QX011598 Manual

N
Q-300XT/Q-400XT
Semi Automatic Stretch Wrapper
Machine Manual
Serial Number: QX011598
1
Table of Contents
1.0 Introduction ........................................................................................................................ 5

1.1 Support ............................................................................................................................. 6
2.0 Specifications ...................................................................................................................... 7
2.1 Machine Specifications .................................................................................................... 8
3.0 Options .............................................................................................................................. 11
3.1 Click-n-Go Remote ..................................................................................................... 11
4.0 Safety ................................................................................................................................. 19
4.1 Pictograms ...................................................................................................................... 21
5.0 Installation Instructions ................................................................................................. 23
5.1 Prepare the Area ............................................................................................................. 23
5.2 Personnel, Equipment and Tools.................................................................................... 24
5.3 Installation ...................................................................................................................... 25
6.0 Operator Instructions ..................................................................................................... 29
6.1 Sequence of Operation ................................................................................................... 30
6.2 Components.................................................................................................................... 31
6.3 Assemblies ..................................................................................................................... 33
6.3.1 FDS and Counterweight .......................................................................................... 33
6.3.2 FDS Lift Drive ........................................................................................................ 33
6.3.3 EZ Thread Gate ....................................................................................................... 34
6.3.4 Pallet Grip ............................................................................................................ 35
6.4 Controls .......................................................................................................................... 37
6.4.1 Mode and Fault Indicators ...................................................................................... 39
6.4.2 Presets ..................................................................................................................... 41
6.4.3 Configurations......................................................................................................... 45
6.5 Initialize the Machine ..................................................................................................... 48
6.5.1 How to Stop the Machine ....................................................................................... 48
6.5.2 How to Start the Machine ....................................................................................... 48
6.6 Thread the Film .............................................................................................................. 49
6.7 Operate the Machine ...................................................................................................... 51
6.8 Film Roll is Empty, Film Break Recovery..................................................................... 51
7.0 Maintenance ..................................................................................................................... 53
7.1 Daily and Weekly Maintenance ..................................................................................... 53
2
Table of Contents
7.1.1 XT Cut and Clamp ............................................................................................... 54
7.1.2 Pallet Grip ............................................................................................................ 55
7.2 Monthly Maintenance .................................................................................................... 55
7.3 Settings and Adjustments ............................................................................................... 56
7.3.1 FDS Up, Down Travel Proximity Sensor ............................................................... 56
7.3.2 Belt Slack Switch ................................................................................................ 58
7.3.3 Turntable Home Proximity Sensor ......................................................................... 59
7.3.4 Turntable Drive Belt ............................................................................................... 61
7.3.5 Lantech Intelli-sensor .......................................................................................... 62
7.3.6 Load Cell ................................................................................................................. 63
7.4 Motor Control Boards .................................................................................................... 65
7.4.1 FDS Lift Motor ....................................................................................................... 65
7.4.2 Turntable ................................................................................................................. 66
7.4.3 Power Roller Stretch Plus ....................................................................................... 67
7.5 Potentiometer Settings.................................................................................................... 68
7.5.1 Film Delivery System ............................................................................................. 68
7.5.2 Turntable ................................................................................................................. 69
7.6 Film Delivery System..................................................................................................... 71
7.6.1 Power Roller Stretch Plus ....................................................................................... 71
7.7 Standard Parts Replacement ........................................................................................... 74
7.7.1 FDS Lift Belt........................................................................................................... 74
7.7.2 FDS Lift Drive ........................................................................................................ 76
7.7.3 Turntable Drive Belt ............................................................................................... 77
7.7.4 Turntable Drive ....................................................................................................... 78
7.8 Pallet Grip ................................................................................................................... 79
7.8.1 Pivoting Roller ........................................................................................................ 79
7.8.2 Groove Roller.......................................................................................................... 80
7.9 XT Cut and Clamp ...................................................................................................... 81
7.9.1 Turntable Clamp Actuator Proximity Sensor ................................................................. 81
7.9.2 XT Actuator Tab ..................................................................................................... 83
8.0 Troubleshooting ............................................................................................................... 85
8.1 General Data ................................................................................................................... 85
8.2 Film Delivery System..................................................................................................... 86
3
Table of Contents
8.3 Turntable ........................................................................................................................ 89
8.4 Pallet Grip ................................................................................................................... 91
8.5 XT Cut and Clamp ...................................................................................................... 92
9.0 Appendix ........................................................................................................................... 95
9.1 Glossary.......................................................................................................................... 95
9.2 Warranty ......................................................................................................................... 97
10.0 Parts Lists and Drawings ................................................................................................ 99
4
INTRODUCTION
1.0 Introduction
This manual tells the operator and maintenance personnel how to safely install and operate the
machine. The function of the manual is to make sure that the operator and maintenance personnel
have complete instructions.
1. Introduction
2. Specifications
3. Options
4. Safety
5. Installation
6. Operator Instructions
7. Maintenance
8. Troubleshooting
9. Appendix
10. Parts List and Drawings
The Specifications and Options sections contain data about your machine and special options.
This is important as you install and operate the machine.
The Safety section points out the Warnings and Cautions to make sure that all personnel work in
a safe environment.
The Installation and Operator Instructions sections tell you how to install and use the machine
safely and efficiently.
The Maintenance and the Troubleshooting sections tell you how to make sure that the machine
stays at top performance.
The Appendix section can include the CE Declaration of Conformity, Glossary and Warranty
procedures.
The Parts List and Drawings section includes the BOMs.
This manual helps you operate your machine safely and efficiently. The value is to increase your
productivity and decrease the packaging costs.
5
INTRODUCTION
1.1 Support
For support, use the phone and email data below:
LANTECH AFRICA & EUROPE CUIJK NETHERLANDS

Phone Email Fax
Parts
+31 (0) 485 751 771 europarts@lantech.com
+31 (0) 485 330 755
Service
+31 (0) 485 751 770 euroservice@lantech.com
LANTECH ASIA PACIFIC MELBOURNE AUSTRALIA

Phone Email Fax
+61 3 9796 5275 aus.support@lantech.com +61 3 9703 2725
LANTECH CHINA - SHANGHAI

Phone Email Fax
+86 21 6427 1962
LCH.Parts@Lantech.com
+86 21 6468 6478
Service Hotline
LCH.Service@Lantech.com
+86 400 877 1972
LANTECH NORTH & SOUTH AMERICA LOUISVILLE KENTUCKY

Phone Email Fax
Parts Parts
502-815-9101 tsg@lantech.com
Service Service 502-267-8864
502-815-9103 tsc@lantech.com
Retrofits Retrofits
502-815-9104 retrofits@lantech.com
6
SPECIFICATIONS
2.0 Specifications
All Lantech machines have a serial number tag in 1 of these locations:
On the door of the enclosure
In the electrical enclosure
Figure 2-1
Figure 2-2
The serial number can also be in other areas of the machine.
Note:
The exposed metal parts on all Stretch Wrap Machines have a heavy Rust Preventative applied before
shipment.
You can use Mineral Spirits or a similar cleaner to remove it.
If you remove it, make sure that you apply a light Rust Preventative to the exposed metal before you
operate the machine.
This does not apply to Case Machines.
7
SPECIFICATIONS
2.1 Machine Specifications
General Q300XT Q400XT
2032 mm (80) Wrap Height
Dimensions 3023 mm L x 1702 mm W x 2337 mm H
Standard Height (119" L x 67" W x 92" H) X X
680 kg (1500 lb) X
Weight with Pallet 694 kg (1530 lb) X
Performance
Speed* Loads/Hour 30-40 30-40
762 mm x 762 mm x 508 mm
Minimum Load Dimensions
(30 W x 30 L x 20 H) X X
Maximum Load Dimensions - Standard Height
1321 mm x 1321 mm x 2032 mm
Note: Maximum wrap height increases 254
mm (10) for 762 mm (30) FDS option (52 W x 52 L x 80 H) X X
Maximum Load Dimensions - Extended Height
1321 mm x 1321 mm x 2794 mm
52 W x 52 L x 110 H X X
Load Dimensions - Diagonal 1753 mm (69") Recommended X X
1800 kg (4000 lbs) X

Maximum Load Weight
2268 kg (5000 lbs) X
*Note: Changes to the load dimensions, wrap pattern and the steps to load, unload the turntable can change the
throughput.
8
SPECIFICATIONS
Q300XT Q400XT
Turntable
Turntable Dimensions 1651 mm (65) Diameter X X
Turntable Speed 12 rpm X X
Turntable Height 70 mm (2 ) X X
Turntable Bearing Support 1219 mm (48) Diameter X X
HP (.56 kW) 90 VDC 1750 RPM
TEFC
Motor - 40:1 Speed Reducer X
1 HP (.75 kW) 90 VDC 1750 RPM
Turntable Drive TEFC Motor - 30:1 Speed Reducer X
Film Delivery System (FDS)
Gearmotor 1/5 HP (.15 kW) 90 VDC
FDS Lift Drive 2250 RPM 45:1 50 RPM Output TENV X X
Power Roller Stretch Plus with EZ
Thread X
Power Roller Stretch Plus with EZ
Thread and Pallet Grip X
HP (.37 kW) 90 VDC 1750 RPM
FDS Drive TENV Motor X X
Standard Film Pre-Stretch 200% 250%
All Commercial Grade Films 50-150
Film Gauge X X
254 mm (10) Diameter
508 mm (20) Width (Standard)
Standard Film Capacity 762 mm (30) Width (Optional) X X
Electronically controlled with Reduced
Wrap Force Wrap Force at the start of the wrap cycle X X
Pallet Grip Option X
Electrical Requirements
Electrical Supply Dedicated, Grounded Electrical Supply X X
Power - US 120 Volts, 20 Amps X X
Power - EU 220 Volts, 16 Amps X X
Controls Microcontroller X
Microcontroller in NEMA 12 Enclosure X
Warranty 5 Years X X
9
SPECIFICATIONS
10
OPTIONS
3.0 Options
This section includes the options that are not on the standard machine.
3.1 Click-n-Go Remote

The Click-n-Go is a wireless remote that starts the wrap cycle.
The option includes:

A receiver that attaches to the machine
A remote transmitter with holder and safety cord
Figure 3.1 - Machine Mounted Receiver Figure 3.2 - Remote
1 Sensor 3 Channel Buttons (Blue)

2 Beacon Flashes when the Receiver is Armed Start (Green)
3 Beeper Alarm Sounds when the Receiver is Armed Stop (Red)
4 Quick Connect Cable Low Battery Indicator (LED)
5 Enclosure Transmitter Holder with Safety Cord
11
OPTIONS
General
Infrared Device
Line of Sight Operation
Immune to Interference
The Range of Operation is 9 m (30)
There are 2 steps to start the wrap sequence. This makes sure that the machine does not start
accidentally.
The Start button overrides the remote transmitter.
Remote Transmitter
3 channel selections
Start Button
Stop Button This is not an Emergency Stop.
Low Battery Indicator
9-Volt Alkaline Battery
Remote holder
All remote transmitters can stop
a machine with the remote
option.
Only the transmitter that arms
the receiver can control the start
of the machine. The special
code for each transmitter makes
sure that the remote does not
start the incorrect machine.
2 aiming features Figure 3.3 - Remote Aiming Features
Receiver
The beeper and visual alarms when the remote start is Armed. The volume control is
adjustable (Rotating shutter on the beeper).
3 channel selections (Dip Switch settings Default is Channel 1).
The receiver includes a label with the correct channel number for the correct machine, to
help the operator.
Adjustable Arming time (Dip switch settings Default is 8 seconds.
The remote stops the machine if the operator uses the remote or the lanyard (if applicable) to
start the machine.
12
OPTIONS
Installation
1. Attach the receiver to the top of the mast on the turntable side.
2. Make sure that the receiver sensor points to the turntable.
3. Put the cable through the hole in the mast and install the quick
connect into the receiver
4. Attach the number labels on the receiver to show the channel
settings.
Note: You can use the remote for multiple machines.
The channels must be different if the machines are less than 9 m
(30) of each other.
Refer to the channel settings.
5. Install the battery in the transmitter and replace the cover. Make
sure that the tab pushes forward and the cover is tight.
6. Attach the transmitter holder to the loading device (i.e. forklift).
Clean the surface and attach with the adhesive; or Figure 3.4 - Receiver Mount
Drill the holes and attach with screws
Install the Receiver Locking Tab Safety Cord
Figure 3.5
13
OPTIONS
Line Of Sight Operation
18'
Make sure that the receiver sensor is in the (5.5m)
line of sight and in the range of the 19' (5.8m)
transmitter.
Note: The conditions in the list below can

change the range of the remote:
23'

(7m)
Part tolerances
Condition of the lens on the 32'
transmitter and receiver (9.8m)
Sequence of Operation
This sequence of operation refers to the
remote start sequence only. Refer to section
6 for the Sequence of Operation for the
machine. Figure 3.6 - Line Of Sight Area
1. The operator puts a load on the turntable.

2. Remove the forklift, pallet jack from the load to prevent a blockage
when you start the wrap cycle.
3. The operator points the remote transmitter at the receiver sensor and
pushes the channel button to arm the receiver.
4. The beacon illuminates and the alarm sounds. The receiver unit is
Armed.
5. The operator points the remote transmitter at the receiver sensor and
pushes and releases the Start button.
6. The wrap cycle starts.
Functions
Channel (Blue 1-2-3) Use these buttons to make the selection of the
channel for the correct machine (Arm receiver unit).
Start (Green) Use this button to start the wrap sequence. Figure 3.7 - Remote
Stop (Red) Use this button to stop the wrap sequence.
To start the machine after a Stop, Arm the receiver and push the start button.
The Manual functions are off. To turn these functions on, push the E-stop, then reset
it.
14
OPTIONS
Receiver Settings
The remote start receiver includes the switch settings for the Channels and Arm times. The
receiver is in the enclosure.
Figure 3.8
1 Channel Settings
2 Arm Time Settings
Channel Settings
The Channel setting on the receiver includes 4 switches. Use these switches to engage 1 of the 3
channels. The default setting is for Channel 1.
Receiver Channel Settings

Switch 1 Switch 2 Switch 3 Switch 4
Channel 1 Off Off Off Off
Channel 2 On Off Off Off
Channel 3 Off On Off Off
Note: You can use the remote for multiple machines. The channels must be different if the
machines are less than 9 m (30) of each other. Refer to the channel settings.
15
OPTIONS
Arm Time Settings
The Arm time setting on the receiver includes 7 switches.
Use these to set the time that the receiver engages to start the machine from the remote
transmitter.
If the time setting releases, you must arm the receiver to start the machine.
If the beacon illuminates and the alarm sounds, the receiver unit is Armed. The default time to
arm the receiver is 8 seconds.
Receiver Arm Time Settings

Seconds Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6 Switch 7
1 Off Off Off Off Off Off Off
2 Off Off Off Off Off Off On
3 Off Off Off Off Off On Off
4 Off Off Off Off Off On On
5 Off Off Off Off On Off Off
6 Off Off Off Off On Off On
7 Off Off Off Off On On Off
8 Off Off Off Off On On On
9 Off Off Off On Off Off Off
10 Off Off Off On Off Off On
11 Off Off Off On Off On Off
12 Off Off Off On Off On On
13 Off Off Off On On Off Off
14 Off Off Off On On Off On
15 Off Off Off On On On Off
16
OPTIONS
Troubleshooting
Problem Possible Cause Solution
Use the remote to Arm and start
the machine.
The manual functions are The remote transmitter stopped the Push the Start button on the
1
not available. machine. control console.
Push then Reset the E-stop to
engage the Manual Functions.
Examine the power cord and make
sure that it connects into the correct
receptacle.
No power at machine. Reset the Emergency Stop.
Examine, replace the main fuses.
Examine the power receptacle for
power.
Make sure that the cable for the
The cable connection to the receiver
quick connect attaches at the
is not correct.
receiver.
Examine the power source and
The transmitter does not No power at receiver unit. make sure that it applies the power
Arm the receiver. to the receiver.
2 (The beacon does not The transmitter is out of range or

Adjust the sensor.
illuminate and the beeper does not point at the receiver sensor.
does not sound)
Look at the channel selection. Push
The channel on the transmitter is
and release the correct channel
incorrect.
button.
The channel setting on the receiver is Compare the channel settings to the
incorrect. label (1-2-3).
There are blown fuses on the
Examine, replace the fuses.
receiver.
The low battery indicator illuminates. Replace the battery.
There is debris on the transmitter
Clean the lens.
lens.
There is debris on the receiver sensor
Clean the cover.
cover.
There is blockage in the line of sight Remove the blockage, adjust the
of the receiver sensor. direction of the sensor.
17
OPTIONS

Point the transmitter at the receiver
The receiver is not Armed.
sensor and push the channel button.
The time for the receiver to Arm Adjust the Arm time on the
releases before it gets the start signal. receiver.
Move the transmitter into the correct
The transmitter is out of range or does
range of the sensor and adjust the
not point to the receiver sensor.
direction.
The transmitter does Receiver Armed by a different The transmitter that Arms the
3 receiver is the only transmitter that
not start the machine. transmitter.
can start the machine.
Examine the intrusion circuit. Refer
No intrusion input to microcontroller.
to electrical drawings.
The fuse for the Start function in the
Examine, replace the fuse.
receiver is bad.
The fuse for the Stop function in the
Examine, replace the fuse
receiver is bad.
Move the transmitter into the correct
The transmitter is not in range or does
The transmitter does range of the sensor and adjust the
4 not point to the receiver sensor.
not stop the machine. direction.
Incorrect logic in microcontroller. Install the correct logic.
The transmitter lens is dirty. Clean the lens.
The transmitter range is
5 The receiver sensor cover is dirty. Clean the cover.
less than 9 m (30).
The transmitter does not point to the Adjust and make sure that the
receiver sensor correctly. transmitter points to the sensor.
6 The beacon does not
illuminate when the The bulb is defective. Replace the bulb.
receiver is Armed
but the beeper sounds.
7 The beacon illuminates
when the receiver is
Armed but the The beeper does not operate correctly. Replace the beeper.
beeper does not
engage.
18
SAFETY
4.0 Safety
This manual tells the operator and maintenance personnel how to safely install and operate the
machine. The section includes:
General safety
Personnel safety
Safety & Environmental Controls
Warnings, Cautions and Notes
General Safety
Read the manual to install, operate, and repair the machine safely.
Obey all safety decals.
Obey all warnings to prevent an injury to personnel.
Obey all cautions to prevent damage to the machine.
Obey all Lockout/Tagout procedures before you change, adjust, repair a part.
Refer to the adjustment data to prevent a safety hazard.
Personnel Safety
To prevent an injury and safety risk, do not install, operate, repair the machine while
influenced by drugs, alcohol, medication.
A part that moves can catch loose clothing, long hair, jewelry and cause injury to
personnel.
Data on Personal Protective Equipment (PPE) is in the Installation section of this manual.
Refer to the Installation section for personnel and tools to safely install the machine.
19
SAFETY
Safety & Environmental Controls
Make sure that you recycle all waste.
Release all chemical waste to a certified Waste Processing Company only.
To decommission the machine, the owner of the machine and all auxiliary equipment,
must:
Obey applicable environmental regulations and discard electrical components safely.
Obey all applicable environmental, plant, and industrial safety regulations.
This applies to local, regional, and federal controls, and includes all OSHA and CE
regulations.
Lockout/Tagout
Obey these procedures to prevent an injury from unexpected energizing, start-up, release of
stored energy.
This applies to local, regional, and federal controls, and includes the current controls for:
Australia OSHA Prevention of Unexpected Startup
Europe CE Machinery Directive Isolation of Energy Sources
USA OSHA Control of Hazardous Energy
Warnings, Cautions, and Notes

Warning Tells the operator that there is a hazard that can cause a serious injury.
Caution Tells the operator that there is a hazard that can cause a minor injury or damage to the
equipment, environment.
Note Gives additional data that is helpful to the operator.
20
SAFETY
4.1 Pictograms
The pictograms tell personnel of possible dangerous areas around the machine. Obey all
pictograms and safety decals.
Some of the pictograms in the list below do not apply to your machine.
Do Not Operate Without

No Entry
Guard in Position
Maximum Capacity Do Not Step
Do Not Reach Fire Can Occur
Electrical Warning
Hot Surface
Explosion Warning
Release of Pressure Electrical Shock Warning
Do Not Walk on Conveyor
Pull In Warning
Hit is Possible From Above
21
SAFETY
Fall Warning Hit is Possible From The Side
Film Delivery System Warning
Cut Warning Crush Warning
Do Not Reach
Obey the Safety Instructions
Machine Can Fall
Chemical Waste Environment
Important Note Refer To Manual
22
INSTALLATION
5.0 Installation Instructions

Read the Installation section and do the steps in sequence.
Note: Illustrations are for reference only.
Note: Functions, descriptions and data can be different on your machine. Refer to Section 3
Options.
CAUTION
Obey the torque specifications to prevent damage to the fasteners. Too much
torque can cause the fasteners to loosen.
Note:
The exposed metal parts on all Stretch Wrap Machines have a heavy Rust Preventative applied before
shipment. You can use Mineral Spirits or a similar cleaner to remove it.
If you remove it, make sure that you apply a light Rust Preventative to the exposed metal before you
operate the machine.
This does not apply to Case Machines.
5.1 Prepare the Area

The space requirements can be different on each machine. Refer to your machine dimensions
when you prepare for the installation.
Location:
Make sure that the mast has a clearance of a minimum of 762 mm (30) to the nearest
blockage.
A flat and level floor no more than 6 mm ().
Make sure that the floor can hold the weight of:
The machine
The maximum load weight
Forklift
Pallet Jack
Other equipment in the area
Personnel
23
INSTALLATION
5.2 Personnel, Equipment and Tools
Standard Height
Personnel
1 Forklift Operator
1 Electrical/Mechanical Technician
Equipment
1 Forklift
1 Ladder
Tools
Wrenches And Sockets (Metric and Standard)
Extended Height
(Mast Shipped In Horizontal Position)
Personnel
2 Forklift Operators
1 Mechanical Technician
1 Electrical Technician
Equipment
2 Forklifts
1 Ladder
Tools
Wrenches and Sockets (Metric and Standard)
Allen wrenches (Metric and Standard)
Torque Wrench
Straps, Chains
24
INSTALLATION
5.3 Installation
Standard Height Mast
The Mast is in the up position
Step 1
Remove the protective materials.
Step 2
Remove the bolts, brackets and boards that
hold the machine and the components to the
skid.
Step 3
Put the forks of the forklift into the loops in
the aft of the machine. Figure 5.1
Step 4
Slowly lift the machine and set it in position.
CAUTION
Do not lift a machine with an extended length base or larger turntable with the
fork loops.
Larger Turntables and Extended Bases:

Put the forks below the base frame.
Lift slowly to make sure that the machine is
balanced.
Figure 5.2
25
INSTALLATION
Step 5
Remove the FDS shipping bracket from the mast (Figure
5-3).
1. Remove the M10 nut that holds the bracket to the
base.
2. Remove the M8 bolt and nut that hold the bracket to
the FDS.
Step 6
The counterweight is in the access panel on the mast.
There are 2 brackets that hold the counterweight in
position (Figure 5-4).
1. Remove the (2) M10 bolts.
2. Remove the brackets.
Step 7
Stow the shipping brackets and the counterweight Figure 5.3
brackets in the mast.
CAUTION
Before you move the machine to a different location, install the shipping and
counterweight brackets.
Figure 5.4
Step 8
Connect the power cord to the dedicated, grounded electrical supply.
Note: The machine has a 3.6 m (12) power cord with a 20-amp plug. Use a 20-amp receptacle.
Do not use an extension cord.
26
INSTALLATION
Step 9
There is a lanyard that adds the option for a remote start. The lanyard includes a ring on the arm
of the switch.
1. Connect the lanyard cord (cord not included) to the ring.
2. Use the pulleys to thread the cord on the ceiling.
3. Make sure that the forklift is clear of the load to operate the lanyard.
Figure 5.5
27
INSTALLATION
28
OPERATOR INSTRUCTIONS
6.0 Operator Instructions
Note: Functions, descriptions and data can be different on your machine. Refer to Section 3,
Options.
Note: It is important to know all components. This includes how to thread the film and operate
the controls.
Note: Some machines have a remote Emergency Stop. It is important to know the location of
all E-stops before you operate the machine.
WARNING
WARNING
Obey all safety decal instructions and warnings.
WARNING
Do not make a change to this machine without approval from Lantech. It can
cause a safety hazard and cancel the warranty.
CAUTION
Do not use a sharp object that can cause damage to the roller to remove the film
that is wound onto the pre-stretch roller.
CAUTION
Do not let a heavy load stay on the turntable for extended periods of time. This
can cause damage to the turntable.
29
6.1 Sequence of Operation
The sequence of operation starts with a load on the turntable.
1. Push the Film Assist button.
2. Pull the film and attach it to the load.
3. Push the Start button.
4. The turntable turns and the FDS moves up. The speed of the FDS is set on the control
console.
5. The film pre-stretches and is applied to the load.
6. The load height sensor senses the top of the load and the FDS stops to apply the top wrap.
Q300XT
7. On the first full revolution of the turntable during the top wraps:
a. The turntable speed decreases to the Home speed.
b. The XT Cut and Clamp engages to release the beginning film tail.
c. The turntable speed increases.
8. The FDS completes the top wraps.
9. The FDS lowers to the bottom of the load and stops to apply the bottom wrap.
10. The turntable speed decreases to the Home speed.
11. The XT unit clamps and cuts the film.
12. The XT retracts as the turntable moves to the home position.
13. The operator removes the load from the turntable.
Q400XT
7. The FDS lowers to wrap the bottom of the load.
8. Pallet Grip engages and makes a cable of film on the bottom edge of the film.
9. The pivoting roller engages and attaches the film cable to the pallet.
10. On the last revolution of the bottom wraps, the XT unit engages to clamp and cut the film.
11. At the end of the wrap cycle, the FDS raises and disengages the Pallet Grip.
30
6.2 Components
Q300XT and Q400XT
6
3
7 2
4
Figure 6.1
1 Mast
2 Film Delivery System (FDS)
3 Turntable
4 XT Cut and Clamp
5 XT Actuator
6 Controls
7 Roper
31
Turntable
2 3
4
5
Figure 6.2
1 Turntable Top
2 Urethane Ring
3 Drive Ring with Home Proximity Actuator
Bearing Support Ring with Home Position Proximity
4
sensors
5 Center Bearing
6 Turntable Drive Motor and Belt Tensioner Area (Motor

Not Shown)
32
6.3 Assemblies
6.3.1 FDS and Counterweight
The FDS pre-stretches and applies the

film.
The belt connects the counterweight
and the FDS. The counterweight
balances the weight of the FDS.
6.3.2 FDS Lift Drive

The drive raises and lowers the FDS
during the wrap cycle.
FDS Up, Down Proximity sensors
The mast includes 2 proximity sensors
that sense the maximum travel of the
FDS.
These sensors are adjustable. Use
them to set the maximum up and down
travel limits of the FDS.
FDS Belt Slack Switch

This switch senses a loose belt
condition.
A loose belt stops the FDS down
travel.
Figure 6.3
1 FDS Lift Drive
2 Turntable Drive (Base)
FDS Up Travel proximity sensor (Down Travel
3
sensor not shown)
4 FDS Belt Slack switch
33
6.3.3 EZ Thread Gate
The gate opens to 2 positions.
1. To thread the film:

Release the latch to open the gate to thread
the film.
2. Access to the rollers and gate:

Lift the lever on the bottom right side of the
gate for the access position (Figure 6.4 and
6.5).
Figure 6.4
Figure 6.5
34
6.3.4 Pallet Grip
Standard on Q400 XT
Option on Q300XT
The Pallet Grip locks the load to the pallet.

It includes an angled roller, a groove roller and
pivoting roller.
As the FDS lowers, the Pallet Grip engages and
makes a cable of film. This cable attaches below
the top boards of the pallet to lock the load to the
pallet.
Angled Roller moves the film down and helps

to align the edge of the film on the groove roller.
The roller attaches to the gate.
Groove Roller is adjustable to increase,

decrease the quantity of film that makes the
cable. The roller attaches to the gate.
Figure 6.6
Pivoting Roller is actuated by the machine
base. The roller moves the film cable down on the pallet. The actuator is adjustable to increase,
decrease the angle of the roller.
Pallet Grip Film Tail Reduction

To decrease the dimensions of the
beginning film tail (Film Tail
Reduction), set the P.4. Preset timer to
3.0 seconds.
Figure 6.7
35
Film Tail Elimination
Use the Configuration Setup to engage this option (Configuration Bit C-17).
Film Tail Elimination Sequence
1. The wrap cycle starts and the FDS is at the bottom of the load.
2. The Pallet Grip engages.
3. The FDS moves to the top of the load to apply the top wraps.
4. The turntable speed decreases and the XT Cut and Clamp engages to release the beginning
of the film tail.
5. The FDS applies the top wraps and moves to the bottom of the load to apply the bottom
wraps.
6. The film cable assembly engages to make a cable of film on the bottom edge of the film.
7. The pivoting roller engages to apply the film cable to the pallet.
8. As the FDS applies the bottom wraps, the beginning of the film tail wraps before the film
clamp and cut sequence.
Figure 6.8
36
6.4 Controls
The Controls are on the side of the mast.
The Emergency Stop (E-stop)
Power On button (illuminates)
Mode and Fault Indicators (LEDs)
Potentiometers for Turntable rotation, FDS speed control
and Wrap Force
Touch pad
Figure 6.9
37
2 6
3 1 7
4 8
5 9
10 11
12
13
14 15
16 23 30
17 24 31
18 25 32
19 26 33
20 27 34
21 28 35
22 29 36
37
38
Figure 6.10
38
6.4.1 Mode and Fault Indicators
1 Power On The illuminated green button applies the control power to the machine.
2 Cycle Pause The wrap cycle is paused.
3 Not Used
4 Turntable 2 (Option) The second turntable is On (dual turntable option).
5 Power On The Control Power is On.
6 Band Mode The Band mode is On.
7 Film Break There is a film break.
8 One-Way Wrap The option for One-Way Wrap is On.
9 Top Sheet Cycle (Option) The Top Sheet Cycle is On.
The indicator shows the number of wraps to be applied to the top of the
10 Top Wrap Count
load. Wrap counts increment from 1 9.
The indicator shows the number of wraps to be applied to the bottom
Bottom Wrap Count of the load. Wrap counts increment from 1 9.
11
The indicator shows how much wrap force is applied to the load. It
12 Wrap Force Display
shows the lbs. of force.
Potentiometers
13 Wrap Force The potentiometer sets the wrap force applied to the load.
The potentiometer increases, decreases the speed of the turntable. The
14 Turntable Speed
maximum speed is 12 rpm.
The potentiometer increases, decreases the up and down travel speed
15 FDS Speed
of the FDS
Touch Pad Controls - Do not use a pointed object on the touch pads. Use only your finger.
16 Jog (Turntable) This turns the turntable.
This automatically sets the turntable and the FDS to the home position.
17 Home The turntable turns at low speed and stops at the home position. The
FDS lowers to the home position.
18 Not Used
19 Turntable 2 (Option) This controls the second turntable on a dual turntable system.
20 Not Used
21 Not Used
22 Not Used
23 Platen Up (Option) This control lifts the top platen arm.
24 Platen Down (Option) This control lowers the top platen arm.
25 One-Way Wrap (Option) The One-Way Wrap is On.
This control pauses the wrap cycle. Push it a second time to continue
26 Cycle Pause
the wrap cycle.
39
This control releases the film from the FDS. The film releases for
27 Film Assist
approximately 5 seconds.
28 Not Used
The Top Sheet Cycle is On.
29 Top Sheet Cycle (Option)
Push the control again to continue the wrap cycle.
This control moves the FDS in the up direction. It stops at the Up
30 FDS Up
Travel proximity sensor.
This control moves the FDS in the down direction. It stops at the
31 FDS Down
Down Travel proximity sensor.
32 Presets This control gives access to the microcontroller functions.
This control sets the number of film bands to the load and then
33 Band
continues the wrap cycle.
34 Not Used
35 Not Used
36 Not Used
37 Start This starts the wrap cycle.
A red spring-loaded button that stops the operation of the machine.
38 The Emergency Stop
To release, twist the E-stop.
40
6.4.2 Presets
Preset Mode
The Preset Mode gives access to
timers and counters.
Access to All Settings

A jumper on Option C gives
access to the Settings on the
Microcontroller (MC-1)
Push the Presets button to get

access to the Preset Mode.
The display panel shows the Preset
Mode: Jumper
Option
P. in the Top Wrap C
Count window
1 in the Bottom Wrap
Count window
Decimal value for the
Wrap Force (i.e. 1.5).
Note: In the Preset Mode no other

functions are available to the
operator.
Figure 6.11
41
Adjust the values of the Presets to tune the machine.
1. Push the Presets button for the Preset Mode.
2. Push the Bottom Wrap Count for the correct count.
Push the button to move through the presets.
To Change the Value:

Push FDS Up to increase the value.
Push FDS Down to decrease the value.
When the Presets are set:
Push the Presets button to hold the values and close the Preset Mode.
Preset Number
Appears Here
P 1
.
Preset Value
1.5 Appears Here
Figure 6.12
42
The Microcontroller holds the Settings.
To adjust:
1. Push the Presets button to get access to the Preset Mode.
2. Push and hold the Start button.
3. Continue to hold the Start button and push the Top Wrap Count button.
4. Release the Start button and the Top Wrap Count button.
After 2 seconds, the machine goes into the Manual Mode and the Factory Settings are set.
A decal in the access door includes the instructions to change the Presets. The decal includes the
Preset number, a description, the factory setting, and a space to record the values.
Preset Description Timer

The Load Height Sensor Delay Timer
This sets the length of time that the FDS travels after the load height sensor finds the top
P.1 1.5 seconds
of the load.
When it is clear, the FDS up travel stops and starts the timer. If the sensor sees the load
before the timer expires, the FDS goes up until the sensor is clear.
Reduced Wrap Force
This sets how long the load wraps with Reduced Wrap Force at the start of the wrap 3.0 seconds
P.2
cycle.
The pre-stretch is in the Reduced Force mode until this time delay is complete.
FDS Delay
This sets how long the FDS stays at the bottom of the load at the start of the wrap cycle. 3.0 seconds
P.3
This timer starts at the start of the wrap cycle. The FDS stays at the bottom of the load
until this time delay is complete.
Band Mode
P.4 4 counts
This sets the number of bands of film applied to the load during the wrap cycle. Each
turntable revolution is 1 band of film.
The Time Delay To Puncture the Film For Auto Film Cut-off
P.5 Not Used
This sets the time for the solenoid on the Auto Film Cut-off to break the film. The
timer starts when the speed of the turntable decreases at the end of the wrap cycle.
The Time Delay to Turn the PRS Drive off at the end of the cycle 0.1 seconds
P.6
The proximity sensor on the turntable controls when the Pre-Stretch stops.
The Time Delay to Puncture the Film for Auto Film Cut-off on Turntable 2
(Optional)
P.7
Not Used
This sets when the solenoid on the Auto Film Cut-off breaks the film. It starts when
the turntable speed decreases at the end of the wrap cycle.
43
Preset Description Timer

The Time Delay to Break the Film for Auto Film Cut-off on Turntable 2 (Option)
P.8
This sets when the pre-stretch stops at the end of the wrap cycle. It starts when the Not Used
solenoid on the Auto Film Cut-off breaks the film.
An Alternative Stop Position Turntable 1 (Option)
P.9 Not Used
This sets the distance that the turntable travels after the wrap cycle stops at an alternative
stop position.
An Alternative Stop Position Turntable 2 (Option)
P.0. Not Used
This sets the distance that the turntable travels after the wrap cycle stops at an alternative
stop position.
The FDS Descent Timer to apply a Top Sheet Turntable 1 (Option)
P.1.
This sets how long the FDS lowers before the wrap cycle stops and applies a top sheet. 2.0 seconds
The FDS Descent Timer to apply a Top Sheet Turntable 2 (Option)

P.2.
This sets how long the FDS lowers before the wrap cycle stops and applies a top sheet. Not Used
The Number Of Top Counts to apply a Top Sheet

P.3. 2 counts
This sets the number of top wraps to be applied after a top sheet is put on the load.
The Length of Time of FDS Lift At End Of Wrap Cycle
P.4. 0.2 seconds
This sets how long the FDS moves up at the end of the wrap cycle. This is an option.
FDS Delay Timer After a Film Break
P. 5. This sets how long the turntable turns before the FDS continues the wrap cycle after a 10 seconds
film break occurs.
This is applicable when the wrap cycle continues from the point of the film break.
Turntable Deceleration during Top Wraps for Film Tail Elimination
P.6.
This sets when the turntable speed decreases to minimum speed to release the film tail 8.0 seconds
from the clamp. This is for the Early Release option.
Top Platen Ascent Timer
P.7.
This sets how long the Top Platen continues at the end of the wrap cycle. This is Not used
applicable only with the Top Platen option.
Backup Timer on Reverse 90 XT Turntable
P.8.
This sets the time that the turntable turns in the opposite direction to an alternative stop 5.0 seconds
position.
The Number Of Multiple Wrap Cycles To Be Applied To the Load
P.9. Not used
This sets the number of wrap cycles. This preset is only available with the Multiple
Wraps option.
44
6.4.3 Configurations
The Configuration Mode gives access to the options in the microcontroller.
To get access to the Configuration Mode:

1. Push the E-stop.
2. Make sure that the power is off.
3. Open the door to the enclosure and find
the microcontroller.
4. Remove jumper E.
5. Reset the E-stop
6. Make sure that a C shows on the display in the Top Wrap Count indicator.
To change the configuration value:

1. Push the FDS Up button until a C shows on the Wrap Force indicator.
2. Push the Bottom Wrap Count button to change the value of the Configuration Bit.
To save the changes:

1. Install jumper E.
2. Make sure that the C does not show on the Top Wrap Count indicator.
45
Boards for the FDS Lift:
Configuration Data for the following program chips:

30080010, 30080011, 30080012, 30080013, 30080014
Setting
Configuration Bits 1, 2, and 3 tell the microcontroller what type of SCR-2 MCB is
C1 controlling the FDS
C2 If it is the KBMM board: Set C1 = 1, C2 = 0 and C3 = 0
C3 If SCR-2 is KBPB: Set C1 = 0, C2 = 1 and C3 = 0

If SCR-2 is KBMG: Set C1 = 1, C2 = 1, C3 = 0
If the SCR Drive for the Turntable Speed Control is KBMM 0
C4
If it is KBMG Regen 1
For Reduced Wrap Force at the end of the cycle 0
C5
For High Force 1
For adjustable Top and Bottom wrap counts 0
C6
For non-adjustable wrap counts 1
C7 Not used 0
To disengage the FDS manual functions during the wrap cycle 0
C8
To engage the manual functions during the wrap cycle 1
C9 Not used 0
Option Film Assist
0
C10 To disengage the Film Assist with the Auto Top Platen Down button
To engage the Film Assist with the Auto Top Platen Down button 1
Option Top Platen
To raise the Top Platen manually at the end of the wrap cycle 0
C11
To raise the Top Platen automatically at the end of the wrap cycle 1
46
Option Wrap Cycle

To start the wrap cycle without the Top Platen on the load 0
C12
To prevent the wrap cycle from starting without the Top Platen on the load 1
For the Standard Film Break Delay time of 3.5 seconds 0
C13
For the Extended Film Break Delay time of 8 seconds 1
C14 Not used 0
For normal operation 0
C15
For manufacture diagnostic mode (Lantech Use Only) 1
C16 Not used 0
To disengage the Film Tail Elimination function 0
C17
To engage the function 1
C18 Not used 0
C19 Not used 0
If the machine has a horizontal mount for the adjustable load height sensor 0
C20
If the mount is vertical 1
If the machine has a manufacture date after Sept. 1 2003 0
C21
If the manufacture date is before Sept. 1 2003 1
C22 Not used 0
C23 Not used 0
C24 Not used 0
47
6.5 Initialize the Machine
CAUTION
Before you initialize the machine, read How to Stop the Machine.
6.5.1 How to Stop the Machine

Push the Emergency Stop.
6.5.2 How to Start the Machine

1. Reset the E-stop.
2. Push the Power On button.
The Power On indicator and the Power On buttons illuminate and all functions are available
to the operator.
48
6.6 Thread the Film
WARNING
Make sure that the film roll is in the correct position. Refer to the illustration below.
Figure 6.13
1 Push the E-stop
2 Open the EZ Thread Gate
3 Thread the film between the Mast and the Top Guard and between the Rollers
4 Close the Gate
5 The Tackifier is on this Side
49
The standard film roll measures 254 mm (10) in diameter and 508 mm (20) in width.
Thread the Film
1. If your machine has Pallet Grip, move the FDS up until the cabling assembly and the angled
roller disengage.
2. Push the E-stop.
3. Look for damage on the film roll. Step 6
4. Put the film roll on the film post.
5. Release the latch on the EZ Thread gate.
6. Pull out 914 1219 mm (3 - 4) of film and
twist it into a rope.
7. Refer to the diagram and thread the film.
8. Close the gate. The film must be loose to
make sure that it does not break.
9. Twist the E-stop to release it.
12. Pull the film and attach it to the load, skid.
Step 8
Figure 6.14 Figure 6.15
50
6.7 Operate the Machine
4. Pull the film and attach it to the load.
6. Remove the load from the turntable at the end of the cycle.
6.8 Film Roll is Empty, Film Break Recovery

If the film breaks, if the film roll is empty, a cycle for Film Break Recovery starts automatically.
The FDS and the turntable stop and the film break indicator flashes.
To continue the wrap cycle from the point where it stopped:

1. Replace the film roll, correct the film break condition.
2. Thread the film.
4. Pull the film and attach to the load.
To start the wrap cycle from the home position:

1. Push the Home button.
2. Replace the film roll, correct the film break condition.
3. Thread the film.
5. Pull the film and attach to the load.
51
52
MAINTENANCE
7.0 Maintenance
Note: Functions, descriptions and data can be different on your machine. Refer to section 3 for
options.
WARNING
WARNING
WARNING
Do not make a change to this machine without approval from Lantech. It can
cause a safety hazard and cancel the warranty.
7.1 Daily and Weekly Maintenance

Tighten, replace loose fasteners.
Look for oil leaks.
Listen for unusual noise during operation.
53
MAINTENANCE
7.1.1 XT Cut and Clamp
Look for, remove the debris (film pieces, wood chips) from around the XT unit.
Move the XT unit to the up position to remove the debris. (Figure 7.2).
Figure 7.1
Figure 7.2
54
MAINTENANCE
7.1.2 Pallet Grip
Standard on Q400 XT
Option on Q300XT
Remove the debris from in and around the
Pallet Grip.
Make sure that the pivoting roller moves freely
and retracts fully.
Examine the groove roller and make sure that it
turns freely.
Make sure that the film moves over the groove
in the groove roller as the load wraps.
7.2 Monthly Maintenance

Examine the FDS belt for wear.
Figure 7.3
Examine the turntable drive belt for correct
tension and wear.
Examine the pre-stretch belt for correct tension and wear.
Examine the pre-stretch chains and sprockets for wear.
Lubricate the chains with SAE 30 oil.
Refer to section 3, Options, for other lubrication requirements.
55
MAINTENANCE
7.3 Settings and Adjustments
7.3.1 FDS Up, Down Travel Proximity Sensor
Installed Alternative
Factory Setting Setting Setting Notes
FDS Up Travel proximity
sensor 89 mm (3 )
Adjust to limit up travel.
FDS Down Travel proximity 19 mm (3/4)
sensor Standard
Measure from the bottom of the 38 mm (1-1/2")
proximity sensor to the base of w/Bottom Safety
the mast. Sensor
3
89mm 3/4 1 1/2
OR
19mm 38mm
56
MAINTENANCE
FDS Up, Down Travel Adjustment
There are 2 proximity sensors to control the up, down travel of the FDS. The sensors are in the
mast and start when the FDS travels up and down. Get access to the sensors through the door on
the aft of the mast.
To adjust the proximity sensors:

1. Loosen the nuts on the sensor.
2. Move the sensor until it sees the FDS.
3. Tighten the nuts.
To adjust the up, down travel limit positions:

1. Loosen the adjustment knob on the proximity sensor.
2. Move the sensor up, down to the correct height.
3. Tighten the knob.
57
MAINTENANCE
7.3.2 Belt Slack Switch
The Belt Slack switch senses a fault in the FDS down travel.
You can install, adjust the switch through the top door of the mast. It is on the bottom side of the
top cap.
Note: Before you adjust the switch install the FDS shipping bracket to remove the tension from
the belt.
To adjust the switch:

Use a 5/32 Allen wrench to turn and tighten the bolt.
The standard arm position is 30 from level.
Figure 7.6
Figure 7.7
58
MAINTENANCE
7.3.3 Turntable Home Proximity Sensor
Factory Installed Alternative

Setting Setting Setting Notes
Turntable Home
proximity sensor (PLS-
1)
8 mm
Measure from the
(5/16)
actuator for turntable
home to the end of the
proximity sensor.
5/16
8mm
Figure 7.8
59
MAINTENANCE
Turntable Home Proximity Sensor
The turntable uses a proximity sensor to see when the turntable is in the home position. The
sensor is below the turntable top and sees an actuator tab on the drive ring.
1. Push the E-stop and disconnect the power.
2. Remove the turntable tensioner guard and loosen the drive belt tension.
3. Remove the turntable top.
a. Install (2) 3/8x16 eyebolts into the holes on the turntable top.
a. Remove the (4) M8 flat head screws from the middle of the turntable.
b. Attach a strap, chain to the turntable top and to the forklift.
c. Set the turntable top safely out of the work area.
4. Examine the sensor.

a. Connect the power to the machine.
b. Twist the E-stop to release it.
c. Push the Power On button. The sensor and LED 4 illuminate.
WARNING
Use caution when the turntable top is off. There are moving parts that can
cause an injury.
5. Adjust the sensor:

a. Push the E-stop.
b. Disconnect the power.
c. Loosen the jam nuts on the sensor.
d. Adjust to a clearance of 8 mm (5/16) between the
sensor and the actuator.
e. Tighten the jam nuts.
6. Twist the E-stop to release it. Figure 7.9

8. Turn the drive ring to the home position.
9. Replace the turntable top.
10. Apply an anti-seize compound to the M8 screws before you attach to the turntable top.
11. Torque to 24 N-m (18 lb-ft).
60
MAINTENANCE
7.3.4 Turntable Drive Belt
Adjust the tension on the turntable drive belt.
1. Remove the cover from the belt tensioner.
2. Make sure that the belt is installed correctly.
3. Loosen the 10 mm locknut until the plate
moves freely.
4. Put a 3/8 torque wrench with a short
extension into 3/8 square opening on the pivot
plate.
5. Torque counterclockwise to 68 N-m (50 lb-ft). Figure 7.10 10 mm Locknut
Tighten the flange locknut by hand as you set
the torque.
6. Use the torque wrench to tighten the 10 mm
locknut on the plate to 52 N-m (39 lb-ft).
7. Replace the cover.
Figure 7.11 Set the Torque
3
1
2
1
2
Figure 7.12 Belt Tensioner

1 Pivot Plate Locknut
2 3/8 Drive Slot
3 Flange Locknut
61
MAINTENANCE
7.3.5 Lantech Intelli-sensor
The Intelli-sensor is a load height sensor that sees

objects in its view. It has a set range.
The Intelli-sensor is on the FDS.
A gauge sets the overwrap on the top of the
load.
The Intelli-sensor sees the load height.
Move the pointer to adjust the level of overwrap.
To complete a test on the Intelli-sensor

1. Examine the electrical connection.
2. Make sure that it attaches correctly. Figure 7.13
3. Complete a test on the unit:
a. For the test use (2) 305 mm (12) square sheets of material.
Make sure that 1 is white and the other is flat black.
b. When the sensor is clear (detection range clear):
The red LED and the green LED illuminate.
c. When the sensor is blocked:
The green LED illuminates.
d. The sensor is set to see:
The white sheet in no more than 127 mm (5) of the distance on the sensor label.
Example: 2438 mm (96) sees at 2311 mm (91)
The black sheet in no more than 254 mm (10) of the distance on the sensor label.
Example: 2438 mm (96) sees at 2083 mm (82).
62
MAINTENANCE
7.3.6 Load Cell

Load Cell
With film in the FDS, 3 mm
measure the space between (1/8)
the load cell and the
actuator.
Figure 7.14
Figure 7.15
63
MAINTENANCE
Calibrate the Load Cell Amplifier Board
1. Disconnect the power.
WARNING
2. Record the current position of jumper J4 on the motor control board. Move it to the CAL
position.
3. Make sure that the jumper J1 is set to STD.
Note: The 20 CAL and 30 CAL jumper settings, potentiometers do not apply.
4. Attach the voltmeter positive lead to load cell output (TP-Load Cell In) and negative lead to
circuit common (TP-C).
5. Apply the power and push the Power On button.
Calibration - These steps make sure that the load cell senses the force on the load.
6. Make sure that there is no pressure on the load cell and the voltmeter shows 0 VDC. If a
voltage is more than 0, adjust the Zero Offset potentiometer to 0 VDC.
7. Thread the film and use a force gauge to apply 2.3 kg (5 lbs) of force to the film.
8. Make sure that the voltmeter shows 1 VDC at load cell output. If the voltage is negative,
turn the load cell 180.
To adjust:
9. Turn the GAIN CAL potentiometer clockwise to increase and counterclockwise to
decrease the output. The GAIN CAL is on the FDS in the small junction box.
10. Complete the calibration at 2.3 kg (5 lbs) and increase the force to 4.5 kg (10 lbs). Make sure
that the voltage is 2 VDC at load cell output.
11. Disconnect the power.
12. Remove the voltmeter leads from the circuit. Refer to the position of jumper J4 in step 2 and
move it to the original position.
64
MAINTENANCE
7.4 Motor Control Boards
7.4.1 FDS Lift Motor
Notes
Settings Setting Setting
DB Dead Band 35%
RESP Response 50%
IR Internal Resistance
35%
Compensation
RCL Reverse Current Limit 60%
FCL Forward Current Limit 60%
MAX Maximum Speed 65% (90VDC)
FACC Forward Acceleration 20%
RACC Reverse Acceleration 20%
Jumpers
2.5 amp - 20
J2 Current Limit
5 amp - 30
J3 Armature Voltage A90
J4 Reference Voltage 15 V
J5 SPD/TRQ SPD
50%
25% 75%
0% 100%
Figure 7.16
65
MAINTENANCE
7.4.2 Turntable
Notes
Setting Setting Setting
DB Dead Band 35%
RESP Response
50%
IR Internal Resistance Compensation
35%
RCL Reverse Current Limit
25%
FCL Forward Current Limit
60%
MAX Maximum Speed 65% = 12 RPM
90 VDC
FACC Forward Acceleration
45%
RACC Reverse Acceleration
10%
MIN Minimum Speed 20% = 16-17
VDC
Jumpers
ARM Armature Voltage A90
CL Current Limit 7.5 Amps
50%
25% 75%
0% 100%
Figure 7.17
66
MAINTENANCE
7.4.3 Power Roller Stretch Plus
Notes
KP 50%
TCI 50%
KD 25%
Cur. Lim. (Current Limit) 60%
Set Pt. Cal 10 VDC
Meter Cal Adjustment
Jumper J1A/J1B 115V/230V
Jumper J2 XT
Jumper J3 6 Amps Or
Motor
Nameplate
Amp Rating
Jumper J4 2.5 LBS.
Load Cell Amplifier Board Jumper J1 STD
50%
25% 75%
0% 100%
Figure 7.18
67
MAINTENANCE
7.5 Potentiometer Settings
7.5.1 Film Delivery System
Dead Band (DB) Keeps the motor in position.
If Dead Band is set too low, a small output voltage can cause the motor to move.
If the motor continues to move down, (drift):
1. Turn the potentiometer counterclockwise until the motor stops.
2. Measure the voltage between the M1 and M2 terminals to make sure that the output is 0
VDC.
Response (RESP) Dynamic Response Control - This potentiometer sets the response of the
control board. If the potentiometer is set too high, it can cause the control board to operate
incorrectly.
Internal Resistance Compensation - This controls how the motor control board measures the
differences between a load and a no-load condition. This is a factory setting.
If you replace the FDS motor, see the steps below.
1. Move the FDS up at low speed with a full film roll.
2. Attach the film to the load and make sure that you maximize the force-to-load.
3. If the motor surges, turn the potentiometer clockwise.
Reverse Current Limit (RCL) Controls the maximum current to the FDS lift motor when it
moves up.
Forward Current Limit (FCL) Controls the maximum current (amperage) to the FDS drive
when it moves down.
Maximum Speed (MAX) Controls the maximum speed of the FDS in the down direction.
1. Turn the FDS Speed knob clockwise.
2. Adjust the voltage to 90 VDC.
3. Measure the voltage across the M1 and M2 terminals.
Forward Acceleration (FACC) Controls the FDS rate of acceleration in the down direction.
Adjust counterclockwise to decrease the time.
Adjust clockwise to increase the time.
Reverse Acceleration (RACC) Controls the FDS rate of acceleration in the up direction.
68
MAINTENANCE
7.5.2 Turntable
Dead Band (DB) Keeps the motor in position.
If Dead Band is set too low, a small output voltage can cause the motor to move.
If the motor continues to move down, (drift):
1. Turn the potentiometer counterclockwise until the motor stops.
2. Measure the voltage between the M1 and M2 terminals to make sure that the output is 0
VDC.
Response (RESP) Dynamic Response Control - This potentiometer sets the response of the
control board. If the potentiometer is set too high, it can cause the control board to operate
incorrectly.
Internal Resistance Compensation - This controls how the motor control board measures the
differences between a load and a no-load condition. This is a factory setting.
If you replace the turntable motor, see the steps below.
1. Operate the turntable at low speed with a full film roll.
2. Attach the film to the load and make sure that you maximize the force-to-load.
3. If the motor surges, turn the potentiometer clockwise.
Reverse Current Limit (RCL) Controls the maximum current to the turntable. The RCL sets
the current available to the motor to decrease the speed at the end of the wrap cycle.
Forward Current Limit (FCL) Controls the maximum current (amperage) to the turntable
drive when it accelerates.
Minimum Speed (Min) Controls the speed that the turntable turns during Home speed at the
end of the cycle.
1. Push the Turntable Jog button to move the turntable off the Home position.
2. Push the Home button.
3. Adjust the MIN potentiometer to get 16 VDC at terminals M1 and M2.
Maximum Speed (Max) Controls the maximum rotation speed.

1. Turn the Turntable Speed knob fully clockwise.
2. Adjust the potentiometer to 12 RPM.
Refer to Section 3 for options that can change the speed of the turntable.
3. Push and hold the Turntable Jog button.
To increase speed, turn the potentiometer clockwise.
To decrease speed, turn it counterclockwise.
69
MAINTENANCE
Forward Acceleration (FACC) Controls the turntable rate of acceleration.
Reverse Acceleration (RACC) The reverse acceleration is also a Forward Acceleration. It

controls the rate the turntable speed decreases when you change from a high speed to a lower
speed.
If it is set too far clockwise, it can cause the turntable to move past the Home position.
Make sure that it moves at minimum speed for the last 3 feet of travel before the Home
position.
70
MAINTENANCE
7.6 Film Delivery System
7.6.1 Power Roller Stretch Plus
Current Limit Sets the range of adjustment, to 200% for J3.
KD Sets the time for the pre-stretch to adjust to a film demand. (Example a load corner).
Set it fully counterclockwise to minimize the effect of this potentiometer.
KP Sets the level of response of the pre-stretch to a film demand. (Example a load corner).
Meter Cal - calibrates the voltage output. This is not adjustable.
Set Pt. Cal - Adjusts the reference voltage for the drive board.
1. Connect a digital voltmeter (DVM) to TP-C (NEG) and to terminal TB2 pin 3 (POS).
2. Push the Film Assist button to engage the drive board for approximately 7 seconds.
3. Adjust the potentiometer to 10 VDC.
TCI Sets the time for the pre-stretch to adjust to a film demand, such as a load corner.
71
MAINTENANCE
Power Roller Stretch Plus
The load cell amplifier board is on the FDS in the small junction box.
The load cell motor control board is in the control panel.
Examine the jumpers on the amplifier board and the load cell. Make sure that they are in the
correct position.
50%
25% 75%
0% 100%
KP - 50%
TCI - 50%
KD - 25%
Cur. Lim. - 60% PH-A PH-B
Set Pt. Cal. - 10 VDC) +15V RED
GRN +15V
Meter Cal. - 5 lbs. = 50 Millivolts, 10 lbs. = 100 Millivolts WHT COM COM BLK
BLK -15V
SH SH
COM
RED -IN WHT
J1 +IN GRN
30 CAL
AMPS
LBS 20 CAL
2.5/4.5/6.4/CAL TP
STD
XT/STD 6/8/11 A3-14
KP
J2 J3 J4
TP-C
Jumpers:
TCI
J1A/J1B - 115V/230 VAC
TP L.C. In
J2 - STD
KD
J3 - 6 Amps
TP Meter Out
J4 - 2.5 Lbs.
Cur.
Lim.
GAIN ZERO 30 20
J1A J1B CAL OFFSET CAL CAL
115V/230V 230V/115V
Figure 7.19
72
MAINTENANCE
Power Roller Stretch Plus
The steps below make sure that the motor control board adjusts to the changes of force that is
applied to the load during the wrap cycle.
Low Speed Operation

Adjust the TCI potentiometer counterclockwise if the FDS, at homing speed, pulses, chatters, or
surges.
Normal Speed Operation

During the wrap cycle, look for changes in the force to the film. An example is that the force
tightens as the demand increases at the corners of the load.
Increase the KP potentiometer function if the force at the corners is high. Turn the KP
potentiometer clockwise to adjust.
Decrease the KP potentiometer function if the force at the corners is low. Turn the KP
potentiometer counterclockwise to adjust.
Irregular Speed Operation

This condition can occur on rectangular loads and long narrow loads.
If the KP adjustment does not minimize the symptoms, turn the potentiometer slowly clockwise
in small increments (up to a maximum turn).
Make sure that the KD potentiometer is set fully counterclockwise for standard operations.
Heavier Gauge Film

A different film can pull more horsepower from the pre-stretch.
If this condition occurs, refer to the motor nameplate for the full load current. Set the J3 jumper
to a higher setting.
Turn the Force to Load potentiometer fully counterclockwise for low force. Adjust the current
limit to calibrate the low force setting.
Turn the current limit potentiometer clockwise to increase the current to the motor.
73
MAINTENANCE
7.7 Standard Parts Replacement
7.7.1 FDS Lift Belt
1. Move the FDS to the correct position to install the
shipping brackets.
2. Push the E-stop.
3. Install the FDS shipping bracket and the
counterweight brackets. Refer to the Installation
Instructions.
4. Reset the E-stop.
6. Move the FDS down until the Belt Slack switch
engages and the belt is slack.
Figure 7.20
8. Before you remove the lift belt, look at the routing of the belt and the rollers in the mast.
9. Remove the cotter pins from the shaft at the top cap of the mast.
10. Remove the belt from the shaft.
11. Remove the belt from around the rollers in the mast down to the FDS lift drive.
12. Unwind the belt from the drum. Count the number of revolutions.
74
MAINTENANCE
13. Attach the belt to the drum.
a. Put the belt through the slot on the drum.
b. Put the metal pin into a
pocket at the end of the
belt.
c. Remove the pin from
the pocket of the belt.
d. Pull the belt out of the
slot in the drum.
14. Put the new belt through
the slot in the drum.
Make sure that the open
Figure 7.21
end of the pocket points to
the drum.
Put the pin in the pocket of the belt.
This holds the pin in the pocket while you
tighten the belt on the drum.
15. Wind the belt around the drum the same
number of revolutions recorded in step 12.
This helps align the belt when it is
installed and attached to the top cap.
16. Install the belt
a. Over the rollers at the top of the mast, and
b. Below the roller on the FDS. Figure 7.22
c. Attach to the shaft on the top cap. 1 Counterweight Roller and Belt
d. Replace the cotter pins in the shaft. 2 FDS Lift Belt and Rollers
17. Complete the belt installation, and apply the power to the machine.
To tighten the belt, move the FDS up at the minimum speed.
18. Remove the FDS shipping bracket and counterweight supports and stow in the mast.
19. Apply the power to the machine.
20. Push the FDS Up and Down buttons to make sure that the belt is aligned.
75
MAINTENANCE
7.7.2 FDS Lift Drive
1. Push the FDS Up, Down buttons to move it to the
correct height to install the shipping brackets.
2. Push the E-stop.
3. Install the shipping bracket and the counterweight

bracket. Refer to the Installation Instructions.
4. Apply the power to the machine.
5. Push the FDS Down button until the belt loosens

and the Belt Slack switch engages.
7. Open and remove the access door and then remove

the panels on the mast to get access to the drive.
8. Disconnect the motor wires in the electrical panel Figure 7.23
and remove the motor cable.
9. Use a 10 mm socket to remove the M6 bolt on the lift
drum.
10. Remove the lift drum from the reducer shaft. Keep
the shaft key.
11. Remove the drive:
Remove the 4 M6 bolts and nuts on the bracket.
(Use a 10 mm socket and 10 mm wrench)
12. Use the same steps in the opposite sequence to install
the replacement drive.
Figure 7.24
76
MAINTENANCE
7.7.3 Turntable Drive Belt
2. Install (2) 3/8-16 eyebolts into the holes on the turntable top.
3. Attach a strap, chain in the eyebolts and attach to the forklift.
4. Remove the (4) M8 flat head screws from the middle of the turntable.
6. Remove the tensioner cover.
3
1
2
1
2
Figure 7.25 Belt Tensioner

1 Pivot Plate Locknut
2 3/8 Drive Slot
3 Flange Locknut
7. Loosen the 10 mm locknut on the pivot plate.

8. Remove the drive belt from the pulley and the
drive ring on the turntable.
9. Install the new belt on the drive ring and then
on the pulley.
10. Attach the turntable top to the drive ring on the
turntable base.
11. Apply an anti-seize compound to the M8
screws before you install the turntable top
13. Refer to the procedures for tension setup for Figure 7.26 10 mm Locknut
the turntable drive belt.
14. Replace the tensioner cover.
77
MAINTENANCE
7.7.4 Turntable Drive
2. Open and remove the access door. Remove the
panels on the mast to get access to the drive.
3. Disconnect the motor wires.
4. Remove the cover from the belt tensioner.
5. Retract the tensioner.
a. Use a 3/8 drive ratchet and short extension,
small flat blade screwdriver and a small Phillips
screwdriver.
b. Put the 3/8 drive extension into the square
opening on the arm and turn counterclockwise.
c. Put the flathead screwdriver into the slot on the
tensioner cam and turn clockwise.
Figure 7.27
d. Turn the arm clockwise to release the tension on
the belt.
e. Put the Phillips screwdriver into the hole on the plate to hold the assembly in position.
6. Install (2) 3/8-16 eyebolts in the holes in the turntable top.
7. Remove the (4) M8 flat head screws near the center of the turntable and lift the top.
8. Attach a strap, chain in the eyebolts and attach to the forklift.
9. Remove the bolts and remove the drive.
10. Remove the brackets from the drive and attach to the replacement unit.
11. Attach the drive and connect the wires.
12. Attach the drive belt on the drive ring and then on the pulley.
13. Remove the screwdriver to release the tensioner.
14. Attach the turntable top to the drive ring on the turntable base.
17. Refer to the procedures for tension setup.
18. Replace the tensioner cover.
78
MAINTENANCE
7.8 Pallet Grip
7.8.1 Pivoting Roller
Notes
The pivoting roller and the
groove roller set the height
of the film cable on the 62
pallet.
1. Adjust the actuator to increase, decrease the angle of the roller when it is engaged.
2. Increase the movement of the roller to lower the position of the cable on the pallet. The
standard adjustment for the roller is 62 from floor level.
3. Loosen the bolts to adjust.
62
79
MAINTENANCE
7.8.2 Groove Roller
Notes
The pivoting roller and the
groove roller set the height of 203mm
the film cable on the pallet. (8)
Adjust the groove roller to increase, decrease the quantity of the film to make the cable.
To adjust:
1. Fully engage the pivoting roller and loosen the 2 bolts on the groove
2. Adjust the roller.
The standard adjustment for a standard height 127 mm (5) pallet:
203 mm (8) from the floor to the top of the groove in the guide roller.
203mm
8
Figure 7.30
80
MAINTENANCE
7.9 XT Cut and Clamp

7.9.1 Turntable Clamp Actuator Proximity Sensor
Turntable at Clamp Actuator

Position proximity sensor
3 mm
Measure from the turntable
(1/8)
actuator to the end of the
proximity sensor
1/8
3mm
Figure 7.31
81
MAINTENANCE
Turntable Clamp Actuator Proximity Sensor
The turntable uses a proximity sensor to sense when the turntable is at the clamp actuator
position. The sensor is below the turntable top and sees an actuator tab on the drive ring.
To adjust the sensor:
1. Push the E-stop and disconnect the machine.
2. Remove the turntable tensioner guard and loosen the tension on the drive belt.
a. Install (2) 3/8x16 eyebolts into the holes on the turntable top.
b. Remove the (4) M8 flat head screws from the middle of the turntable.
c. Attach a strap, chain to the turntable top and to the forklift.
d. Set the turntable top safely out of the work area.
4. Complete a test on the sensor:

a. Connect the power to the machine.
b. Twist the E-stop to release it.
c. Push the Power On button. The sensor and LED 7 illuminate.
WARNING
Use caution when the turntable top is off. There are moving parts that can
cause an injury.
5. Adjust until the sensor:

a. Push the E-stop.
b. Disconnect the power.
c. Loosen the jam nuts on the sensor.
d. Adjust to a clearance of 3 mm (1/8) between the sensor and the actuator.
e. Tighten the jam nuts.
8. Turn the drive ring to the home position.
9. Replace the turntable top.
82
MAINTENANCE
7.9.2 XT Actuator Tab
XT Actuator Tab And Cam Engagement
Measure from the top of the turntable skirt to 25 mm

the bottom edge of the actuator tab and cam. (1)
Make sure that the actuator tab extends 13
mm () above the top of the cam.
Film Cable Height Q300

51 mm
(2)
Measure from the top of the actuator wheel
to the bottom of the cable roller bracket.

13mm
2
1
51m
25mm m
83
MAINTENANCE
84
TROUBLESHOOTING
8.0 Troubleshooting
This section tells some of the problems that can occur.
Refer to the electrical and mechanical drawings.
Refer to the Maintenance section for adjustments.
Refer to Section 1.1 for Lantech support.
8.1 General Data
No power at the receptacle. Examine the power circuit.

The Power cord is disconnected. Connect the power cord.
The Emergency Stop is engaged. Twist to release the E-stop
1 The machine does not start.
The control power is not on. Push the Power On button.
The DC power supply does not operate Make sure that the input and
correctly. output voltages are correct.
The fuses on the Microcontroller board are Replace the fuses.
defective.
No jumper on position C on the Examine the jumper on position
2 You do not have access to
Microcontroller. C on the Microcontroller.
the presets.
Examine the Mode/Fault
There is a fault condition.
indicators for fault condition.
3 The FDS does not apply The photoelectric sensor for the load Use the Film Height Above Load
the film to the top of the height sensor is not set correctly. gauge and adjust the sensor.
load.
85
TROUBLESHOOTING
8.2 Film Delivery System

FDS speed control is set too low. Adjust the speed control.
Examine, replace the sensor.
(PLS-112).
FDS Up Travel proximity sensor does
Examine the cable for damage.
not operate correctly.
Make sure that the cable connects
4 Push the Up button and with the sensor.
the FDS does not move up.
Make sure that the input and output
voltage to the drive control is
The control for the FDS lift does not correct. (SCR-2)
operate correctly.
Examine, replace the fuses on the
drive board (SCR-2).
The gear drive and motor do not operate Examine the armature wires on the
correctly. drive motor.
The speed control is set too low. Adjust the speed control.
Examine, replace the sensor.
(PLS-107).
The Down Travel proximity sensor does
not operate correctly. Examine the cable for damage.
with the sensor.
Make sure that there is no blockage
5 Push the Down button in the path of the FDS.
and the FDS does not
move down. Examine the guide rollers for
blockage.
The FDS does not move freely. Examine the FDS lift belt for slack
condition (LS-4).
Examine, replace the Belt Slack
switch.
with the sensor.
Make sure that the input and output
voltage to the drive board is
correct. (SCR-2)
FDS lift drive board does not operate
Examine, replace the fuses on the
correctly.
FDS lift drive board.
Examine the armature wires on
FDS lift drive motor.
86
TROUBLESHOOTING

The speed control is set too low. Adjust the control.
The load height sensor is not set correctly. Align, adjust the sensor. (PC-7)
The FDS does not wrap to
The load height sensor does not operate Examine, replace the load height
6 the top of the load.
correctly. sensor.
The FDS Up Travel proximity sensor is Adjust, replace the sensor. (PLS-
set too low. 112)
The FDS control is set too low. Adjust the speed control.
The FDS does not move
7 the correct distance above The load height sensor is not set correctly. Align the load height sensor. (PC-7)
the top of the load during
the wrap cycle. The load height sensor does not operate Examine, replace the sensor.
correctly.
Use a metal tool (i.e. a screwdriver)
to energize the proximity sensor.
The FDS does not stop at Make sure that it illuminates when it
The sensor does not operate correctly.
8 the Up Travel proximity energizes.
sensor.
Move the FDS to the Up Travel
proximity sensor and examine the
function at LED1. Adjust the
sensor.
The FDS speed control is set too high. Adjust the speed control.
The FDS moves above the
Load height sensor is not set correctly. Adjust the sensor. (PC-7)
9 load height during the wrap
cycle. Load height sensor does not operate Examine, replace the sensor. (PC-7)
correctly.
The lift belt is in a slack condition not Look for blockage of the FDS,
The FDS does not move to tight. counterweight.
10
the bottom position during
The Down Travel proximity sensor is Adjust the sensor (PLS-107). Refer
the wrap cycle.
not set correctly. to section 7 Maintenance.
The FDS down speed is set too low (two Adjust the speed.
speed FDS option includes second speed
potentiometer).
The top wrap counter does not operate Examine the Turntable Home
correctly. proximity sensor (PLS-1) input for
function.
11 The FDS does not move
down during the wrap The Down Travel proximity sensor does Examine, replace the sensor. (PLS-
cycle. not operate correctly. 107)
with the sensor.
The Belt Slack switch does not operate Examine, replace the sensor (LS4)
correctly.
87
TROUBLESHOOTING

The Reduced Wrap Force delay is set Adjust Preset P.2.
too low.
Refer to section 6 for Presets and
adjustment.
The Reduced Tension is not set Refer to section 7 Maintenance to
correctly on the FDS drive board. calibrate the motor control board.
The Wrap Force potentiometer is set too Adjust wrap force.
high.
Pre-stretch chain drive system is Examine, replace the drive chains
damaged. and sprockets.
Make sure that there is no film
The idler rollers do not turn freely. buildup around the bearings.
Examine, replace the rollers.
12 The FDS does not apply The Film Check limit switch does not Examine, replace the switch (PLS-3).
the film. operate correctly.
Examine the control board fuses and
The PRS Motor Control board does not the input and output voltages.
operate correctly.
Examine the armature wires on the
PRS motor.
Refer to the diagram to thread the
The film is not threaded correctly.
film.
Remove the damaged film.
Look for damage on the film roll.
Replace the film roll.
There is an adhesive from the film on the Use ammonia, detergent to clean the
roller. rollers.
The pre-stretch rollers are too tight. Align the chain and sprocket on the
pre-stretch rollers.
There is an adhesive from the film on the Use ammonia, detergent to clean
roller. rollers.
The wrap force is set too high Decrease the wrap force.
Remove the sharp edges.
13 The film breaks during Increase the Reduced Wrap Force
wrap cycle. delay (Preset P.2) and FDS delay at
There are sharp edges on the load, skid.
start of wrap cycle (Preset P.3).
This keeps the FDS at the lower
position to apply a layer of film
before the FDS moves up.
The pre-stretch rollers, idler rollers are

Examine, replace the rollers.
damaged.
88
TROUBLESHOOTING

The film winds around the There is an adhesive from the film on the Use ammonia, detergent to clean the
pre-stretch roller. roller. rollers.
14 Caution: Do not use a
sharp object to remove the
film that is wound onto There is damage on the pre-stretch rollers. Examine, replace the rollers.
the pre-stretch roller.
15 The load does not wrap
with the correct force-to- The Wrap Force is set too low Increase the Wrap Force
load.
8.3 Turntable

Compare the weight of the load
The load is too heavy.
with the capacity.
The turntable speed is set too low. Adjust the turntable speed control.
The turntable drive does not operate Examine the turntable drive motor
16 The turntable does not correctly. and reducer.
turn when you push the
Look for damage on the belt.
Jog button.
There is damage to the turntable drive belt.
Make sure that the belt tension is
set correctly.
Examine the input fuses and the
The turntable motor control board does not
output voltage on the motor control
operate correctly.
board. (SCR-1)
Make sure that the machine is on a
The floor is not flat.
level floor.
There is debris below the turntable Remove the debris.
Look for damage, debris on the
Look for damage to:
urethane ring.
Urethane ring
Do not let a load stay on the
17 The turntable makes an Drive ring turntable for an extended period of
unusual noise when it Center bearing time. This can cause damage to
turns.
To examine these components, remove the the urethane ring.
turntable top Examine the drive ring for damage,
(Refer to the section 7 Maintenance) debris.
Examine the bearing support for
damage, debris.
Lubricate the center bearing.
89
TROUBLESHOOTING

Make sure that the machine is on a
The floor is not flat.
level floor.
There is debris below the turntable Remove the debris
Look for damage, debris on the
Look for damage to:
urethane ring.
Urethane ring
Do not let a load stay on the
Drive ring turntable for an extended period of
Center bearing time. This can cause damage to
18 The turntable does not
start easily. To examine these components, remove the the urethane ring.
turntable top Examine the drive ring for damage,
(Refer to the section 7 Maintenance) debris.
Examine, replace the turntable
drive belt.
Turntable drive does not operate correctly. Examine the turntable drive motor
and reducer.
Compare the weight of the load
The load is too large, heavy.
with the capacity.
Examine the sensor (PLS-1) input
for function. LED4 on the
microcontroller flashes as the
The incorrect number of turntable moves through the home
19
top, bottom wraps is The Turntable Home proximity sensor position.
applied to the load. does not operate correctly Remove the turntable top and
examine, adjust the sensor.
with the sensor.
Adjust Preset P.1 to the factory
Preset P.1 is set too high.
setting. (1.5 seconds).
Examine the sensor (PLS-1) for
function. LED4 on the
microcontroller flashes as the
20 The FDS wraps The Turntable Home proximity sensor turntable moves by the home
continuously at the top of does not operate correctly. position.
the load
Remove the turntable top and
adjust, replace the sensor.
with the sensor.
90
TROUBLESHOOTING
8.4 Pallet Grip

The FDS does not lower correctly to wrap Lower the FDS Down Travel
the pallet. proximity sensor.
21 The film cable does not
Adjust the height of the groove
catch the 4 corners of the
The groove roller is set too high for the roller.
pallet.
height of the pallet Make sure that the film cable
wraps the top 25 38 mm (1-1
) of the pallet.
The FDS does not lower correctly to wrap Lower the FDS Down Travel
the pallet. proximity sensor.
Adjust the height of the groove
The groove roller is set too low for the roller. Make sure that the film
height of the pallet. cable wraps the top 25 38 mm
(1-1 ) of the pallet.
Lower the FDS to fully engage the
roller.
Adjust the angle of the roller.
The film cable did not
22 The pivoting roller does not move
form correctly.
correctly to make the film cable.
Note: The standard setting is 62 from

floor level.
62
Increase the Wrap Force.

Note: Machines without PRS Plus
The Wrap Force is set too low. A slack
(Load Cell) Increase the Reduced
film does not make a tight cable of film.
Tension settings on PRS Drive
board (SCR-3).
The AFC device is out of adjustment. Adjust the position of the AFC.
The Auto Film Cut-off is Off Make sure that the Configuration
Machines with Auto Film (Configuration Bit C-14). Bit C-14 is on.
Cut-off (AFC):
The Preset timer (P.4) is set too low (Time
23
The film does not cut at to operate the FDS Up at the end of the Adjust the Preset timer P.4
the end of the wrap cycle. wrap cycle).
Make sure that the FDS lifts and
If the film cable stays at the bottom of the disengages the groove roller.
film, the film does not cut correctly.
91
TROUBLESHOOTING
8.5 XT Cut and Clamp

Make sure that SOL-1, LED 9
illuminate when the actuator tab
engages.
Examine the solenoid cable
Actuator tab does not operate correctly.
connection for damage.
XT Cut and Clamp does Adjust the proximity sensor (PLS-21).
24 not cut, clamp the film Remove the turntable top to make this
correctly. adjustment.
Remove debris in the XT unit.
Make sure that the LED 7 illuminates
when the turntable is at the clamp
Proximity sensor for the turntable at the actuator position.
clamp actuating position (PLS-21) does
Adjust the turntable proximity sensor
not operate correctly.
(PLS-21).
Remove the turntable top to make this
adjustment.
There is debris in the clamp. Remove the debris (film pieces, wood
chips, etc.).
The XT unit does not
The XT belt is out of adjustment. Adjust, replace the belt.
25 move to the home
position. There is damage to the actuator bar, guide. Repair, replace.
The blade is out of adjustment Adjust, replace the blade.
There is damage to the blade.
Adjust the spring on the cutter.
The XT does not cut the
26 The actuator tab releases before the end of
film Align the actuator tab and XT cam.
the cut and clamp cycle.
The load is not in the correct position on Make sure that the load is in the
the turntable. correct position on the turntable.
The XT unit does not retract to the home Adjust the return spring on the cutter
position. blade.
The grooved roller is set too high. Adjust the height of the roller.
Preset P.6 is set too low. This can cause Adjust the P.6 Preset.
The XT does not clamp the film to pull over the clamp.
27
the film.
Make sure that SOL-1, LED 9
illuminate when actuator tab engages.
Examine the solenoid cable
The actuator tab does not operate correctly. connection for damage.
Adjust the turntable proximity sensor
(PLS-21). Remove the turntable top
to make this adjustment.
Remove the debris (film pieces, wood
chips, etc.).
92
TROUBLESHOOTING

The Reduced Wrap Force is set too low. Adjust Preset P.2
Refer to section 6 for adjustments.
Adjust the height of the grooved
roller.
The XT does not catch enough film in the
Adjust the FDS Down Travel
clamp.
proximity limit sensor (PLS-107).
Refer to section 7 Maintenance.
The film pulls out of the
The turntable speed increases too quickly. Examine, adjust the turntable drive
clamp at the beginning of
28 board (SCR-1).
the wrap cycle.
The turntable minimum speed is set too
high. Refer to section 7 Maintenance.
The PRS+ drive board, the load cell Calibrate the PRS+ drive board and
amplifier board is out of adjustment. the load cell amplifier board.

Preset P.6 (Delay to turn off PRS) is set Adjust the P.6 Preset.
too high.
Make sure that the load is in the
correct position on the turntable.
The load hangs off of the turntable.
The cycle can stop if the film makes
contact with the load before it
The film is cut but does completes the cut.
29
not make a complete
break. The PRS+ drive board (SCR-3), the load Calibrate the PRS+ drive board and
cell amplifier board is out of adjustment. the load cell amplifier board.

The turntable minimum speed is set too Examine, adjust the turntable drive
low. board (SCR-1).
93
TROUBLESHOOTING
94
APPENDIX - GLOSSARY
9.0 Appendix
CE Declaration of Conformity
Glossary
Warranty
9.1 Glossary
Auto Film Cut-off- This is an option that automatically cuts the film at the end of the wrap
cycle.
Banding This set the number of wraps that the FDS applies to the load then continues the wrap
cycle.
Bottom Wrap - This sets the number of wraps for the bottom of the load. The settings are from 1
to 9.
Dual Turntable - This option adds a second turntable. The operator can put a load on 1 turntable
while the other load is in the wrap cycle.
EZ Thread - This is a standard option on the Film Delivery System that makes it easy to thread
the film.
Emergency Stop - The Emergency Stop is a red button that safely stops the machine in an
emergency condition.
Film Delivery System (FDS) - This is the Electrical/Mechanical assembly that applies the film to
the load.
Initialize - This sets the safety circuits and puts all components in the start position.
Intelli-sensor - This is a pallet height sensor that sees the load.
Lockout/Tagout - These procedures make sure that the machine is off and not started up before
you complete the maintenance and repair work.
Mast The upright that holds the FDS and the control panel.
One-way Wrap - This option applies 1 layer of film to the load and wraps in only 1 direction.
Pallet Grip This option locks the load to the pallet. This is an option on the Q300 and
Q300XT. It is standard on the Q400 and Q400XT.
Pre-Stretch - A procedure that extends the length of the film before the FDS applies it to the load.
95
APPENDIX - GLOSSARY
Presets - Presets are adjustable timers and counters that control the machine operation.
Top Platen - This is a device that holds a load during the wrap cycle.
Top Sheet - This option lets the operator apply a sheet of film on top of the load during the wrap
cycle.
Top Wrap - This sets the number of wraps for the top of the load. The settings are from 1 to 9.
Turntable Top - This is a circular plate that holds the load and turns during the wrap cycle.
Wrap Force - The film tension as it is applied to the load.
XT Cut and Clamp This unit clamps and cuts
96
WARRANTY
9.2 Warranty
All Lantech machines include a warranty against a defect in:
Material
Design
Manufacturing
Lantech has the option to repair, replace the machine, part if:
Lantech is the manufacturer, vendor of the part
The part is defective
Lantech knows about the defect before the warranty period ends
Obey the steps below to prevent the cancellation of your warranty
The actions can cancel the warranty:

The failure to operate the machine by Lantech instructions
The failure to obey the maintenance instructions
A change to the parts, the machine without Lantech approval
An accident that can cause the machine to be damaged
An environment where the weather conditions can cause the machine to be damaged.
The failure to operate the machine by the environmental specifications.
This includes:
An environment where moisture causes corrosion of parts
Explosive environment
The failure to prepare the area correctly for installation and maintenance
This includes:
The electrical supply is not sufficient
The floor is not flat
The thickness of the floor is not correct
The floor has a crack in the area where the machine is installed
The machine is installed near joints in the floor
The warranty stops if the machine moves to a new customer.
Unless Lantech agrees in writing, this warranty does not include the requirements for federal,
local, safety, environmental regulations and standards.
European standards:
Supply of machine with Orgalime General Conditions
97
WARRANTY
98
PARTS LIST and DRAWINGS
10.0 Parts Lists and Drawings
How to Use This Section
This section helps the operator and maintenance personnel find the parts and assemblies. The
drawings follow each parts list.
How to Find a Part Number
1. Find the drawing that contains the part.

2. Find the part on the drawing and the item number for the part.
3. Use the item number to find the part on the parts list. Refer to the part number, description
and quantity.
Send your parts order to the local Lantech Distributor.
Refer to Section 1.1 for Lantech support.
99
PARTS LIST and DRAWINGS
100

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1.0 Introduction ........................................................................................................................ 5

The Parts List and Drawings section includes the BOMs.

LANTECH AFRICA & EUROPE CUIJK NETHERLANDS

LANTECH ASIA PACIFIC MELBOURNE AUSTRALIA

LANTECH CHINA - SHANGHAI

LANTECH NORTH & SOUTH AMERICA LOUISVILLE KENTUCKY

On the door of the enclosure

In the electrical enclosure

The serial number can also be in other areas of the machine.

This does not apply to Case Machines.

1800 kg (4000 lbs) X

3.1 Click-n-Go Remote

The option includes:

Figure 3.1 - Machine Mounted Receiver Figure 3.2 - Remote

1 Sensor 3 Channel Buttons (Blue)

Drill the holes and attach with screws

Install the Receiver Locking Tab Safety Cord

line of sight and in the range of the 19' (5.8m)

Note: The conditions in the list below can

1. The operator puts a load on the turntable.

Receiver Channel Settings

Receiver Arm Time Settings

2 (The beacon does not The transmitter is out of range or

Problem Possible Cause Solution

Warnings, Cautions, and Notes

Do Not Operate Without

Maximum Capacity Do Not Step

Do Not Reach Fire Can Occur

Release of Pressure Electrical Shock Warning

Do Not Walk on Conveyor

Hit is Possible From Above

Fall Warning Hit is Possible From The Side

Film Delivery System Warning

Cut Warning Crush Warning

Obey the Safety Instructions

Machine Can Fall

Chemical Waste Environment

Important Note Refer To Manual

5.0 Installation Instructions

This does not apply to Case Machines.

5.1 Prepare the Area

Larger Turntables and Extended Bases:

6 Turntable Drive Motor and Belt Tensioner Area (Motor

The FDS pre-stretches and applies the

6.3.2 FDS Lift Drive

FDS Belt Slack Switch

1. To thread the film:

2. Access to the rollers and gate:

The Pallet Grip locks the load to the pallet.

Angled Roller moves the film down and helps

Groove Roller is adjustable to increase,

Pallet Grip Film Tail Reduction

Film Tail Elimination Sequence

Access to All Settings

Push the Presets button to get

Note: In the Preset Mode no other

To Change the Value:

Preset Description Timer

Preset Description Timer

The FDS Descent Timer to apply a Top Sheet Turntable 2 (Option)

The Number Of Top Counts to apply a Top Sheet

To get access to the Configuration Mode:

To change the configuration value: