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Orion FLEX RTD - User Manual

Orion FLEX RTD
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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

  • S
    scotthicksAug 15, 2025
    What to do if the Orion Stretch Wrapping Systems control panel has no power and the E-stop is flashing?
    • A
      Anne RamosAug 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.
  • A
    Ashley MirandaAug 25, 2025
    What causes the Orion FLEX RTD Stretch Wrapping Systems carriage to jam at the top of the mast and not move?
    • M
      muellerruthAug 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.
  • N
    nicholasmartinAug 31, 2025
    How do I resolve the issue of no power feed in my Orion Stretch Wrapping Systems?
    • W
      wallstracySep 1, 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
    Joseph MorrisSep 7, 2025
    What causes stored values to revert to zero on Orion Stretch Wrapping Systems?
    • M
      Mathew PerkinsSep 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.
  • T
    Theresa AtkinsSep 10, 2025
    Why doesn't the turntable stop in the correct position on my Orion Stretch Wrapping Systems?
    • M
      Michael MartinezSep 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.
  • R
    Ralph SmithNov 17, 2025
    Why won't the turntable or tower rotate on my Orion FLEX RTD Stretch Wrapping Systems?
    • M
      maynathanNov 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
    James StuartNov 20, 2025
    Why is the film breaking inside the carriage of my Orion Stretch Wrapping Systems?
    • W
      williamphillipsNov 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...
  • S
    Susan BurnsNov 26, 2025
    Why does the Orion FLEX RTD film break between the last aluminum roller and the load?
    • E
      Erin WhiteNov 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

General Safety Guidelines

Outlines essential safety practices for machine operation.

System Safety Recommendations

Lists specific safety precautions for operating personnel.

Hazard Message Definitions

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

Operation Safety Precautions

Safety measures for operating the stretch wrapper.

Maintenance Safety Procedures

Safety guidelines for performing maintenance tasks.

Lockout;Tagout Procedure

Step-by-step guide for safe electrical and pneumatic lockout.

System Operation

Operating Procedures Guide

General guide to operating the stretch wrapper.

Starting and Shutting Down the System

Step-by-step instructions for system power management.

Loading the Stretch Film

Instructions on how to properly load the film roll.

Run Screen Interface

Details the primary operational screen of the machine.

Wrap Settings Configuration

Screen for setting top/bottom wraps and carriage speeds.

Main Drive Settings Configuration

Timers Screen Adjustments

VFD Parameters Screen

VFD Diagnostics Information

Fault History Screen

Displays logged machine faults and occurrence times.

Alarm Displays and Corrections

Lists critical alarms and their recommended corrections.

Troubleshooting

Control Panel Error Messaging

Addresses issues related to no control power or flashing E-stop.

Stored Values Reset Issues

Solutions for when stored values revert to zero or settings are unusable.

Turntable;Tower Position Errors

Resolves issues with incorrect stopping positions for turntable/tower.

Turntable;Tower Rotation Issues

Addresses inconsistent or jerky turntable/tower movement.

Carriage Lift Movement Problems

Solutions for carriage not moving up or down correctly.

Film Clamp Operation Issues

Troubleshooting for the film clamp not operating properly.

Film Cutter;Brush Arm Issues

Addresses problems with the film cutter or brush arm operation.

Film Cutter Not Cutting Film

Solutions for when the film cutter fails to cut film.

Maintenance

Maintenance Procedures

General overview of maintenance tasks.

Reducer Oil Change Guide

Preventative Maintenance Schedule

Orion FLEX RTD Specifications

General IconGeneral
BrandOrion
ModelFLEX RTD
CategoryStretch Wrapping Systems
LanguageEnglish

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