any of these ranges for top and bottom wraps please do as follows:
Before proceeding ensure that machine is in MANUAL, STANDBY MODE (machine is
powered on and all machine manual functions are enabled) Press the STOP (red) Button
Set the Top and Bottom wrap count selector switch to the position corresponding with the
desired count range.
1 = Range #1
2 = Range #2
3 = Range #3
Press the START (Green) pushbutton and maintain for approximately 12 seconds. Pull the
STOP (Red) pushbutton out. Perform standard machine reset procedure by double push-
pull operation of the red mushroom stop button. At this point machine is ready and new
preset values are loaded.

MACHINE WRAPPING TEST
Notice: It is advisable to test-run the equipment with several pallet loads before attempting
to wrap using film. Please position the operator beside the EMERGENCY STOP push
button.
Start up of the machine (system) may determine the need for the adjustment of:
- Load height stop photoswitch (on the carriage)
- Top limit switch position
- Bottom limit switch position
- Roping bar height adjustment
Before the test procedures adjust the wrapping cycle parameters i.e. top wraps, bottom
wraps, height photocell on/off, film tension, carriage speed (those two parameters may be
adjusted during the wrapping cycle).
LOADING THE FILM
The film roll can be loaded on the carriage mandrel from either end of the roll. When using
tacky film, please verify that the inward tacky surface of the film is inward on the load.
1. Disconnect power (turn off power switch).
2. Swing up the top mandrel spool.
3. Put the roll of film on the bottom mandrel.
4. Install the top mandrel on top of the roll to prevent upward movement.
5. Pull the handle marked PULL TO OPEN to open film distributor cradle.
6. Pass the roped tail of the film through opening (as shown on the film quick threading
pattern DWG. # 418180 Fig.1).
7. Close the film distributor cradle by pushing bar marked PUSH TO CLOSE.
8. When the film feeding is completed (fig. 2) – turn the power switch on.
9. Peel off the first few winds of the film (multistrech will run due to displacement of the
dancer roller) and fix the film end onto the load.
The system is now ready to begin the first wrapping cycle.

MACHINE INSTALLATION
After the visual inspection has been completed, the electrical power and the compressed air
shall be connected as specified on the diagrams supplied with the machine.
An electrical diagram is provided with each machine in the envelope attached to the panel
box.
ASSEMBLY PROCEDURE
The structural frames of the machine have to be installed on a leveled floor.
Locate the main wrapper section into its final position, keeping the tower assembly* away
from any traffic.
The wrapper mainframe section must be bolted to the floor by the 1/2” concrete floor
anchors (leg & shield or expandable type).
Any wiring that has been disconnected to facilitate transport is marked with a number
located on the junction box to which the wiring must be reconnected. Any wire run that
appears too short or long may indicate that the position of the mechanical components is
incorrect. Verify the status of all assemblies before proceeding.
* The tower deviation from vertical must not exceed 1/4” on the distance of 10 feet (angle: 0
degrees 6’).
CONTROL PANEL
In the case of the free standing panel (console) place it adjacent to the system and anchor
firmly to the floor. Connect the liquid tight (rigid conduit) to the main junction box located on
the wrapper main frame next to the tower.

LOADING THE FILM
The film roll can be loaded on the carriage mandrel from either end of the
roll. When using tacky film, please verify that the inward tacky surface of the
film is inward on the load.
1. Disconnect power (turn off power switch).
2. Swing up the top mandrel spool.
3. Put the roll of film on the bottom mandrel.
4. Install the top mandrel on top of the roll to prevent upward movement.
5. Pull the handle marked PULL TO OPEN to open film distributor cradle.
6. Pass the roped tail of the film through opening (as shown on the film quick
threading pattern DWG. # 418180 Fig.1).
7. Close the film distributor cradle by pushing bar marked PUSH TO CLOSE.
8. When the film feeding is completed (fig. 2) –turn the power switch on.
9. Peel off the first few winds of the film (multistrech will run due to
displacement of the dancer roller) and fix the film end onto the load.
The system is now ready to begin the first wrapping cycle.

PROXIMITY SENSOR ADJUSTMENT
Occasionally the Feed Back Proximity Sensor may need some adjustment. The position of
the feed back proximity sensor against the cam is shown on drawing # 419139.
Adjustment instructions:
-Remove the carriage cover
-Unbolt the two nuts holding the proximity switch -item # 1
-Turn the Proximity sensor -(item # 2) to create the gap between the cam and the front
side of proximity sensor about 1/8 “
-Tighten on the nuts securing the Proximity Sensor
-Turning the trim pot SPAN adjust the moment when motor starts to turn when dancer
roller moved from its home position up to 1 1/2”.

MACHINE MAINTENANCE
All general information about machine maintenance is based on normal machine working
conditions: indoor, moderate dust and low moisture environment, and maximum rotation of
32 RPM of turntable/rotary arm. They should be regarded as guidelines, reviewed and
corrected according to requirements of actual use and conditions.
MOTOR MAINTENANCE
An occasional inspection of the brushes should be made in order to establish a wear rate.
Replacement brushes should be installed before old brushes wear to 9/16” long, measured
on the long side. After replacing brushes run the motor near rated speed for at least l/2 hour
with no load to seat the new brushes.
Failure to properly seat the new brushes may cause commutator damage and rapid wear of
the new brushes. If the commutator becomes rough, scored or out of shape, a competent
motor shop should disassemble it and resurface the commutator.
With every third brush change, have a competent motor shop resurface the commutator and
blow the carbon dust out of the motor.
REDUCER OIL CHANGE
All external cap screws and plugs on the reducing transmission should be checked for
tightness after the first week. It is recommended to change the oil every six months or at
least 1800 hours of operation, whichever comes first. When adding or changing oil, the
transmission should never be filled above the oil level mark indicated, because leakage and
overheating may occur. Below is the list of the type of lubricant that should be used.
List of recommended reducer oils
Manufacturer Lubricant
American Oil Co.. American Cyl Oil no: 196-L
Cities Service Oil Co. Citgo Cyl Oil 100-5
Gulf Oil Corp. Gulf Senate 155
Mobil Oil Corp. Mobil 600 W Suer-r Cyl. Oil
Philips Oil Corp. Andes S 180
Texaco Inc. 624 + 650T Cyl.Oil
Shell Oil Co. Velvata Oil J82
Union Oil of Cal. Red Line Worm Gear Lube 140
RING BEARING MAINTENANCE (when applicable)
The ring bearing (located under the turntable) should be re-lubricated internally and
externally.
Internally: by injecting grease into all the lubrication nipples in succession until a collar of
fresh grease appears around the perimeter of the ring. The re-lubrication interval suggested
for these bearings, used in Stretch Wrapping Machinery is 750 hours, with a maximum
period of 6 months. The lubricant should be fresh and applied in sufficient quantities to
make sure all surfaces are lubricated.

Externally: by lubricating and wiping the chain drive with oily cloth. The frequency of
lubrication depends on entirely upon the usage of the machine and environment in which
the machine is placed (dust, moisture etc.).
Machines working under extremely dirty conditions should be lubricated every 400 operating
hours but at minimum, every 2 months. Longer lubrication intervals may occur only when
machine is working under very clean and dry conditions but should be not be longer than 6
months.
List of recommended lubricants for the ring bearing lubrication
Manufacturer Lubricant
BP Energrease LS2
Castrol Speeroll AP2
Esso Beacon 2
Gulf Crown Grease 2
Mobil Mobilus 2
Shell Avania Grease R2
Texaco Glissando FT 2
Valvoline LB-2
TOWER RACEWAYS MAINTENANCE
The film distributor (carriage) is sliding on the plastic guides attached behind its back plate.
The section of the tower on which the plastic guides move (raceways) should be cleaned
and re-greased approximately every 600 hours of machine operation.
NOTICE: If the machine works in a dusty and corrosive environment, the raceways should
be re-greased more often (at least every 100 hours).
CHAIN MAINTENANCE
To clean the chain, wipe it with an oily cloth every month. When machine is working in a
dusty and damp environment, it may be necessary to repeat the cleaning operation more
often. As the chain lubricants please use the most common chain lubricants on the market.
With time, the chain will tend to stretch. A loose chain should be tightened at the chain
tensioner, or by moving the reducer on its mounting plate.
NOTICE: Chain tension first adjustment must be done after the first two weeks of machine
usage.
PNEUMATIC SYSTEM MAINTENANCE (when applicable)
The air supply system must be checked weekly and must be free from the moisture. In cold
environments, it may be necessary to drain the air supply system daily.
CAM FOLLOWER MAINTENANCE (when applicable)
The cam followers have deep grease pockets and do not need frequent relubrication. The
portion of the tower on which the cam followers run, should be cleaned and regreased every
300 hours of operation. If the machine operates in a dusty or corrosive environment the
tower should be relubricated more often.