Wulftec WRTA-150 User manual

User’s
Manual
and
Reference
Guide
WRTA-150

Wulftec / M.J. Maillis Group Page 2 of 36 Version 1.1.1 /May 2013
Table of Contents
TABLE OF CONTENTS..................................................................................................................................2
LIST OF FIGURES ..............................................................................................................................................3
AUTOMATIC WARRANTY ............................................................................................................................4
SAFETY LABELS .............................................................................................................................................5
SAFETY...............................................................................................................................................................7
INSPECTION AND INSTALLATION...........................................................................................................8
INSTALLATION OF FENCE HANDLE .................................................................................................... 10
FILM LOADING AND THREADING ......................................................................................................... 11
WRAPPER CONTROLS................................................................................................................................ 13
MODE OF OPERATION – STANDARD SYSTEM ................................................................................ 19
CUT ARM OPERATION .................................................................................................................................... 20
WRAPPING THE LOAD................................................................................................................................ 20
OPTIONAL PRE STRETCH RATIOS – BELT DRIVEN ..................................................................... 21
SETTING WRAP PARAMETERS .............................................................................................................. 22
FILM CARRIAGE / ROTATION SPEED............................................................................................................ 22
UPPER/LOWER LIMIT SETTINGS................................................................................................................... 22
TOP WRAPS ..................................................................................................................................................... 22
BOTTOM WRAPS ............................................................................................................................................. 22
OVERWRAP ...................................................................................................................................................... 22
FILM TENSION (POST STRETCH)................................................................................................................... 22
PHOTOEYE SETTINGS..................................................................................................................................... 23
DS-60 PHOTOEYE ADJUSTMENT ................................................................................................................. 24
PHOTOEYE RESPONSE DELAY TIME ............................................................................................................. 26
AUTOMATIC HEIGHT SENSING ...................................................................................................................... 26
SETTING THE LIMIT STOP .............................................................................................................................. 26
ANALOG SENSOR ADJUSTMENT.................................................................................................................... 27
PROXIMITY SENSOR........................................................................................................................................ 28
REVOLUTION AND HOME POSITION SENSORS............................................................................................. 28
REED SWITCHES ADJUSTMENT .................................................................................................................... 28
PROXIMITY SENSOR REPLACEMENT ............................................................................................................. 29
MOTOR SPEED CONTROL ........................................................................................................................ 29
MAINTENANCE .............................................................................................................................................. 30
GENERAL MAINTENANCE ............................................................................................................................... 30
CARRIAGE RAILS............................................................................................................................................. 30
RING GEAR...................................................................................................................................................... 30
CHAIN MAINTENANCE .................................................................................................................................... 31
CARRIAGE LIFT CHAIN TENSION ADJUSTMENTS......................................................................................... 31
PRE-STRETCH BELTS ADJUSTMENT ............................................................................................................ 31
PRE-STRETCH CHAIN ADJUSTMENT............................................................................................................. 31
FILTER REGULATOR ....................................................................................................................................... 32
PHOTOEYES..................................................................................................................................................... 32
REDUCER ........................................................................................................................................................ 32

Wulftec / M.J. Maillis Group Page 3 of 36 Version 1.1.1 /May 2013
TROUBLESHOOTING – WRTA 150 ........................................................................................................ 34
List of Figures
FIGURE 1 INSTALLATION OF A WRTA 1 0 ........................................................................... 8
FIGURE 2 ANCHORING POINTS FOR A WRTA 1 0 ................................................................. 9
FIGURE 3 FILM LOADING AND THREADING ......................................................................... 11
FIGURE 4 RETROFLECTIVE PHOTOEYE .............................................................................. 23
FIGURE ANALOG SENSOR ADJUSTMENT .......................................................................... 27
FIGURE 6 PROXIMITY SENSOR ........................................................................................ 28
FIGURE 7 FILM IN CLAMP ............................................................................................... 30

Wulftec / M.J. Maillis Group Page 4 of 36 Version 1.1.1 /May 2013
Automatic Warranty
All parts on stretchwrappers manufactured by Wulftec International Inc. (hereinafter called
“Wulftec”) are warranted to be free of manufacturing defects for a period of four (4) years from the
date of shipment, if installed, maintained and used in accordance with factory specifications except
for the two (2) blue polyurethane coated rollers whose coating carry a lifetime warranty and the 2 ”
ring gear bearing which carries a ten (10) year warranty. Wulftec will, at its discretion, repair or
replace any defective stretchwrapping parts returned freight prepaid. All returned parts are subject
to factory inspection and Wulftec reserves the right to determine the cause of failure. Damage caused
by inadequate supply voltage, misuse, neglect or corrosive environment, is not covered by this
warranty. Damage caused during transport is the responsibility of the carrier and is not
covered under this warranty. All damages detected upon receipt of equipment should be
reported immediately to the carrier and Wulftec should be notified. This warranty only applies
if machine start up, modifications or repairs are made by an authorized Wulftec technician.
Wulftec shall under no circumstances be liable for any direct, indirect, special, incidental, consequential
damages, losses or expenses arising in connection with the use of, or inability to use, our product(s)
for any purpose whatsoever. Except as stated herein, Wulftec makes no other warranty, expressed or
implied, nor does it assume or authorize anyone else to assume for it, any other obligation relating to
our products or any other products. This warranty does not apply to machinery or equipment
deemed by Wulftec to have been subjected to misuse, neglect, or that has been started-up, repaired
or altered by unauthorized personnel. Defective parts must be returned to Wulftec within thirty (30)
days of shipment of a replacement and must be returned prepaid and in their original state. Failure
to do so will void this warranty. Defective parts that have been disassembled, damaged during
removal or otherwise tampered with will not be covered under this warranty, unless otherwise stated
in writing by Wulftec. Wulftec makes no guarantee as to the appropriateness of equipment for
particular purposes. Products serviced and/or parts replaced during the warranty period will carry
the unexpired portion of the original warranty only. The sole obligation of Wulftec under this
warranty will be to provide repairs to stretchwrapping components or replacement parts, ex-works
Wulftec.
Parts Return
Within Canada
Wulftec International Inc.
209 Wulftec Street,
Ayer’s Cliff, Québec
J0B 1C0
1-877-WULFTEC
Within the United States
Wulftec International Inc.
Fedex Trade Networks
30 Phelps St
Derby Line, VT 0 830
Disclaimer
Wulftec has taken every precaution in the preparation of this manual to ensure its accuracy.
However, this information is subject to change without notice and is provided "as is" with no
guarantee. Wulftec shall not be held liable for any direct, indirect, special, incidental or
consequential damages in connection with the use of the information contained in this manual.
Manual Copyright
No part of this manual may be reproduced, in any form, whether in whole or in part without the
written permission of Wulftec. “WULFTEC”, “RUN WITH THE PACK”, “RUN AHEAD OF THE PACK”,
“No-Thread® Powered pre-Stretch” and “Rapid-Thread™” are trademarks of Wulftec. No trademark
license is granted in connection with the material contained in this manual.

Wulftec / M.J. Maillis Group Page 5 of 36 Version 1.1.1 /May 2013
Safety Labels
In an effort to reduce the risk of injury to personnel working around the Wulftec / MJ
Maillis equipment, safety labels are placed at various points to alert them of potential
hazards. Please check equipment and note all safety labels. Make sure your personnel are
vigilant and obey these warnings. Shown below are typical labels that are attached to the
equipment.
PLACED ON ALL CONTROL PANELS.
PLACED ON ALL CONTROL PANELS.
PLACED ON AUTOMATIC MACHINE CONTROL PANELS.
PLACED ON ALL CONVEYORS.
PLACED ON ALL POWERED CONVEYORS, NEAR DRIVE.
PLACED ON ALL MOVING PLATEN, NEAR DRIVE.

Wulftec / M.J. Maillis Group Page 6 of 36 Version 1.1.1 /May 2013
Safety Labels (cont’d)
PLACED ON ALL MACHINE LEGS & TOWER
NOTE: SPANISH, FRENCH AND PORTUGESE LABELS ARE AVAILABLE UPON REQUEST.

Wulftec / M.J. Maillis Group Page 7 of 36 Version 1.1.1 /May 2013
Safety
Read Carefully Before Operating
Any Wulftec Machinery
Wulftec stretch wrap machinery should be handled with the same caution and care as with any
other industrial equipment. Many automatic functions may be potentially hazardous. For this
reason, except for the authorized operator(s) and maintenance crew, other personnel should keep
clear at all times. It is especially important to be aware that mechanical or electrical components
may suddenly become active when the electrical panel is turned on.
Unstable loads being wrapped at high speeds are liable to fly apart and cause machine damage or
personal injury. For this reason, it is suggested that whenever attempting to wrap a "new" load
configuration, all personnel should be well clear of the wrapping area. The load should not be
wrapped at a higher speed than the machine was designed to handle (rotation speed: 17 RPM).
Always assume the machine is in an active mode. Disconnect control power prior to servicing,
adjusting or performing routine maintenance procedures.
WARNING!
Unless specifically stated, preceding all instructions in this manual, it must be well
understood that all inspection, maintenance, and repair should be performed only
when the electrical power is disconnected from the machine.
Please use extreme caution if it should become necessary to inspect, diagnose, or adjust the machine
while it is in operation. Only qualified individuals thoroughly familiar with the particular machine
should perform regular maintenance or inspections.
WARNING! Disconnect machine power supply before loading film.

Wulftec / M.J. Maillis Group Page 8 of 36 Version 1.1.1 /May 2013
A
B
F
C
E
D
Inspection and Installation
Upon Arrival, visually inspect machine for damage caused in transport. If damage to the machine
has occurred, it must be reported to the freight carrier immediately and Wulftec notified. As stated
in warranty on page , Wulftec is not responsible for damage caused in transit. If no damage is
apparent, carefully remove all wrapping material, strapping, blocks, etc.
NOTE: Wulftec WRT Wrap Machines series are to be lifted for placement only by
the lifting tubes with an overhead crane, pulley blocks or forklift of at least twenty-
five hundred (2, 00) pounds lifting capacity
Lifting points identification
A. Lift here with overhead crane to remove skid.
B. Shipping bracket.
C. Bottom brackets
D. Cross member
E. Lag bolts.
F. Lift here with forklift.
Figure 1 Installation of a WRTA 150
Unpacking procedure
1. Remove lag bolts holding skid together. (10 pieces)
2. Leave cross member attached to machine. (1 piece) and lift machine from side with strap as
shown to remove skid, then set machine down on floor.
3. Insert forks as far as possible into lifting tubes. (See forklift requirement above).
4. Lift machine while moving forward until machine is in vertical position.
. Lift machine above floor and remove bottom brackets.
6. Move machine to desired location and anchor to floor.
7. Unwrap carriage and install safety bumper and photoeye bracket.
8. Remove shipping bracket.
NOTE: Because of machine configuration, in various circumstances, some of the
elements of the machine may need to be disconnected. Please follow
instructions/indications on elements and/or relevant diagrams to reconnect.
NOTE: Wulftec recommends using 10 heavy-duty expansion shields of ¾”
diameter thread size with a minimum length of 4” as a minimum anchor in
concrete. The clamp needs to be anchored with 2 anchor nuts of ½” diameter.

Wulftec / M.J. Maillis Group Page 9 of 36 Version 1.1.1 /May 2013
Inspection and installation (cont’d)
Lifting points identification
A. Remove transportation plate that is found
here.
B. Anchoring holes.
1-Mechanical anchors: KB ¾” Ø from Hilti,
4” minimum engagement into concrete.
2-Chemical anchors: threaded rod ¾” Ø, Gr:
2, Epcon system, 3 ½” minimum
engagement into concrete.
Verification of the structural capacity of the
floor to be done by others
Figure 2 Anchoring points for a WRTA 150
Note: The type of anchors for the Control Panel and Clamp (if applicable) is to the customer’s
discretion.
This machine needs to be connected to a dedicated line. A dedicated line is a line that is powered
from one breaker or fuse, and that has no other device connected to it. Furthermore, the line shall
be such that the voltage at the outlet will not drop more than % under full load. Use of extension
cords is not recommended.
To measure the voltage drop, measure the voltage at the outlet with nothing connected to it this is
VA, then measure the lowest voltage during machine operation. Please read during the complete
cycle and note the lowest value, this is VB.
Take the difference between VA and VB and divide it by VA. This will give you the voltage drop
percentage. Drop= (VA-VB)/VA. This drop should remain under % for proper machine operation,
and for compliance with the electrical code.
As an example, an outlet connected to a 1 A breaker, wired with #14AWG wire, should not be
further than 70' from the breaker, to meet the % voltage drop.
NOTE: Because of machine configuration, in various circumstances, some of the
elements of the machine may need to be disconnected. Please follow
instructions/indications on elements and/or relevant diagrams to reconnect.
A
B

Wulftec / M.J. Maillis Group Page 10 of 36 Version 1.1.1 /May 2013
Inspection and installation (cont’d)
Installation of Fence Handle
See the following drawings in order to facilitate the installation of the handle on the safety fencing.
Refer to assembly drawing 6MFEN00496.
1: Clamp key switch plate in place with edge, flush with post. Transfer holes approximately center of
slot for adjustment. Drill 9/32” hole through post. Install key switch with carriage bolts.
0MINS00006, rev. 1
Align slide bolt with key switch. Shims must pinch door panel angle iron. Tighten nuts.
1

Wulftec / M.J. Maillis Group Page 11 of 36 Version 1.1.1 /May 2013
Film Loading and Threading
The film roll should be loaded so that the tacky surface will face inward on the pallet load.
1. *Make sure the machine is in stop mode before opening the fencing door. Do not press on E-stop.
2. *Open safety fencing door (if applicable).
3. Push the lock on the carriage gate latch to unlock carriage door.
4. Remove empty film roll.
. Ensure that the inner core of the new film roll is undamaged. If the lower (bottom) of the inner
core is damaged or somewhat unwound, trim or shave it with a sharp knife.
6. Lift the film roll and make it slide along the film support roll. Then move the bottom of the film
roll over the bottom cone film roll holder to ensure that the roll is securely in place.
7. Pull the film from the roll until a good film web is reached, cut the film and discard the damaged
portion.
8. Pull out the film manually; ensure enough length to reach the clamp when it’s closed.
9. Place film loosely between door and pre-stretch rollers, then close the door and ensure that the
carriage locks are correctly locked (this is a 2-position lock; make sure to reach the 2
nd
position
when closing the door).
10. Pull out the film manually in order to verify proper loading and operation of the film carriage.
11. Cut off the excess film and place the film on the clamp, then close the clamp with the clamp jog
push button (located on the wipe plate near the e-stop).
12. Close the door, press reset to rearm the door circuit then acknowledge the alarm and restart the
machine.
13. If film breaks during a wrap cycle, repeat steps 7 to 12 or attach film to the product.
Figure 3 Film loading and threading
Carriage Lock

Wulftec / M.J. Maillis Group Page 12 of 36 Version 1.1.1 /May 2013
Film loading and threading (cont’d)
WARNING! Before threading the film, press on the dancer bar once door is
opened to make sure the pre-stretch rollers are not turning. If they are, contact a
Wulftec Customer Service representative immediately. Do not touch the carriage.
Inadvertent movement of the dancer bar will cause the rollers to turn abruptly,
creating the possibility of serious injury. The operator must respect the film
loading and threading instructions AT ALL TIMES!
NOTE: If the film web breaks during the cycle, reattach the film, or if necessary,
rethread the film following the instructions. It is not necessary to reset the
machine. If E-stop is activated, the pre-stretch and the clamp will not work. If the
E-Stop is pressed, pull it.
The machines equipped with a standard carriage are programmed to stop when a
lack of film occurs. In a wrap cycle during which the rotation speed is higher
than 10Hz and the pre-stretch motor stops working for more than three (3)
seconds, the machine will fall into a stop state. The cause is either a stop a lack
of film or a film break. Follow the film threading procedure (previous pages) to
rethread the film to start/restart a cycle.
The machines are equipped with a proximity
sensor used to determine if the carriage door
is closed properly. This sensor can be seen
through the hole in the carriage cover. When
the light is lit, it indicates that the carriage
door is closed properly. If the door is open,
the pre-stretch motor will stop working or if
the machine is running a wrapping cycle, it
will stop by itself rapidly. If the light is not lit, make sure the
door is properly closed. The machine is ready for a start cycle.

Wulftec / M.J. Maillis Group Page 13 of 36 Version 1.1.1 /May 2013
Wrapper Controls
Controls Functions
Power on/off Turns power OFF/ON to the machine.
Reset Brings the carriage down and moves the rotary arm
back to home position.
Carriage
Up/Down
With the machine cycle stopped, allows carriage to be
moved up or down.
Reinforce wrap Reinforce wrap function allows the operator to reinforce
any section of the load by pausing the carriage
movement while the rotary arm continues. The
number of turns in reinforce wrap is determined by the
amount of time the switch is activated. This function
allows the operator to set a number of reinforce wraps
in a minimal amount of time.
Manual rotation Manual rotation moves the rotary arm to desired
position.
Start/stop Starts or stops the wrap cycle (also continues the wrap
cycle after the top cover pauses or after stopping "in
cycle" by using the emergency stop) and brings the
carriage down in spiral up mode.
Emergency stop Temporarily stops the sequence by cutting all power to
the drives. Wrapping sequence may be re-started after
pressing E-stop. (To re-start the wrap cycle, simply
release the E-stop and press the START/STOP button.)
Note: If inverted controls option has been chosen, you will keep the same controls although the
control cabinet has a different appearance.
Note: An amber safety flashing light is installed on top of the enclosure. The light flashes during
machine operation.

Wulftec / M.J. Maillis Group Page 14 of 36 Version 1.1.1 /May 2013
Wrapper Controls (Cont’d)
This page is used to change passwords

Wulftec / M.J. Maillis Group Page 15 of 36 Version 1.1.1 /May 2013
Wrapper Controls (Cont’d)
Controls Functions
Carriage speed up Controls speed of carriage in up direction, which has
effect on cycle time and film overlap. It should be
adjusted with great care when trying to optimize speed
while maintaining quality wrap on product. Min. on
potentiometer is lowest speed attained.
Carriage speed down Controls speed of film carriage in the downward
direction, which has an effect on cycle time and film
overlap. It should be adjusted with great care when
trying to optimize speed while maintaining quality wrap
on product. Min. on potentiometer is lowest speed
attained.
Rotation speed Allows the rotation to be set at the speed best suited to
the load, variable from min. (being the lowest speed
attainable without stopping) to 17 RPM.
Film tension Controls the tension between film carriage and pallet
load (i.e. higher % tension = tighter wrap).

Wulftec / M.J. Maillis Group Page 16 of 36 Version 1.1.1 /May 2013
Wrapper Controls (Cont’d)
Controls Functions
Top wraps Determines the number of wrap layers at the top of the
load, adjustable from 0 to 10.
Bottom wraps Determines the number of wrap layers at the bottom of
the load, adjustable from 0 to 10.
Autoheight Timer Used to set the timer for the overwrap.

Wulftec / M.J. Maillis Group Page 17 of 36 Version 1.1.1 /May 2013
Wrapper Controls (Cont’d)
Controls Functions
Automatic Mode
On/Off
Used to select the machine automatic or semi-
automatic mode. In automated mode, the clamp and
cut arm will be activated.
Autoheight off/on Allows "autoheight sensing" for pallet load height
variations. (There are limit switches on the carriage
with adjustable stops on tower as safety override).
Carriage Speed
Manual
Used to set the carriage speed (%) when machine is set
to manual mode.
Carriage Raise Timer Used to set the time during which the carriage will
move up at the beginning to clear the clamp.

Wulftec / M.J. Maillis Group Page 18 of 36 Version 1.1.1 /May 2013
Wrapper Controls (Cont’d)
Controls Functions
Cycle Counter Counts the amount of wrapping cycles since the
machine was first started.
(Resettable) Cycle
Counter
Counts the amount of wrapping cycles since the last
reset. To reset this counter, you will need to enter the
password.
Reset Press Reset button to reset the resettable cycle counter.

Wulftec / M.J. Maillis Group Page 19 of 36 Version 1.1.1 /May 2013
Mode of Operation – Standard System
1. Load film and then put power on.
2. On the touch screen, go to the automatic page.
3. Select Wrapping Off if wrapping not required.
4. Depress "Reset".
. When reset completed, depress "Start". *The button will light up.
6. Machine waits for a load.
Beginning of the Wrap Sequence
NOTE: You can temporarily stop the wrapping sequence at any time. This can be
done by pressing the Start or E-Stop button. (To re-start the wrap cycle, simply
release the E-Stop and press Start). It is to be noted that by resetting the machine,
a new cycle is initiated.
7. Place the load in the center of the wrapping zone.
8. Activate the pull cord or start/stop button to begin rotation.
9. After 1. turns, the clamp releases the film.
10. The carriage moves up.
11. The top of the load is sensed.
12. The machine completes the top wraps.
13. The carriage moves down.
14. The carriage stops at bottom limit switch.
1 . The machine completes the bottom wraps.
16. The rotation slows to minimum speed.
17. The rotation stops at home position.
18. The film push arm goes out.
19. The clamp closes.
20. The cutter wire rotates into film and cuts it on contact.
21. The film is wiped.
22. The film push & wipe arm goes back to home position.
End of Wrap Sequence
To activate Manual mode, go to the manual page on the touch screen. By doing so, automatic
sequence and reset are immediately interrupted.

Wulftec / M.J. Maillis Group Page 20 of 36 Version 1.1.1 /May 2013
Cut Arm Operation
1. During the last ½ turn, the rotation slows down.
2. When the boom reaches its home position, the cut arm is activated.
3. During its activation, the cut wire heats up and cuts the film web.
4. When the arm reaches the second proximity sensor, the motor is “reversed” and the arm returns
to its home position.
. It stops when it reaches the back proximity sensor.
6. Machine is now ready for another cycle.
Wrapping the Load
1. Turn the power switch to "On" (the power on light should be illuminated).
2. Place a load under the arm.
3. Pull the end of the film from the carriage and stick it on the pallet or on the load.
4. Be sure that all pallet jacks, forklifts and personnel are clear of the wrapping area.
. Select the required wrapper controls.
6. Depress the "Start" button to initiate the wrap cycle.
7. When the wrap cycle has been completed, press the cut film web onto the load or tuck it at the
end under the lower film wrap, if required.
8. The load may now be removed and the machine is ready for the next cycle.