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Orion FLEX HPD - User Manual

Orion FLEX HPD
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FLEX
STRETCHWRAPPER
MANUAL
Models
RTA, RTD, HPA, HPD, LPA, LPD
Revision Date - February 15, 2016
Machine Manual
Revision 3.0
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4750 County Road 13 NE
Alexandria, MN 56308
Phone: (901) 888-4170
Toll Free: (800) 333-6556
FAX: (901) 365-1071

Table of Contents

Questions and Answers

  • E
    elizabeth39Aug 14, 2025
    What to do if the Orion Stretch Wrapping Systems control panel has no power and the E-stop is flashing?
    • J
      Julia SmithAug 15, 2025
      If the control panel has no power and the E-stop is flashing, it indicates that the E-Stop circuit is activated, safety photocells are not aligned, the wiring in the E-stop circuit is compromised or components in the E-Stop circuit have failed. You can try the E-Stop reset sequence: 1. Reset all safety features (close carriage door, latch carriage safety switch bar [RT only]). 2. Pull the E-Stop to the OUT position. 3. Press the Green Start Button. 4. Press the Cycle Reset button on the screen. If the issue persists, re-align photocells with their respective reflectors, then perform an E-Stop Reset. If the issue still persists, refer to the electrical schematic for wiring layout and wire numbers.
  • E
    Emily LeeAug 25, 2025
    What causes the Orion FLEX HPD Stretch Wrapping Systems carriage to jam at the top of the mast and not move?
    • H
      hmcbrideAug 26, 2025
      If the carriage is jammed at the top of the mast and won't move, it could be due to: * The carriage bottom travel switch did not activate correctly, possibly sticking. Check switch by manually activating (wiggling) the roller tip. If the switch does not activate and release it's input on the PLC correctly, replace the switch. The belt will need to be removed and re-wound correctly. The carriage will need to be brought down manually. * The carriage bottom travel striker is set too low for switch to activate properly. Raise the bottom limit striker so that the carriage travel switch activates it's PLC input before the carriage physically hits the machine's framework. The belt will need to be removed and re-wound correctly. The carriage will need to be brought down manually.
  • L
    Lori HawkinsAug 31, 2025
    How do I resolve the issue of no power feed in my Orion FLEX HPD Stretch Wrapping Systems?
    • G
      Gregory PageAug 31, 2025
      If there's no power feed, it could be due to: * No control power/E-Stop condition. Perform E-Stop reset sequence: Reset all safety features (close carriage door, latch carriage safety switch bar [RT only]), pull E-Stop to the OUT position, press Green Start Button, and press Cycle Reset button on screen. * Incorrect film threading. Compare film with threading diagram on top of carriage. Re-thread film carriage. * Incorrect VFD parameter settings. Review the parameter settings in the VFD. Refer to the supplied VFD Manual for procedure. Refer to the VFD manual and the Orion parameter settings sheet supplied with the machine for maximum frequency settings.
  • S
    Sonya AyersSep 7, 2025
    What causes stored values to revert to zero on Orion FLEX HPD Stretch Wrapping Systems?
    • D
      davispaulSep 7, 2025
      Stored values may revert to zero or unusable settings due to a high voltage spike or voltage brownout below 100 VAC. Remove all household extension cords, move the machine to a different power outlet, and have an electrician verify the site power supply.
  • L
    lopeztristanSep 10, 2025
    Why doesn't the turntable stop in the correct position on my Orion FLEX HPD Stretch Wrapping Systems?
    • M
      Micheal TuckerSep 12, 2025
      The turntable or tower may not stop in the correct position if: * The turntable end of cycle positioning counter value is set incorrectly. In this case you should refer to the factory default settings value list. * The Slow Down Position for Tower / Turntable Timer is adjusted too high. In this case you should refer to the factory default settings value list. * Table / Tower preset speeds are set incorrectly. In this case you should refer to the factory default settings value list. * Table / Tower deceleration value is set incorrectly. In this case you should refer to the factory default settings value list. * There is a component failure. Check error message on the Table / Tower VFD display. Refer to the supplied VFD user manual for error message. Replace if needed.
  • P
    pateldeanNov 17, 2025
    Why won't the turntable or tower rotate on my Orion FLEX HPD Stretch Wrapping Systems?
    • W
      Wesley LevineNov 17, 2025
      The turntable or tower may not rotate due to several reasons: * No control Power / E-Stop Condition. In this case the E-Stop button is Flashing or Green Start button is not illuminated. Perform E-Stop Reset (pull E-Stop button to the out position then press the Green Start button so that it is Illuminated. Press Cycle reset on the Touchscreen.) * The machine is in Cycle Pause. Observe the Cycle Pause Icon on the Run Screen. If it is illuminated, the machine is in a Pause state. Press Resume to resume wrapping. * VFD parameter settings are incorrect. Review the parameter settings in the VFD. Refer to the supplied VFD Manual for procedure. Refer to the VFD manual and the Orion parameter settings sheet supplied with the machine for maximum frequency settings. * Blown Fuse. Locate Tab...
  • A
    Angela OwensNov 20, 2025
    Why is the film breaking inside the carriage of my Orion FLEX HPD?
    • D
      dwayne62Nov 20, 2025
      Film breakage inside the carriage, usually between the rubber stretch rollers, can occur for several reasons: * Incorrect gauge/type of film. The film used should be able to stretch effectively 280% at ambient temperatures. Remove any film that does not comply with the machine's requirements or, change the stretch sprocket on the machine to stretch below the film's fatigue value. * Damaged film. Observe the edges and sides of the roll for damage from handling. Replace improper film with film in good condition. * Incorrectly wound film. Look for heavy, raised stripes along the feed axis of the film, known as "gauge banding". Replace improper film with film in good condition. * Damaged or incorrectly sized film core. The film core should fit the machine's film mandrels. Replace impr...
  • K
    Kristopher McintyreNov 27, 2025
    Why does the Orion FLEX HPD Stretch Wrapping Systems film break between the last aluminum roller and the load?
    • T
      Tammy FischerNov 27, 2025
      Film breaking between the last aluminum roller and the load can be due to: * Film tension set too high. Lower the film tension value at the touch- screen. * Incorrect Zero or Gain settings for the hall effect (Film Feed Trigger). Observe the feedback value of the hall effect located on the touchscreen. Re-set the ZERO and GAIN values according to the film feed setup instructions in the manual. ZERO setting should be a value of at least ten above the hall effect feedback value to operate properly. * Tension spring too heavy. Replace the standard tension spring with the light duty tension spring (supplied with the machine). * Film roll sets too low in relation to the feed rollers. Adjust the bottom film mandrel to allow the bottom edge of the film to run correctly on the trailing ru...

Summary

Introduction and Safety

Safety

Introduces general safety precautions and the importance of machine operation awareness.

System Safety Recommendations

Lists general safety precautions for operating and maintaining automated equipment.

Hazard Messages

Explains the meaning of DANGER, WARNING, and CAUTION messages.

Operation Safety

Outlines safety precautions for personnel operating the stretch wrapper.

Maintenance Safety

Provides safety precautions for personnel performing maintenance or service.

Lockout and Tagout Recommendations

Details procedures for electrical system lockout and tagout.

Pneumatic and Vacuum Systems

Explains lockout/tagout for pneumatic systems and air supply precautions.

Installation and First Time Power Up

Covers the initial unloading and setup of the machine.

Machine Installation

Covers connecting power and air, ensuring the machine is level.

How to Erect an RTA or RTD Flex Orion

Provides step-by-step instructions for erecting specific machine models.

System Operation

Operating Procedures

Covers essential procedures like startup, shutdown, and film loading.

How to Start and Shut Down Your Wrapping System

Guides on safe startup and shutdown procedures for the wrapping system.

Carriage Obstacle Detect Error Recovery

Explains steps to resolve carriage obstacle detection errors.

Loading The Film

Provides instructions on how to load the film roll onto the machine.

Maintenance Prompt

Explains the maintenance reminder system and how to acknowledge or snooze prompts.

Wrap Settings Screen

Screen for configuring top/bottom wraps and carriage speed settings.

Main Drive Screen

Adjusts settings for the main drive, including speed and position.

Timers Screen

Machine Setup Screen

Multistretch Settings Screen

The VFD Parameters Screen

Insta-Cut Screen

Dual Insta-Cut Screen

S Insta-Cut Screen

The VFD Diagnostics Screen

Flex Dashboard Remote Viewing

Guides on configuring remote status viewing via a web browser.

Alarm Displays

Lists critical status messages and fault conditions for the machine.

Troubleshooting

Troubleshooting

Details common problems, causes, and solutions for machine operation issues.

Orion FLEX HPD Specifications

General IconGeneral
BrandOrion
ModelFLEX HPD
CategoryStretch Wrapping Systems
LanguageEnglish

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