Pro Mach Orion CTS Flex Stretchwrapper User manual

CTS
STRETCHWRAPPER
MANUAL
Model
CTS Flex Stretchwrapper
Revision Date - July 25, 2016
Revision 3.0
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The information in this manual is subject to change without notice and does not represent a commitment on the part
of Pro Mach and assumes no responsibility for any errors that may appear in this manual. In no event will Pro Mach
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quential damages resulting from the use or defect of this manual.

Orion Machine Manual
Revision 3.0 CTS Flex Stretchwrapper
25 July 2016 Table of Contents
Page I
Table of Contents
Chapter 1: Introduction and Safety
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Copyright Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Flex Series Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
System Safety Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Hazard Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Maintenance Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Lockout and Tagout Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Pneumatic and Vacuum Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Installation and First Time Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Unloading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Machine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Chapter 2: System Description
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Standard Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Control Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Film Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Structural Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Machine Manual Orion
CTS Flex Stretchwrapper Revision 3.0
Table of Contents 25 July 2016
Page II
Chapter 3: System Operation
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
How to Start and Shut Down Your Wrapping System . . . . . . . . . . . . . . . . . . . . . . .3-1
POWER SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
START AND EMERGENCY STOP SWITCHES. . . . . . . . . . . . . . . . . . . . . .3-1
Carriage Obstacle Detect Error Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Loading The Film. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Universal Go-To Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Run Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Run Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Maintenance Prompt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Security Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Wrap Setting Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Wrap Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Menu Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Wrapper Jogging Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Conveyor Jogging Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Recipe Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Production Data Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
Recipe Viewing Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Machine Settings Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Machine Settings Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Main Drive Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Reinforce Wrap Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Timers Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Machine Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Start Delay Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Factory Defaults Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
Multistretch Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
VFD Parameters Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
Conveyor Timers Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
Dual Insta-Cut Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
S Insta-Cut Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
Diagnostics Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
Diagnostics Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
Inputs Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
Outputs Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
VFD Diagnostics Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
HMI Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
Maintenance Log Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
Fault History Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
Flex Dashboard Remote Viewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
Setting up Dashboard Remote Viewing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
Information & Alarm Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
Message Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46

Orion Machine Manual
Revision 3.0 CTS Flex Stretchwrapper
25 July 2016 Table of Contents
Page III
Alarm Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
Chapter 4: Troubleshooting
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Chapter 5: Maintenance
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Reducer Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Tower Raceways Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Chain Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Proximity Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Cleaning The Stretch Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Preventative Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
PM Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
All H&L Standard Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5,760 Loads or one month . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
17,280 Loads or three months.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
All H&L Heavy Duty (Ring Bearing) Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5,760 Loads Or One Month . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
17,280 Loads or three months.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
34,560 Loads or 6 months.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Ring Bearing Maintenance (If Applicable). . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
HPA LPA Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5,760 Loads or one month . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
17,280 Loads or three months.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
34,560 Loads or 6 months.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
RTD Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
@ 5760 Loads or one month . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
@ 17, 280 Loads or three months. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
@ 34, 560 Loads or 6 months. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
RTA Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5760 Loads or one month. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
17, 280 Loads or three months. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
34, 560 Loads or 6 months. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Chapter 6: Electrical Prints and Mechanical Drawings
Electrical Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Mechanical Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Machine Manual Orion
CTS Flex Stretchwrapper Revision 3.0
Table of Contents 25 July 2016
Page IV

Orion Machine Manual
Revision 3.0 CTS Flex Stretchwrapper
25 July 2016 List of Figures
Page I
List of Figures
Chapter 1: Introduction and Safety
Fork Tube Access Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Chapter 2: System Description
Chapter 3: System Operation
Pulling Strap to Release Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Limit Switch Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Loading the Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
The Run Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
The Maintenance Prompt Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
The Security Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
The Wrap Settings Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
The Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
The Wrapper Jogging Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
The Conveyor Jogging Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
The Recipe Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
The Production Data Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
The Recipe Viewing Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
The Machine Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
The Main Drive Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
The Reinforce Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
The Timers Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
The Machine Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
The Start Delay Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
The Factory Defaults Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
The Multistretch Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
The VFD Parameters Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
The Conveyor Timers Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
The Dual Insta-Cut Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
The S Insta-Cut Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
The Diagnostics Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
The Inputs Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
The Outputs Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
The VFD Diagnostics Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
The HMI Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
The Maintenance Log Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
The Fault History Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
Setting the IP Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
Flex Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

Machine Manual Orion
CTS Flex Stretchwrapper Revision 3.0
List of Figures 25 July 2016
Page II
Chapter 4: Troubleshooting
Chapter 5: Maintenance
The Multistretch Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Proximity Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Chapter 6: Electrical Prints and Mechanical Drawings

Orion Machine Manual
Revision 3.0 CTS Flex Stretchwrapper
25 July 2016 Introduction and Safety Contents
Page I
Introduction and Safety Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Copyright Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Flex Series Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
System Safety Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Hazard Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Maintenance Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Lockout and Tagout Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Pneumatic and Vacuum Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Installation and First Time Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Unloading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Machine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Machine Manual Orion
CTS Flex Stretchwrapper Revision 3.0
Introduction and Safety Contents 25 July 2016
Page II

1.
Page 1-1
Orion Machine Manual
Revision 3.0 CTS Flex Stretchwrapper
25 July 2016 Introduction and Safety
Introduction and Safety
Introduction
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 require-
ments. 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.
Note: This manual covers standard features of the machine. Certain
options may not be fully covered due to their unique application.
Every effort has been made to ensure document accuracy how-
ever, Orion Packaging retains the right to change specifications
without notice.
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 CTS Flex Stretchwrapper
2. Serial Number (See sticker on electrical cabinet)
3. Built in Alexandria Minnesota, USA

Machine Manual Orion
CTS Flex Stretchwrapper Revision 3.0
Introduction and Safety 25 July 2016
Page 1-2
About this Manual
Orion is committed to helping you maximize the productivity of your system. This manual
is specifically designed for your packaging system, to assist you in the operation and
maintenance of your new equipment. Please take the time to familiarize yourself with the
contents of this manual.
• Section 1 is the Introduction and Safety section. This section discusses safety, lock
out/ tag out, hazard messages, and installation information.
• Section 2 is the System Description section. This section discusses machine specifica-
tions. A Machine Layout Drawing is found at the end of this section.
• Section 3 is the System Operation section. This section describes the operator control
panels, the Human Machine Interface, and operational procedures.
• Section 4 is the Troubleshooting section. A Troubleshooting chart is found in this sec-
tion.
• Section 5 is the Maintenance section. In this section you will also find a suggested
maintenance schedule including a maintenance log. Assembly drawings conclude this
section.
Copyright Notice
© 2016 Pro Mach
Section 106 of the 1976 Copyright Act forbids any party other than the author (Pro Mach) to:
Reproduce owned work in copies or phonorecords, to prepare derivative works based upon
the work; to distribute copies or phonorecords of the work to the public by sale or other trans-
fer of ownership, by rental or lease.
Copyright protection subsists from the time the work is created in fixed form. The copyright
in the work of authorship immediately becomes the property of the author who created the
work (Pro Mach.) Only the author or those deriving their rights through the author can right-
fully claim copyright.

Orion Machine Manual
Revision 3.0 CTS Flex Stretchwrapper
25 July 2016 Introduction and Safety
Page 1-3
Flex Series Warranty
Effective January 1, 2013- For all products in the Flex Series, Orion provides an industry leading warranty from
the delivery date of its products to be free from defects in materials and workmanship as described below. This
warranty assumes that normal service will be performed by the user.
Flex Turntable Style Machines including LPS, LPD, LPA, HPS, HPD and HPA are warranted for Five (5)
Years from the date of the machine shipment on all standard components, both electrical and mechanical, and
the structure to free from defects in material and workmanship. During the warranty period Orion will, at its
option, either repair or replace the failed component.
Flex Rotary Tower Machines including RTD and RTA are warranted for Four (4) Years from the date of
shipment on all standard components, both electrical and mechanical, to be free from defects in material and
workmanship. Structural components manufactured by Orion are warranted to be free from defects in material
and workmanship for a period of Five (5) years. During the warranty period Orion will, at its option, either
repair or replace any failed component.
Components not manufactured by Orion specified by the customer and that are other than Orion Packaging Sys-
tems standard brand are warranted by Orion to the extent that they are warranted by Orion's supplier of these
items.
The polyurethane pre-stretch rollers on the FLEX-HPD/LPD/HPA/LPA models carry a Lifetime Warranty
and are guaranteed to be free from defects in material and workmanship, and to perform to Orion standards in
Orion film delivery systems which have been properly maintained. Rollers are not warranted against physical
damage, corrosion, abuse, or negligence. The lifetime warranty does not apply to the rollers used on LPE model
and these are covered under the Five (5) Year portion of this warranty instead. Wear parts such as e.g. belts,
fuses, light bulbs, circuit breakers, brakes, motor brushes, slip ring brushes, etc. are excluded from this warran-
ty.
DAMAGE IN TRANSPORT
Damage in transport is the responsibility of the carrier and is not covered under our warranty.
FREIGHT CHARGES
There will be no freight charges for warranty parts that are ordered for shipment via UPS regular ground service
from Orion. Any other method of shipment, (UPS red/blue, Federal Express, common carrier, etc.) will be at
the expense of the customer/distributor.
PARTS RETURN POLICY
For most components valued at under $300 list price, Orion does not require that the defective component be
return ed. All defective components valued at $300 or more list price must be returned to Orion in Alexandria,
MN. It is at Orion's sole discretion as to whether any given component must be returned, regardless of its value,
for the purpose of determination
of warranty status and the nature of the defect. Furthermore, confirmation that the part does not need to be re-
turned must be provided by Orion at the time of order placement.
IMPORTANT EXCLUSIONS
EXCEPT AS STATED HEREIN, ORION MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED
AND IN NO EVENT SHALL BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. ORI-
ON MAKES NO WARRANTY AS TO FITNESS OF EQUIPMENT FOR PARTICULAR PURPOSE. ORION
NEITHER ASSUMES NOR AUTHORIZES ANYONE ELSE TO ASSUME FOR IT, ANY OTHER OBLI-
GATION OR LIABILITY RELATING TO ITS EQUIPMENT. THIS WARRANTY DOES NOT APPLY TO
DAMAGE TO EQUIPMENT WHICH, IN THE JUDGMENT OF ORION, HAS BEEN SUBJECT TO IN-
CORRECT VOLTAGE SUPPLY, NORMAL WEAR AND TEAR, TO MISUSE, NEGLECT, OR HAS BEEN
REPAIRED OR ALTERED BY UNAUTHORIZED PERSONNEL. DEFECTIVE PARTS MUST BE RE-
TURNED TO ORION, FREIGHT PREPAID, WITHIN 14 DAYS OF SHIPMENT OF THE REPLACEMENT
PART, EXCEPT FOR COMPONENTS VALUED AT UNDER $300 LIST PRICE UNDER THE CONDI-
TIONS STATED ABOVE. DEFECTIVE PARTS MUST BE RETURNED IN THEIR ORIGINAL STATE
ALONG WITH A FULLY COMPLETED ORION WARRANTY PARTS RETURN FORM. DEFECTIVE
PARTS THAT HAVE BEEN DISASSEMBLED, DAMAGED DURING REMOVAL, OR OTHERWISE
TAMPERED WITH, WILL NOT BE COVERED UNDER WARRANTY, UNLESS OTHERWISE STATED
IN WRITING. ORION'S SOLE OBLIGATION UNDER THIS WARRANTY WILL BE TO PROVIDE RE-
PAIRS TO COMPONENTS OR REPLACEMENT PARTS, F.O.B. ORION'S POINT OF SHIPMENT EX-
CEPT AS STATED ABOVE. ALL ASPECTS OF THE ABOVE STATED WARRANTY AND
PROCEDURES RELATED TO ORDERING PARTS UNDER WARRANTY WILL BE UPHELD WITH NO
EXCEPTIONS.
Made with pride in the USA www.orionpackaging.com

Machine Manual Orion
CTS Flex Stretchwrapper Revision 3.0
Introduction and Safety 25 July 2016
Page 1-4
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 be disconnected prior
to all inspection, maintenance or repair work.
At Orion, we are committed to building quality packaging and material handling equip-
ment. To achieve this, our machines must be efficient, easy to maintain, and safe to oper-
ate.
Before attempting to operate the equipment, become familiar with the safety recommen-
dations and operational components of your CTS Flex Stretchwrapper. You should also
become familiar with the technical information pertaining to components used within the
system, including their operating and safety features. This information is located in the
Vendor Data Manual and in other literature supplied with the equipment. To maximize
machine safety and efficiency you must operate the machine correctly and comply with
the safety features described.
Stay alert and remember: Safety is the responsibility of everyone who operates or ser-
vices your BEC system.

Orion Machine Manual
Revision 3.0 CTS Flex Stretchwrapper
25 July 2016 Introduction and Safety
Page 1-5
System Safety Recommendations
Safeguarding personnel that operate and/or maintain automated equipment is the primary
consideration. Because it is very dangerous to enter the operating space (work envelope)
of a machine during operation, adequate safeguards must be in place and safety precau-
tions must be observed.
The following general precautions are recommended for all personnel who perform sys-
tem operation or maintenance.
• Do lockout-tagout procedures whenever you do maintenance and repair work.
• All personnel who repair, maintain, or operate the equipment need to know the loca-
tion of all EMERGENCY STOP buttons.
• Do not operate the equipment with any of the safety guards removed.
• Do not wear neckties, loose clothing, or long loose-hanging hair around any equip-
ment.
• Observe and follow the DANGER, WARNING, and CAUTION messages throughout
this manual, in vendor manuals, and displayed on the equipment.
• DO NOT use steps or stands that allow anyone to reach over guards.
• Personnel should attend all available safety and operational training courses.
• Personnel should know and follow the recommended safety procedures whenever
they must enter the packaging systems motion area.
• Personnel should not enter the packaging system while control power is "ON".
• Personnel should not power up the system if someone is in the working path of the
machine
• The system should be powered down when not in use.
• Personnel should pay special attention to all the posted warnings and cautions located
on any devices. Observe all safety and/or precautionary steps and procedures when
working with the system.
• Personnel should keep the system clean to make it easier to spot hazards.

Machine Manual Orion
CTS Flex Stretchwrapper Revision 3.0
Introduction and Safety 25 July 2016
Page 1-6
Hazard Messages
Notations appear on pages of this manual to alert the reader to important messages regard-
ing a significant hazard for personnel or equipment. These messages convey three levels
of risk as defined below. Failure to observe these instructions can result in death, serious
injury, damaged equipment, or loss of product or production.
DANGER Denotes the possibility of serious injury or death to personnel.
WARNING Denotes the possibility of potential injury or damage to equipment.
CAUTION Denotes the possibility of damage to product or an interruption of produc-
tion.

Orion Machine Manual
Revision 3.0 CTS Flex Stretchwrapper
25 July 2016 Introduction and Safety
Page 1-7
Operation Safety
The following safety precautions are recommended for all personnel who will operate this
CTS Flex Stretchwrapper.
• Operators should immediately report unsafe working conditions to a supervisor.
• The operator should understand the function of the entire system including all external
devices and equipment that interact with the system.
• Before starting operation, the operator should understand the complete task that the
system is designed to accomplish.
• The operator should know the location and functional status of all devices (switches,
sensors, control signals) that can cause the system to move.
• The operator should know where each EMERGENCY STOP button is located for
both main and external control devices. Do not hesitate to use them in an emergency.
• The operator should make sure all safety devices are functioning and periodically
checked for proper operation.
• The operator should ensure that all personnel are outside the system before starting
operation.
• The operator should never enter, or allow others to enter the system during automatic
operation.

Machine Manual Orion
CTS Flex Stretchwrapper Revision 3.0
Introduction and Safety 25 July 2016
Page 1-8
Maintenance Safety
The following safety precautions are recommended for all personnel who are responsible
for the maintenance or service this CTS Flex Stretchwrapper.
• Personnel should ensure that all safety devices are functioning and periodically
checked for proper operation before performing maintenance.
• Before performing any maintenance, service, or inspection inside the main control
panel, the power source should be turned off and locked out.
• Maintenance should be performed on the system with the power OFF. Lockout and tag
out procedures should be followed to protect personnel from injury and to indicate the
equipment is being serviced.
• Place a lock on the main electrical disconnect, as shown below, while performing
maintenance.
• Personnel should pay careful attention to all devices that may be powered or capable
of motion, such as conveyors and pneumatic devices.
• Release or block all stored energy devices (hydraulic or pneumatic) that may present a
danger when working with the system. Before working with pneumatic devices, shut
off the air supply and purge the air lines.
• Be aware when removing a servomotor or brake that the associated mechanical part
will fall unless supported in some manner.
• Use only specified replacement parts. Never use non-specific fuses that have not been
specified. Potential fire and/or damage may result.
• Before restarting the system, ensure personnel are not in the system and that the sys-
tem and external devices are operating properly.

Orion Machine Manual
Revision 3.0 CTS Flex Stretchwrapper
25 July 2016 Introduction and Safety
Page 1-9
Lockout and Tagout Recommendations
Electrical System
(See OSHA 1910.147 & OSHA 1910.333 (b)(2) for exception to procedures)
To avoid hazards of electrical shock or other personal injuries, the main power disconnect
for the system and any other separate sources of power for the system shall be locked out
& tagged as a safety precaution during entry and maintenance to the system.
To accomplish this, set the Main Power Disconnect operating handle to the "OFF" posi-
tion and install a personal locking device through the padlock hole on the operating han-
dle. Attach a Danger tag to the handle containing a statement prohibiting unauthorized
operation of the disconnect and removal of the tag signed by the individual responsible for
locking out the system. If several personnel are performing maintenance, each individual
shall install a lockout device and tag.
A qualified person shall verify that the equipment is de-energized by:
1. Operating controls to verify equipment cannot be restarted.
2. Using test equipment to test circuits and electrical parts that will be exposed to person-
nel.
Stored electric energy that might endanger personnel shall be released by discharging the
circuits. Check appropriate equipment manuals on exact procedures.
To re-energize equipment, a qualified person shall conduct tests and visual inspections, as
necessary, to verify that all tools, electrical jumpers, shorts, grounds, and other such
devices have been removed, so that equipment can be safely energized. Personnel exposed
to the hazards associated with re-energizing equipment shall be warned to stay clear of
equipment. Each lock and tag shall be removed by the person who applied it or under their
direct supervision. A visual determination that all personnel are clear of the equipment
shall be accomplished before the operating handle on each Main Power Disconnect is
placed to the "ON'' position.

Machine Manual Orion
CTS Flex Stretchwrapper Revision 3.0
Introduction and Safety 25 July 2016
Page 1-10
Pneumatic and Vacuum Systems
To avoid hazards of moving mechanisms, pinch points and other personal injuries, the
main compressed air supply valve for the system shall be locked out & tagged as a safety
precaution during entry and maintenance to the system.
1. To accomplish this, turn the Main Air Supply valve to the "OFF" position and install a
personal locking device through the padlock hole on the valve handle.
2. Also attach a Danger tag to the handle containing a statement prohibiting unautho-
rized operation of the disconnect and removal of the tag signed by the individual
responsible for locking out the system.
If several personnel are performing maintenance, each individual shall install a lockout
device and tag. Qualified personnel shall vent any stored or accumulated air in pneumatic/
vacuum devices before working on them. Check appropriate equipment manuals on exact
procedures.
To re-supply compressed air to the equipment, a qualified person shall conduct visual
inspections, as necessary, to verify that mechanisms are properly connected, as well as all
tools and other objects have been removed so that equipment can safely operate. Personnel
exposed to pneumatic/vacuum hazard areas shall be warned to stay clear of equipment.
Each lock and tag shall be removed by the person who applied it, or, under their direct
supervision. A visual determination that all personnel are clear of the equipment shall be
accomplished before the main air supply valve is turned to the “ON'' position.