Eagle 2000 B, 2000 BE, 2000 BHS, 2000 EB, 2000 EBT Operation Manual

packagingconnection.com

770-410-3456 Div. of Express Worldwide, Inc.

Operations Manual

Eagle 2000 Series Stretch Wrapper

Models B, BE, BHS, EB, EBT, BWS

READ ALL INSTRUCTIONS CONTAINED IN THIS

MANUAL PRIOR TO MACHINE INSTALLATION!

- 1 -

Contents

page

1. Machine Safety Information

1.1 Safety & Warnings 3

1.2 Specifications 5

1.3 Outline & Applications 8

1.4 Position of Operation 8

1.5 Safety Precautions Prior to Operation 8

2. Machine Installation

2.1 Machine Structure & Main Components 9

2.2 Transportation 10

2.3 Installation 11

2.4 Operational Environment 14

3. Operation

3.1 Operational Steps & Film Loading 15

3.2 Basic Machine Operation 16

3.3 LCD Screen Operation 17

3.4 LCD Screen Navigation & Language 19

3.5 Password Settings 24

4. Weight Scales (Optional)

4.1 Introduction 26

4.2 Error Codes 28

5. Maintenance & Troubleshooting

5.1 Troubleshooting Guide 29

5.2 Carriage Load Safety Switch 31

5.3 Turntable Home Switch 32

5.4 Turntable & Carriage Adjustment 34

6. Illustrations & Parts List

6.1 Base (Turntable) 35

6.2 Idler Roller 37

6.3 Mast 38

6.4 Carriage 40

6.5 Film Roller 42

6.6 Extended Rollers 43

7. Electrical Schematics 44

- 2 -

1.1 Safety & Warnings

 Before servicing, always power down and unplug the machine from the power source.
 Ensure that the correct voltage is being supplied from the power source.
 Do not touch the turn table while machine is in operation.
 Place all items to be wrapped in the center of the turntable.
 Keep the machine and surrounding area clean, clear and free of debris to ensure safe operation.

Warning Labels

DO NOT MODIFY OR REMOVE WARNING LABELS

Turntable Edge (x2) Platform Platform

Use Caution When Stepping or

Walking

(Turntable may move)

Table Rotation Direction Do Not Step

- 3 -

1.1 Safety & Warnings

DO NOT MODIFY OR REMOVE WARNING LABELS

Film Carriage

Do Not Open While Running

Control Panel (Bottom)

Electrical Hazard

Do not service machine while powered up and

connected to power source!

- 4 -

1.2 Specifications - Eagle 2000B

Power Supply 110VAC, 60Hz

Turntable Speed

Turntable Motor 1 HP 750W 1420 RPM 220V 1:30 Gearbox

Turntable Diameter 59”

Turntable Diagonal 80”

Turntable Height 3.4”

Turntable Gear 1:5

Turntable Chain 12A-1 ISO

Carriage Up/Down 1/3 HP 1390 RPM 220V 1:60 Gearbox

Carriage Up/Down Chain 08B-1 ISO

Pre-Stretch Motor 1/3 HP 1390 RPM 220V 1:20 Gearbox

Pre-Stretch Gear Ratio 1:12

Pre-Stretch Chain 06B-1 ISO

Film Stretch 250% pre-stretch with adjustable load force

(Standard 0-12 rpm) (Optional 0-20rpm)

1

Film Lift

Photo-eye controlled to match pkg height2

Film Width 20” (standard) or 30” (option)

Adjustable Internal Limit Switches 8” Top & Bottom Rails

Max Film Height 87”

Mast Height 94”

Max Turntable Weight Capacity 5,000lbs

Max Package Height (2” Overlap) 87”

Machine Dimensions 96.5” X 59” X 99”

Shipping Weight 1,295lbs

Attachment

Ramp or Custom Heavy Duty3

Noise ≤75 DB

Environment Humidity ≤98% Temperature 32-104°F

1

Note: Black product requires custom photo-eye installation.

2

Factory ramp is for use with hand pallet jacks only. Maximum combined weight of jack and product must not
exceed 1,300lbs. Custom heavy-duty ramps are available for use with loads exceeding 1,300lbs. (See page 5
for details)

3

Turntable maximum RPM can be increased to 20 RPM upon request.

- 5 -

1.2 Specifications - Eagle 2000BE

Power Supply 110VAC, 60Hz

Turntable Speed

(Standard 0-12 rpm) (Optional 0-20rpm)1

Turntable Motor 1 HP 750W 1420 RPM 220V 1:30 Gearbox

Turntable Diameter 59”

Turntable Diagonal 80”

Turntable Height 3.4”

Turntable Gear 1:5

Turntable Chain 12A-1 ISO

Carriage Up/Down 1/3 HP 1390 RPM 220V 1:60 Gearbox

Carriage Up/Down Chain 08B-1 ISO

Pre-Stretch Motor 1/3 HP 1390 RPM 220V 1:20 Gearbox

Pre-Stretch Gear Ratio 1:12

Pre-Stretch Chain 06B-1 ISO

Film Stretch 250% pre-stretch with adjustable load force

Film Lift

Photo-eye controlled to match pkg height2

Film Width 20” (standard) or 30” (option)

Adjustable Internal Limit Switches 8” Top & Bottom Rails

Max Film Height 120”

Mast Height 126.5”

Max Turntable Weight Capacity 5,000lbs

Max Package Height (2” Overlap) 118”

Machine Dimensions 96.5” X 59” X 130”

Shipping Weight 2,060lbs

Attachment

Ramp or Custom Heavy Duty3

Noise ≤75 DB

Environment Humidity ≤98% Temperature 32-104°F

1

Note: Black product requires custom photo-eye installation.

2

Factory ramp is for use with hand pallet jacks only. Maximum combined weight of jack and product must not
exceed 1,300lbs. Custom heavy-duty ramps are available for use with loads exceeding 1,300lbs. (See page 5
for details)

3

Turntable maximum RPM can be increased to 20 RPM upon request.

- 6 -

1.2 Specifications - Eagle 2000EBT

ITEM SPECIFICATION EAGLE 2000EBT

Power Supply 110VAC, 60Hz

Turntable Speed

(Standard 0-12 rpm) (Optional 0-20rpm) 1

Turntable Motor 1 HP 750W 1420 RPM 220V 1:30 Gearbox

Turntable Diameter 78.5

Turntable Diagonal 170"

Turntable Height 3.4”

Turntable Gear 1:5

Turntable Chain 12A-1 ISO

Carriage Up/Down 1/3 HP 1390 RPM 220V 1:60 Gearbox

Carriage Up/Down Chain 08B-1 ISO

Pre-Stretch Motor 1/3 HP 1390 RPM 220V 1:20 Gearbox

Pre-Stretch Gear Ratio 1:12

Pre-Stretch Chain 06B-1 ISO

Film Stretch 250% pre-stretch with adjustable load force

Film Lift

Photo-eye controlled to match pkg height2

Film Width 20” (standard) or 30” (option)

Adjustable Internal Limit Switches 8” Top & Bottom Rails

Max Film Height 12”

Mast Height 126.5”

Max Turntable Weight Capacity 5,000lbs

Max Package Height (2” Overlap) 118”

Machine Dimensions 151” X 78.5” X 130”

Shipping Weight 2125lbs

Attachment

Ramp or Custom Heavy Duty3

Noise ≤75 DB

Environment Humidity ≤98% Temperature 32-104°F

1

Note: Black product requires custom photo-eye installation.

2

Factory ramp is for use with hand pallet jacks only. Maximum combined weight of jack and product must not
exceed 1,300lbs. Custom heavy-duty ramps are available for use with loads exceeding 1,300lbs. (See page 5
for details)

3

Turntable maximum RPM can be increased to 20 RPM upon request.

- 7 -

1.3 Outline and Application Field

This machine features a PLC controller. The electric subassembly uses world famous products such
as OMRON, LG and TE components. This provides a reasonable, high reliability and convenient use
for the machine. It can advance production efficiency and prevent goods from being damaged during
transportation. This machine has a wide range of applications and is used in the following industries:
chemical, fiber, tobacco, pharmaceutical, publishing, refrigeration, etc.

1.4 Position of Operation

The operator must stand in front of the operating screen, away from the turntable and carriage. The
operator must insure that no other individual or devices such as the forklift are at risk during

operation.

(See Fig. 1-1)

Fig. 1-1

1.5 Safety Precautions Prior to Operating Machine

 This machine uses 110V, 60Hz, single phase power.
 Do not plug into an extension cord.
 Do not step on the machine when it is running.
 Do not install this machine on soft ground.
 Install on a level surface.
 Do not put the object to be wrapped on the edge of the turntable.
 Turn off the power after done using the machine.
 In an emergency, press the emergency stop button. This will cease movement of the machine.
 Clean the machine once a day.
 Only a Qualified Technician should change or test the wiring and/or electrical components.
 DO NOT push, drag, or slide machine! Doing so will cause severe damage!

- 8 -

2.1 Machine Structure & Components Illustration

Mast

Control Panel

Film Carriage

Turntable

Fig. 2-1

- 9 -

2.2 Transportation

You must have at least 4ft fork tubes or tube extensions fully inserted into the machine and a forklift
rated for 3,000lbs to transport the machine safely. Do not raise the load more than 6” off of the
ground.

(See Fig. 2-2)

ALWAYS USE OSHA HANDLING PROCEDURES FOR HANDLING THE

STRETCH WRAPPER AND REMEMBER TO NEVER PUSH, DRAG, OR

SLIDE THE MACHINE!

Do not transport machine from turntable when mast is
lowered!

When transporting the machine in this configuration;

1. Inspection cover must be removed before raising or
lowering the mast.

2. Carriage must be raised 8 inches

Carriage must be raised 6~8 inches before attempting
to lift machine from this end.

It is acceptable to transport machine by turntable when
mast has been raised.

Fig. 2-2

- 10 -

2.3 Installation

Step 1 - Place the machine in the desired location using a tow motor or crane capable of handling a
load of 3,000lbs.

Step 2 - Remove the lower rear inspection panel on the mast prior to raising the mast. The panel is
located on the end of the machine next to the turntable motor. The panel has a warning label affixed
to it.

(See Fig. 2-4a & Fig. 2-4b)

(See Fig. 2-3)

Fig. 2-3

Fig. 2-4a

Fig. 2-4b

Step 3 - Lift the mast using hoisting tools. A tow motor or hoist rated for at least 3,000lbs is required.
While lifting the mast, use caution to ensure that wires and connectors are not pinched.

(See Fig. 2-5a)

Once the machine is fully upright, one individual can stabilize the mast while a second individual
fastens the four M10 bolts to secure the mast to the base. The M10 bolts are to be tightened to
30ft/lbs of torque.

(See Fig. 2-5b)

Fig. 2-5a

Fig. 2-5b

- 11 -

2.3 Installation

Step 4 - If installing a ramp, place the ramp by locating the ramp shoulder bolt and
placing it into the slot in the ramp. It is highly recommended to anchor the ramp to the
floor.

Step 5 - Affix the carriage onto the corresponding position on the mast and fasten with
four M8 bolts.

(See Fig. 2-8)

(See Fig. 2-6)

(See Fig. 2-7)

Do not force the connectors together.

Insert the connector plugs on the front of the carriage into the receptacles.

Fig. 2-6

Fig. 2-7

Fig. 2-8*

- 12 -

2.3 Installation

Step 6 - Insert the connector plug inside the bottom of the mast into the corresponding receptacles.

(See Fig 2-9a, 2- 9b, 2-9c )

Fig. 2-9a

Note: These connectors are for carriage motor power (pr e-str etch), photo -electric eye, home
limit switch, and E-Stop switch located on the bottom of the carriage.

Fig. 2-9b

Fig. 2-9c

Step 7 - Fasten the lower rear panel into the corresponding position on the post using the pin. (See

Fig. 2-10)

Lower Rear

Panel

Step 8 - Verify that all screws are tight and then turn on the power. Check to see if the power
indicator is on and that text is displayed on the LCD screen.

Pin

Fig. 2-10

- 13 -

2.4 Operational Environment

 Machine should be far from smoke, preferably in a dry, well-ventilated area.
 Normal environment temperature should be within 32ºF and 104ºF.
 No special requirements for electromagnetic radiation.
 Machine should not be placed under direct lighting as it may cause photoelectric eye to

malfunction.

 DO NOT push, drag, or slide machine! Doing so will cause severe damage!

Note: If product to be wrapped is a dark color (black, dark blue, etc...), the standard
photoelectric eye may not work properly. A photo-eye upgrade option is available for sensing
dark objects.

- 14 -

3.1 Operational Steps & Film Loading

BEFORE LOADING FILM, PRESS THE EMERGENCY

STOP BUTTON AND TURN THE POWER

Loading stretch film into carriage

Step 1 - Loosen fastening screw "A" and take off

roll holder "B".

Step 2 - Center the film core over the film shaft
and lower onto the lower orientation
plate "C" of the film shelf.

Step 3 - Mount roll holder "B" and re-tighten
fastening screw "A".

Step 4 - Push down handle "E" to open carriage
door. Then press the film through in the
direction of the arrow and close the door
(do not slam). Pass the film behind and
around the first roller and then between
the first and second roller.

(See Fig. 3-3)

Note: Do not slam or force the carriage door closed. Doing so
may cause damage to hinges and carriage door locking mechanism. Do not use sharp objects
on or near rollers as they can be easily damaged.

(See Fig. 3-1)

(See Fig. 3-1)

SWITCH TO THE OFF POSITION

(See Fig. 3-1)

A

B

C

Fig. 3-1

Fig. 3-2

Fig. 3-3

- 15 -

3.2 Basic Machine Operation

1

2

3

4

5

8

1. Screen
Controller

2. Table Speed

3. Carriage Speed

4. Load Force

5. Power Indicator

6

6. Start Button

7. Reset Button
8 Emergency Stop
Button

9. Power Switch

7

9

The turntable speed and load force knobs can be adjusted to achieve desired film tension.

The speed and load force work in conjunction. If the table speed is increased, the load force
will need to be decreased to maintain the same film tension. If the table speed is decreased,
the load force will need to be increased to maintain the same film tension.

- 16 -

3.2 Basic Machine Operation

3

7

2

1

4

6

Step 1 – Turn on the power to the machine.

Step 2 – Using the Screen Controller, select a job mode.

Step 3 – Place the load to be wrapped onto the turntable.

Once the load has been placed onto the turntable and detected, the screen notifier

will change from “No Load Detected” to “Machine Ready”.

Step 4 – Connect the loose end of the stretch film to the bottom of the load (ie: corner of the pallet)

Step 5 – Press the start button to begin wrapping the load.

Step 6 – Once the job finishes, split the film between the stretch wrapper and the now wrapped

load and secure any loose ends of film.

Step 7 – Remove the load from the turntable and place the next load onto the turntable.

Repeat steps 2-7 as required

5

- 17 -

3.3 LCD Screen Operation

The LCD screen displays information used to control the machine and to make changes to
operational parameters. Active keys are shown with a circle or square around them. Pressing the
corresponding key will execute the function.

To change a setting, press the SET button.

Use the left and right ◄ ► arrows to move the cursor to the value/item to be changed.

Numeric values can be entered using the number pad or by scrolling through preset values using the
up and down arrows ▲ ▼.

When applicable, the left and right arrows ◄ ► can be used to previous/next positions within a field.

Once the desired value has been entered, press ENT to save any changes.

Note: Pressing SET will not save changes at this point.

Pressing the ESC key will go back to the previous screen.

- 18 -

3.4 Navigating LCD Screens

Menu

From this screen, you can navigate to;

① Settings

Machine settings and delay timers

② Job Mode

Auto, Manual, Single Wrap, Top Wait, Slow Wrap

③ Job Count

View number of completed job cycles have been run for the
shift and cumulative total.

④ Password

Set machine password.

⑤ Language

Change menu language.

Settings – page 1

From this screen, you can set the number of wraps to complete
at the top and bottom of the load. Additionally, the number of
up/down cycles can be set from this screen.

Press the ► button to view page 2.

Settings – page 2

From this screen, you can change how far past the top of the
package the film will be applied.

To change the settings, press SET, enter the amount of time in
tenths of a second (ie; 15=1.5 seconds). Press SET, enter a
value for the highlighted item and press ENT to save and move
the cursor to the next field.

Press the ◄ button to view page 1.

- 19 -

3.4 Navigating LCD Screens

Job Mode

From this screen, you can select the different types of modes
the machine has.

To the bottom left of the screen, there is a text notifier that
displays machine status.

Job Mode / Auto

This mode is used to automatically wrap packages.

To begin, press the Start button

The machine will wrap around the package once at the bottom
and the carriage will begin traveling up to the height of the
package. At the top of the package, the machine will wrap the
number of times set in the top cycle parameter and then the
carriage will travel to the bottom of the package and wrap the
number of times set in the bottom cycle parameter.

To the bottom left of the screen, there is a text notifier that
displays machine status.

Job Mode / Manual

This mode is used when you need to wrap goods by hand or
use the machine as a turntable.

① Table - Start/Stop turntable rotation
② Up - Start/Stop carriage travel up
③ Down - Start/Stop carriage travel down

Job Mode / Single Wrap

This mode is used when only one upward wrap is required.

To begin, press Start button

The machine will wrap the package once at the bottom. The
carriage will travel up to the top of the package, wrap the
number of times set in the top cycle parameters and the
turntable will stop. The carriage will then travel back down to the
bottom.

To the bottom left of the screen, there is a text notifier that
displays machine status.

- 20 -

3.4 Navigating LCD Screens

Job Mode / Top Wait

This mode is used when a cover will be placed on the top of the
package.

To begin, press Start button

The machine will wrap the package once at the bottom and the
carriage will travel to the top of the package and pause for the
operator to place a cover on the package. To continue, press
the Start button. The machine will wrap the number of times set
in the top cycle parameter and the carriage will travel back
down to the bottom of the package were it will wrap the number
of times set in the bottom cycle parameter.

To the bottom left of the screen, there is a text notifier that
displays machine status.

Job Mode / Slow Wrap

This mode is used when wrapping a tall unstable load.

To begin, press Start button

The machine will wrap around the package with a slow turntable
rotation speed and low tension. Once the carriage reaches the
top of the package, it will change to a normal tension cycle
based on the preset parameters and continue wrapping to the
bottom of the package.

To the bottom left of the screen, there is a text notifier that
displays machine status.



- 21 -

3.4 Navigating LCD Screens

Job Count

This screen displays the current number of cycles and the total
number of cycles of the machine.

To reset the current yield, press the ► key

Set Menu Language

From the Main Menu, select ⑤ Language

To change the language, select either;

English

⓪

Spanish

①

E-STOP

Film Tension Lost

If the machine has been placed in E-STOP, this screen will be
displayed.

Once the E-STOP condition has been cleared, a screen
indicating that a reset is required will be displayed.

If film tension is lost during a job, the machine will pause the
job and display a screen indicating film tension has been lost.
Once film tension has been restored, the job can be continued
by pressing the Start button.

- 22 -

3.4 Navigating LCD Screens

Job Notifiers

At the bottom-left corner of the auto and semi-auto job
screens, there is a textual display of the status of the
machine. A few examples of text that may be displayed are;

Machine Ready

A load has been detected as being placed on the turntable
and the machine is ready to run the selected job mode.

In Cycle

“In Cycle” will be displayed during operation of the selected
job mode.

Load Not Preset

The machine is ready to run the selected mode, but no load
has been detected as being placed on the turntable.

Film Carriage Not Home … Press RESET

The film carriage has not returned to its home position at
the bottom of the mast.

Machine Reset – In Progress

This message will be displayed after pressing the reset
button on the machine control panel. Once the machine
reset process has completed, this message will be cleared
from the screen.

- 23 -

3.5 Password Settings

IF DEFAULT PASSWORD IS CHANGED AND FORGOTTEN, THE

ONLY MEANS OF RESET IS BY ON-SITE SERVICE CALL OR PLC

REPLACEMENT ALL ASSOCIATED EXPENSES AND FEES WILL

BE THE RESPONSIBILITY OF THE MACHINE OWNER

Setting a New Password

FACTORY DEFAULT PASSWORD: 1234

Press ESC until the Main Menu is displayed

Press ④ Password

Press SET

Enter your new password using the numeric keypad.

Press ENT

Note: For security reasons, a random generated number will
be displayed in place of your new password.

Enter the old password using the numeric keypad.

Note: If you have not previously set up a password, use the
factory default password.

Press ENT

Note: For security reasons, a random generated number will
be displayed in place of your old password.

- 24 -

3.5 Password Settings

If there is a error during the process, the screen will display
"INVALID PW, SEE MANUAL"

Press ALM to clear the error.

Note: If this message is displayed, the new password has not
been set. You will need to re-enter the new and old passwords
again.

How to Enter a Password

Any time a menu item is selected that is password protected,
the Input Password screen will be displayed.

To enter a password, press SET

The black background behind the number will clear to indicate
the system is ready for password entry.

Use the numeric keypad to enter your password.

Note: The factory default password is; 1234

Press ENT and, if the correct password was entered, the menu
will proceed to the item selected.

- 25 -

4.1 Weight Scale - Introduction & System Overview

Key Operation / Function
ON / OFF  Turns Scale On / Off

Press and hold for 2+ seconds to operate

Hold  Hold Weight on Scale (Manual Hold)

Press 'Hold' with scale loaded.

 Hold Peak Weight (Auto Hold)

Press 'Hold' prior to loading scale. Can be used for multiple package weighing or
unstable loads.

 Release Hold Function

Press 'Hold' again to return to normal operation.

 Return (Settings Mode)

Previous

 Settings Mode: Return

- 26 -

4.1 Weight Scale - Introduction & System Overview

Total  Add Weights

With package on the scale, press the 'Total' key to enter weight and retain in memory. Press
'Total' after weighing each package to add weight to cumulative total.

 View Total

Press 'Total' and 'Print' key at the same time. The total weight value will flash continuously.

 Exit Total Mode

Press and hold the 'Total' key to display "Clr n".
Clear Totals - Press 'Zero' key to display "Clr y", then press 'Print' key
Keep Totals - Press 'Print' key while "Clr n" displayed

 Settings Mode: Previous / Home

First press = Previous
Second press = Home

kg/lb  Change Display from Kilograms to Pounds

 Settings Mode: Left Arrow

Print  Print Totals

While in View Totals Mode (See - Total: View Total), press and hold 'Print' for 3 seconds to
print.
(Optional Prin ter Hardware Required)

- 27 -

4.2 Weight Scale - Error Codes

Error
Code

uuuuuu

nnnnnn

ERR1

ERR2

ERR3

ERR4

ERR5
ERR6

Possible Cause Solution

 Overloaded condition.
 Wrong connection at load cell.
 Load cell has quality problem.

 Overloaded condition.
 Bad connections.

 Load cell has quality problem.

 Overweight calibration error.
 Incorrect weight input or incorrect

weight on weighing platform.

 Underweight calibration error.
 Incorrect weight input or incorrect

weight on weighing platform.

 During calibration, the input signal is

negative.

 During calibration, the signal is

unstable.

 Circuitry error  Replace the PCB.
 System error  Call for Tech Support

 Reduce the weight.
 Check load cell connection.

 Inspect load cell for damage.
 Check the input and output.
 Check scale is resisted or not, foot is kept level

or not.

 Check load cell connection.
 Check input and output resistance of load cell.
 Input weight correctly during calibration.
 Place correct weight on weighing platform.

 The calibration weights Minimum is 10% of

Max. cap. Recommend 60%-80% of Max.
Capacity.

 Check all connections. Check load cell. If

connections and load cell are okay, PCB needs
replacing.

 After the platform is stable, start calibration.

- 28 -

5.1 Troubleshooting Guide

Error Code Possible Cause Solution

Machine will not function

Machine has power and
will not function

"Machine Pause"

Machine will not stop at
home

Machine will not start job
after reset

Screen displays Chinese
lettering

 Machine not plugged in.
 Outlet where Machine is plugged

into has no power or bad outlet.

 Power cord has been damaged.
 Machine internal circuit breaker

tripped.

 Input signal 05 is lit on PLC.
 E-stop is pushed on main panel.
 Carriage base safety switch

pushed.

 Film Feed Door is not closed

properly.

 Drive display should display "rdy"

for them to be ready.

 Input signal 03 is not lit on PLC.
 Bad connection between mass and

turn table.

 Bad Limit Switch/ Adjustment.

 Input 04 is not lit .
 Photoelectric Eye is not reading

package.

 DB9 connector has come

unplugged or is loose.

 DB9 connector is bad.

 Plug machine into 110VAC

outlet.

 Check to see if outlet has

power.

 Call service for new cord.
 If machine breaker is tripped call

tech support.

 Check all E-stop and debris

under carriage.

 Adjustment may be needed to

carriage safety switch reference

4.2 carriage maintenance .

 Close door with a firm push Do

Not slam or force.

 If drive don't display "rdy" call

tech support.

 This Input will only illuminate

when the Limit Switch is on the
cam location.

 Tighten or replace connector

ensure that their no pinched
wires.

 Replace Limit Switch or adjust

so that rides on cam properly.

 Photoelectric Eye is not sending

a signal to PLC.

 Ensure that the both green and

amber are illuminated with load
in place.

 Call tech support
 Tighten connector on PLC and

Screen / Be sure to check power
connections as well.

 Replace DB9 Connector / call

tech support .

- 29 -

5.1 Troubleshooting Guide

Problem Possible Causes Solution

Carriage
does not run

Film breaks

Scale does
not work

Notes:

 Check to see if the machine is plugged in.
 Check carriage speed knob is at minimum

position – if so turn carriage speed knob to a
higher setting.

 Check to see if the chain is broken or

disconnected.

 Carriage sliding block is jammed – realign slide

block.

 Speed is not set well between load force and

turntable speed – adjust the settings.

 Check for cuts in film.
 Move dancer bar without film to see if motor

turned on.

 Pre-stretch chain is broken or jammed –

reinstall chain or refasten chain wheel.

 Is the machine level.
 Are all of the leveling feet in the proper place?

 Plug machine into adequate

power 110 Volt outlet.

 Replace chain or reinstall chain

/ remove any debris.

 Loosen slider blocks to realign

and lubricate with a dry lube.

 Adjust speed potentiometer to

correct speed.

 Replace roll of film.
 Faulty drive / look for rdy on

display. May need replaced.

 Replace chain or reinstall chain

and tighten all hardware.

 Adjust speed potentiometer to

correct speed.

 Start by placing the machine on

a flat surface and using a level.

 Using the leveling feet supplied

and screw into load cell.

- 30 -

5.2 Carriage Load Safety Switch

USE EXTREME CAUTION WHEN ADJUSTING

CARRIAGE SWITCH AS IT CAN BE DAMAGED

BY OVER ADJUSTMENT

Step 1 - Open Carriage Door

Step 2 - Unload any and all stretch film from machine

Step 3 - Loosen jam nut

Step 4 - Loosen bolt in small increments to avoid damage to switch

Step 5 - Close carriage door gently (Do not install stretch film)

Step 6 - If the machine is able to reset, then the carriage door switch

is adjusted correctly. If the machine does not reset, then
repeat steps 4 & 5

Step 7 - Open carriage door and tighten jam nut

Step 8 - Reinstall stretch film

- 31 -

5.3 Turntable Home Switch

BE SURE TO DISCONNECT ALL POWER TO THE MACHINE PRIOR

TO ANY MAINTENANCE WORK

Fig. 4-1

Fig. 4-2

Turntable

 Remove the six M10 flat head cap screws in the turn table.
 Screw in one M10 eyebolt rated for lifting into the tapped hole in the turn plate. Lift the turn table

using a hoist and chain rated for a 500lb load.

(See Fig. 4-1)

 Lift the turntable just clear of the frame and use the forklift to remove the table. For safety reasons,

keep the disk low to the ground.

 Lubricate the chain and gears. Inspect the items and clean out any debris.



The chain and gears need lubricated every three months.

(See Fig. 4-2)

Pre-Stretch Film Carriage

Fig. 4-3



Lubricate the drive chain of the carriage on a monthly basis.

Fig. 4-3

(See Fi g. 4-3)

- 32 -

5.3 Turntable Home Switch

Fig. 4-4

 Remove all 24 idler wheels supporting the turntable rotation if there is excessive bearing play. If

the diameter is less than 53mm or there is abnormal noise during operation, replace the bad
contact rollers.

(See Fig. 4-4)

Name Part Number

1 Shrink Ring FG-03A-20

2 Core Holder Washer FG-03A-21

3 Core Holder FG-03A-19

4 Roll Holder FG-03A-18

5 Film Tension Switch FG-03-11

6 Idler Wheel FG-01A-20

7 Chain 12A

- 33 -

5.4 Turntable & Carriage Adjustment

Test Operation

Turntable

 Turn on the power
 From the Main Menu, press;

o ② Job Mode
o ② Manual Mode
o ① Turntable (starts turntable rotation)
o ① Turntable (stops turntable rotation)

 Verify there is no play in the turntable and that the fasteners are tight.
 The chain tension controls the amount of play in the turntable. The chain should have no more

than ±0.25" of play.

o If greater than ±0.25" of play, tighten the chain using the chain adjustment screw located at

the back of the frame.

Fig. 5-1

Table Chain Adjustment

 Loosen the four holding screws of the turntable motor using a 6mm Allen Wrench.
 Turn the chain tension screw using an 8mm Allen Wrench.

o Clockwise adjustment will tighten the chain and counter-clockwise will loosen the chain.

 After adjusting to an appropriate position, tighten the turntable motor holding screws.

Carriage Chain Adjustment

 Press ② Up to raise the carriage
 Press ③ Down to lower the carriage
 Look and listen for smooth and consistent operation. If the action is not smooth, check the

carriage chain for obstructions, wear, or damage.

- 34 -

6.1 Illustration

Base

- 35 -

6.1 Illustration

r

y

Base (continued)

1 Turntable FG-01A-19 1

2 Idler Gear FG-01A-18 2

3 Block Limit Switch FG-12A-16 1

4 Ramp Bolt 1

5 Idler Wheel FG-01A-20 24

6 Turntable Gear FG-01A-13 1

7 Limit Switch N1CA2 1

8 Chain 12A 1

9 Base Frame n/a 1

10 Tension Screw 91292A217 1

11 Motor Gear FG-01A-31 1

12 Motor Mount Plate FG-01A-28 1

Name Part Numbe

Qt

13 Main Motor CV750-30S 1

14 Cover FG-01A-27 1

15 Motor Fan Cover 1

16 Fan Motor Cover 1

17 Mast Pin 1

- 36 -

6.2 Illustration

y

Idler Wheel

Name Part Number Qt

1 Idler Wheel Bracket n/a 12

2 Idler Wheel Axle FG-01A-24 12

3 Idler Outer Bushing FG-01A-23 24

4 Idler Bearing 60202 24

5 Idler Wheel FG-01A-21 24

6 Idler Wheel Snap Ring 98455A137 24

7 Washer 98454A136 12

- 37 -

6.3 Illustration

Mast

- 38 -

6.3 Illustration

y

Mast (continued)

Name Part Number Qt

1 Mast (Post) n/a 1

2 Mast Cover FG-12-02 1

3 Upper & Lower Limit Switch XCKP2145 2

4 Up-Down Motor NMRV040/80-YS6344 1

5 Motor Axis FG-12-06 1

6 Chain 08B 2

7 Slide Rail FG-AL-01 1

8 Up-Down Shelf FG-12-04 1

9 Transition Shelf FG-12-05 1

10 Slide Blocks FG-12-08 4

11 Sprocket FG-12-07 4

12 Sprocket Bracket FG-12-06 1

- 39 -

6.4 Illustration

Carriage

- 40 -

6.4 Illustration

y

Carriage – Continued from previous page.

Name Part Number Qt

1 Motor Cover FG-08T-20 1
2 Gear Box NMRV40-10-YS6344 1
3 Carriage Top Plate FG-08T-02 1
4 Film Lifter FG-08T-00 1
5 Roll Holder FG-03A-18 1
6 Core Holder Shaft FG-03A-16 1
7 Core Holder Washer FG-03A-21 1
8 Core Holder FG-03A-19 1

9 Protection Plate/ Bottom Plate FG-08T-16 1
10 Micro Switch 7779K22 2
11 Roller Bearing 5972K168 1
12 Large Carriage Gear FG-03-14 1
13 Carriage Prestretch Chain 06B 1
14 Small Carriage Gear FG-03-12 1
15 Film Roller Assembly FG-08-07 1
16 Roller Door FG-08-14 1
17 Extended Roller Assembly FG-08-08 1
18 Right Connection Block FG-08-20 1
19 Left Connection Block FG-08-20 1
20 Film Tension Switch FG-03-11 1
21 Main Roller FG-03-02 1
22 Pin Release Bar Assembly FG-08-17 1
23 Film Roller FG-03-03 1
24 Carriage Door Bracket FG-08-04 1
25 Photo Eye Switch A3R-2MX 1
26 Photo Eye Bracket FG-08-21 1
27 Spring Bolt FG-08-18 2
28 Spring FG-08-17 2
29 Shrink Ring FG-03A-20 1
30 Rivet Bolt M10 1

- 41 -

6.5 Illustration

y

Film Roller

Name Part Number Qt

1 E-Clip 4-MM-EC-2 2

2 Outer Tube Roll n/a 1

3 Roller Bearing FG-BR-02 2

4 Inner Shaft n/a 1

5 Roller Assembly FG-08-07 1

- 42 -

6.6 Illustration

y

Extended Roller

Name Part Number Qt

1 E-Clip 4-MM-EC-2 2

2 Outer Tube Roll n/a 1

3 Roller Bearing FG-BR-02 2

4 Inner Shaft n/a 1

5 Roller Assembly FG-08-07 1

- 43 -

6.6 Motor Controls

- 44 -

6.6 PLC Wiring

- 45 -

6.6 Optional Scale

- 46 -

6.6 Switches & Relays

- 47 -