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Orion FLEX LPA - User Manual

Orion FLEX LPA
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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

  • B
    Brian BrandtAug 14, 2025
    What to do if the Orion FLEX LPA Stretch Wrapping Systems control panel has no power and the E-stop is flashing?
    • N
      nicholashubbardAug 14, 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.
  • K
    Kristin BooneAug 25, 2025
    What causes the Orion FLEX LPA Stretch Wrapping Systems carriage to jam at the top of the mast and not move?
    • E
      Eddie MeyerAug 25, 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.
  • B
    Brent MontgomeryAug 31, 2025
    How do I resolve the issue of no power feed in my Orion FLEX LPA Stretch Wrapping Systems?
    • D
      daniel55Aug 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.
  • J
    Joshua RogersSep 6, 2025
    What causes stored values to revert to zero on Orion Stretch Wrapping Systems?
    • J
      jenkinsthomasSep 6, 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.
  • J
    Jasmine PerezSep 10, 2025
    Why doesn't the turntable stop in the correct position on my Orion FLEX LPA Stretch Wrapping Systems?
    • R
      Robert GarnerSep 10, 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.
  • J
    Jennifer LittleNov 17, 2025
    Why won't the turntable or tower rotate on my Orion FLEX LPA Stretch Wrapping Systems?
    • T
      Thomas HooverNov 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...
  • J
    Jasmine PerryNov 19, 2025
    Why is the film breaking inside the carriage of my Orion Stretch Wrapping Systems?
    • M
      msmithNov 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...
  • D
    David KellerNov 26, 2025
    Why does the Orion FLEX LPA film break between the last aluminum roller and the load?
    • M
      mary40Nov 26, 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

General safety guidelines for operating industrial equipment.

System Safety Recommendations

Precautions for personnel operating and maintaining automated equipment.

Hazard Messages

Explanation of DANGER, WARNING, and CAUTION message types.

Operation Safety

Safety precautions for personnel operating the Flex Stretchwrapper.

Maintenance Safety

Safety precautions for personnel performing maintenance or service.

Lockout and Tagout Recommendations

Procedures for safely locking out power sources during maintenance.

Pneumatic and Vacuum Systems

Safety precautions for pneumatic and vacuum systems during maintenance.

Installation and First Time Power Up

Guidance on machine unloading, inspection, and initial setup.

System Description

Machine Specifications

Details on utilities, speed, drive, control, and film delivery features.

System Operation

Operating Procedures

Basic operations for starting and shutting down the wrapping system.

Run Screens

Description of the primary functions and buttons on the Run screen.

Wrap Setting Screens

Screen for adjusting top/bottom wraps and carriage speed.

Machine Settings Screens

Provides access to various machine setting adjustments.

Main Drive Screen

Allows adjustment of the Main Drive (turntable or rotary arm).

Machine Setup Screen

Used for initial machine configuration and model selection.

Diagnostics Screens

Flex Dashboard Remote Viewing

Message Displays

Alarm Displays

Troubleshooting

Troubleshooting Chart

Details common problems, causes, and solutions for the Flex series.

Maintenance

Maintenance

Proximity Sensor Adjustment

Cleaning The Stretch Rollers

Preventative Maintenance Schedule

Orion FLEX LPA Specifications

General IconGeneral
Power Requirements120 VAC
Film Width20"
Machine Weight1, 200 lbs
Maximum Load Weight2, 500 lbs
Load WeightUp to 2, 500 lbs

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