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PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL

HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1-800-531-2465

I-3

SYSTEM

SYSTEM OVERVIEW PRINT

OVERVIEW PRINT

OVERVIEW PRINTS

Exhibit 1-1: Predator XS Low Profile Overview Layout

NOTE

Shown below are STANDARD assembly drawings. It may not reflect
your purchased system, especially when optional items are added.
Refer to assembly drawings shipped inside the electrical enclosure for
more detail information.

Summary of Contents for PREDATOR XS

Page 1: ...AL NUMBER Please refer to the serial number in all correspondence with Highlight or any Highlight Distributor This identifies your machine and will help in our ability to quickly and efficiently respo...

Page 2: ......

Page 3: ...ndy for quick reference Definitions and Symbols High Voltage This symbol indicates high voltage It calls your attention to items or operations that could be dangerous to you or other persons operating...

Page 4: ...VOLTAGE The user is responsible for conforming to all applicable code requirements with respect to grounding all requirements Do NOT use extension cords to operate the equipment HIGH VOLTAGE Disconne...

Page 5: ...he warranty of the original equipment Satisfaction of this warranty consistent with other provisions herein will be limited to the replacement or repair or modification of or issuance of a credit for...

Page 6: ...ring practices and schematics symbols To guarantee safe operation of the equipment carefully observe the safety messages at the beginning of and throughout this manual Keep this operating manual handy...

Page 7: ...DXS 1 Revision A Added Drive Adjustment section Modified drive board potentiometer settings Other minor corrections throughout February 2006 PREDXS A 2 Revision B Changed format added page numbers Sep...

Page 8: ......

Page 9: ...rints I 3 System Description I 5 CHAPTER 2 INSTALLATION AND ADJUSTMENTS Machine Placement II 1 Machine Set Up II 2 Pre Stretch Adjustment II 5 Frequency Drive II 8 Film Feed Controller Card II 16 Opti...

Page 10: ...table Frame Assembly VI 4 Optional High Profile Turntable Frame Part List VI 5 Tower Assembly VI 6 Tower Part List VI 7 Film Carriage Elevator Assembly VI 9 Film Carriage Elevator Part List VI 10 Cont...

Page 11: ...p II 7 Exhibit 2 3 Description of Hitachi AC Drive Digital Keypad II 8 Exhibit 2 4 Navigation of Hitachi AC Drive Digital Keypad II 9 Exhibit 2 5 Fault Detection of Hitachi AC Drive II 10 Exhibit 2 6...

Page 12: ......

Page 13: ...I Chapter 1 HIGHLIGHT INDUSTRIES INC Predator XS Turntable Stretch Wrapper Operation Manual General System Information Chapter 1...

Page 14: ...ch 56 x 56 x 80 Approximate Shipping Weight lbs 1220 1500 Electrical Specifications 120 VAC 60 Hz Single phase 15 AMP NEMA 12 rated electrical panel Operating temperature 32 F to 110 F Lockable discon...

Page 15: ...le film force 200 250 average pre stretch level 10 diameter roll capacity 20 height roll capacity OPTIONAL pre stretch ratio of 230 300 Requirements Part Number Description Number of Teeth 301339 Driv...

Page 16: ...SYSTEM OVERVIEW PRINT OVERVIEW PRINT OVERVIEW PRINT OVERVIEW PRINTS S S S Exhibit 1 1 Predator XS Low Profile Overview Layout NOTE Shown below are STANDARD assembly drawings It may not reflect your p...

Page 17: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 I 4 Exhibit 1 2 Predator XS High Profile Overview Layout...

Page 18: ...1 2465 I 5 SYSTEM DESC SYSTEM DESC SYSTEM DESC SYSTEM DESCRIPTION RIPTION RIPTION RIPTION Shown below is the machine description Exhibit 1 3 Predator XS Low Profile Machine Description Tower Control B...

Page 19: ...II Chapter 2 HIGHLIGHT INDUSTRIES INC Predator XS Turntable Stretch Wrapper Operation Manual Installation Adjustments Chapter 2...

Page 20: ...part number of your order Positioning of the Machine Place the Predator Turntable Stretch Wrapper close to an area where you will be wrapping your pallet loads Make sure that there is sufficient room...

Page 21: ...front carriage roller removed for shipping purpose 2 Place forks of the forklift through the tubes provided at the rear base of the module remove the machine from these skids and place it at the desig...

Page 22: ...ume 6 Open the electrical control box Make sure all machine power is completely removed when the electrical control box is open Close the electrical control box to resume 7 Trip the carriage foot secu...

Page 23: ...USTMENT Pre Stretch Percentage Change To change the pre stretch percentage follow the procedure below 1 Turn the main disconnect switch off 2 Remove the knob cover on the film carriage 3 Push the safe...

Page 24: ...G MI 49519 1 800 531 2465 II 5 4 To insure safety and correct operation of the stretch gears check the following items a The safety line is back to its home position following the profile of the knob...

Page 25: ...ANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 II 6 Replacing Pre Stretch Percentage Gear Set To swap the pre stretch percentage gear set follow the illustration below...

Page 26: ...ides programming and control interface Exhibit 2 3 Description of Hitachi AC Drive Digital Keypad 1 Run Stop LED ON when the inverter output is ON and the motor is developing torque Run Mode and OFF w...

Page 27: ...10 Power LED This LED is ON when the power input to the inverter is ON 11 Function Key This key is used to navigate through the lists of parameters and functions for setting and monitoring parameter v...

Page 28: ...tables lists the cause associated with the error Error Code Name Cause s E01 Over current event while at constant speed E02 Over current event during deceleration E03 Over current event during acceler...

Page 29: ...used with the HP turntable motor Cutler Hammer AC Drive Digital Keypad Description The digital keypad includes the displays panel and the keypad The display panel provides the parameter display and sh...

Page 30: ...lt mode it is used to reset the fault STOP Motor STOP from the panel active control place has to be selected at Panel RESET Used for active fault resetting In programming mode press RESET key to cance...

Page 31: ...urrent present at the output terminals T1 T2 and T3 The value of the user defined units The output voltage present at the output terminals T1 T2 and T3 The temperature of the unit The AC Drive forward...

Page 32: ...parameters on that page Parameters Once the parameter has been located use the right arrow key to view the parameter setting Programming Mode Use the ENTER key to enter the programming mode The displa...

Page 33: ...s The AC drive detects an abnormal increase in current 1 Check the wiring connections between the AC drive and motor for possible short circuits 2 Check for excessive loading conditions at the motor T...

Page 34: ...ARD The film feed delivery controller card regulates the speed of the pre stretch motor to determine the amount of film force applied to a product The card receives inputs from three variables the Fil...

Page 35: ...etermines the maximum speed of the pre stretch motor Recommended setting is 70 3 VR5 sets the pre stretch motor speed in manual feeding Turn clockwise to increase counter clockwise to decrease Recomme...

Page 36: ...is not in operation This should be used for reference only 8 L4 green indicates the 24 VDC output from the film delivery board The light should be on as long as power is supplied to the machine 9 L5 g...

Page 37: ...otentiometer dial The resistance should increase as the dial is turned clockwise and decrease as it is turned counter clockwise 7 2 Inspect the dancer bar speed potentiometer dial 7 2 1 Locate the dan...

Page 38: ...es above the range of human hearing ultrasound about 20 kHz They sense objects by measuring the time it takes to reflect the ultrasound waves from the object s surface and back to the receiver transdu...

Page 39: ...1 Turn the scale display over and turn off the scale power Step 2 Remove the two small screws holding a small plate on the back of the scale Step 3 Flip the switch under the plate to the right Step 4...

Page 40: ...III Chapter 3 HIGHLIGHT INDUSTRIES INC Predator XS Turntable Stretch Wrapper Operation Manual Operation Instructions Chapter 3...

Page 41: ...lect automatic single wrap mode Press the Start button to begin cycle The film carriage will begin applying the bottom wraps travel upwards to top of the product apply top wraps and then stops Press t...

Page 42: ...ise to decrease Adjusting this will affect the film overlap FILM FORCE The Film Force potentiometer dial determines the amount of film tension applied to the load in a wrapping cycle Turn clockwise to...

Page 43: ...e carriage 1 Rotate the handle and open the film carriage 2 Pull six 6 feet of film off the film roll 3 Follow the diagram below and thread the 6 foot film tail all the way through the rollers 4 Close...

Page 44: ...ax down position 4 Thread the film as instructed and attach it to the product 5 Set the desired numbers for top and bottom wrap counts 6 Select the Up Only or Up Down wrapping mode 7 Turn the Turntabl...

Page 45: ...in Manual mode 5 Once the reinforcement wraps have been applied switch the Turntable selector switch from Manual to Auto The turntable will pause 6 Press the Start button again to complete the automa...

Page 46: ...IV Chapter 4 HIGHLIGHT INDUSTRIES INC Predator XS Turntable Stretch Wrapper Operation Manual Maintenance Chapter 4...

Page 47: ...tenance based on cycling operation and environmental locations Lock out Tag out Procedures Be sure that anyone performing any type of maintenance on this equipment is familiar with and is adhering to...

Page 48: ...rn the M10 bolt on the adjuster tab until the belt is tensioned Retighten the four motor flange screws Exhibit 4 1 Turntable Belt Adjustment Film Carriage Lift Chain Adjustment Refer to figure below t...

Page 49: ...Lift Chain Adjustment Sprocket and Chains All sprockets should be inspected for wear and chains should be checked for proper tension and lubrication on a periodic basis Failure to do so will lead to...

Page 50: ...ule Service With Turntable Reducer Sealed lubricated with premium lubricant No maintenance required N A Film Carriage Reducer Sealed lubricated with premium lubricant No maintenance required N A Film...

Page 51: ...V Chapter 5 HIGHLIGHT INDUSTRIES INC Predator XS Turntable Stretch Wrapper Operation Manual Troubleshooting Chapter 5...

Page 52: ...required contact the distributor from whom you have purchased the equipment or call the number listed on the bottom page of this manual To receive quick and proper technical support please be prepared...

Page 53: ...he control box properly Use a voltmeter to test supply voltage from the plant s outlet Is it reading 120VAC Plug machine into a 120VAC outlet Use a voltmeter to test continuity of the power cord Does...

Page 54: ...is clear the fault Adjust potentiometer towards 100 to set speed Is the Turntable Speed potentiometer dial set high enough Tighten wiring replace dial if necessary Use a voltmeter to test resistance o...

Page 55: ...e proximity switch or photo sensor input to the PLC Does the indicator light turn on when the table is at home position At the end of a cycle does the turntable stop at home Tighten power wiring to th...

Page 56: ...er dial set high enough Tighten wiring replace dial if necessary Use a voltmeter to test resistance of the potentiometers Are they reading 5K across Refer to Power Problem above With machine power pro...

Page 57: ...s off the frequency drive connect them to the turntable frequency drive Run the turntable manually using the jog button on the operator panel Is the film carriage motor running Check film carriage mot...

Page 58: ...bstructions and adjust sensor to pick up target Does the indicator light turn on as the turntable passes the home position Tighten power wiring to the sensor replace if necessary Check conditions of t...

Page 59: ...o the sensor replace if necessary In a wrapping cycle does the carriage lower after the completion of top wraps count Locate the turntable home proximity switch or photo sensor input to the PLC Does t...

Page 60: ...correctly Tighten wiring to the sensor replace if necessary Refer to Power Problem above With machine power properly supplied pull the dancer bar on the carriage Does the film mandrel rotate Problem f...

Page 61: ...ics Is the acceleration parameter on the turntable frequency drive set properly Restore parameters as listed on the electrical schematics Continued to page V 11 Is the film threaded correctly Remove t...

Page 62: ...ial on the operator panel set correctly Make small adjustment at a time to set the film force Tighten wiring replace dial if necessary Use a voltmeter to test resistance of the potentiometers Is it re...

Page 63: ...VI Chapter 6 HIGHLIGHT INDUSTRIES INC Predator XS Turntable Stretch Wrapper Operation Manual Technical Reference Chapter 6...

Page 64: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 1 Turntable Frame Assembly...

Page 65: ...2 BRACKET PROX DETECTION 1 14 700060 CAM FOLLOWER ASSEMBLY 14 W SNAP RING 17mm EXTERNAL X SHAFT FOR CAM FOLLOWER Y PLASTIC HOUSING FOR CAM FOLLOWER Z BEARING 6203ZZ 18 700601 BELT RETURN ROLLER ASSEM...

Page 66: ...INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 3 30 600090 TURNTABLE FRAME WELDMENT 1 31 500465 FRAME COVER PLATE 1 32 200154 PAN HEAD MACHINE SCREW M4 x 6L 4 33 200630 HHCS M12 x...

Page 67: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 4 OPTIONAL High Profile Turntable Frame Assembly...

Page 68: ...2 8 305024 2 Drive Caster 1 9 300506 Bearing 2 Bolt Flange 1 3 16 3 10 645384 Proximity Sensor Trip Weldment 1 11 301021 Gearmotor HP 28 59 1 1 12 403061 Proximity Sensor NPN 1 13 300505 Sprocket 60BS...

Page 69: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 6 Tower Assembly...

Page 70: ...200140 NUT M12 2 15 200090 SHCS M10 x 25L 6 16 200632 THREADED ROD M10 x 60L 2 17 500469 SHAFT IDLER SPROCKET 1 18 300778 SPROCKET IDLER 1 19 300017 BEARING 6002ZZ 1 20 300008 SNAP RING 15mm EXTERNAL...

Page 71: ...URNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 8 34 200078 SHCS M6 x 16L 6 35 500475 BRACKET LOWER IDLER SPROCKET 1 36 200633 SHC...

Page 72: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 9 Film Carriage Elevator Assembly...

Page 73: ...7mm Ext 2 14 500686 BEARING SEAT 1 14a 301842 SNAP RING RTW 35 35mm INT 2 14b 200802 SHCS M6 x 16L S W W 4 15 200633 SHCS M6 x 10L 3 16 600096 CARRIAGE TOP COVER 1 17 500674 CARRIAGE COVER BRACKET 3 1...

Page 74: ...CER BAR ARM Z DANCER BAR ROLLER ASSEMBLY 47 500689 SUPPORT BRACKET 1 48 700466 FILM HOLDER ASSEMBLY 1 O 300026 BEARING NTB1730 P 200078 SHCS M6 x 16L Q 500474 THRUST BUSHING UPPER R FILM CORE HOLDER U...

Page 75: ...M4 x 10L 4 89 600176 PUNCTURE SOLENOID COVER BRACKET 1 90 300719 PUNCTURE SOLENOID 24 VDC TAU 1585 1 91 300720 PUNCTURE TIP 1 92 500761 PUNCTURE GUARD 1 97 700474 ROLLER ASS Y DOOR OUTER 2 98 500762...

Page 76: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 13 Control Box Assembly...

Page 77: ...00048 LOCK PLATE 2 8 600155 ELECTRICAL BOX DOOR 1 9 300041 LOCK W KEY 2 10 200124 PHILLIPS SCREW M4 x 25L 1 11 500080 KEY SAFETY SWITCH 1 12 500016 SPRING 2 13 200788 NUT NYLOC M4 2 14 200106 MACHINE...

Page 78: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 15 Electrical Schematics...

Page 79: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 16 Electrical Schematics Continued...

Page 80: ...REDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 17 Electrical Schematics Continued for OPTIONAL High Profile Turntable...

Page 81: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 18 Electrical Schematics Continued...

Page 82: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 19 Electrical Schematics Continued...

Page 83: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 20 Electrical Schematics Continued...

Page 84: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 21 Electrical Schematics Continued...

Page 85: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 22 AC Frequency Drive Settings...

Page 86: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 23 AC Frequency Drive Settings for OPTIONAL High Profile Turntable...

Page 87: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 24 Electrical Sub Panel Layout...

Page 88: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 25 Electrical Sub Panel Layout for OPTIONAL High Profile Turntable...

Page 89: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 26 Electrical Sensors Layout 27 30 32 28 32 31 34 28 29...

Page 90: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 27 Electrical Sensors Layout for OPTIONAL High Profile Turntable...

Page 91: ...NSFORMER TR 80VA 1 15 403172 CONTACTOR 2 16 403561 BREAKER C60A2PC16A 1 17 400658 FILM FEED CONTROLLER 1 18 500080 KEY FOR SAFETY SWITCH 1 19 403481 AC DRIVE HP HITACHI 3 20 403103 PLC A B MICROLOGIX...

Page 92: ...URNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VI 29 35 400608 GREEN LAMP 916L DC24V 2 36 403559 BREAKER C60N1PC2A 1 37 403560 RELAY...

Page 93: ...VII Chapter 7 is here HIGHLIGHT INDUSTRIES INC Predator XS Turntable Stretch Wrapper Operation Manual Part List Chapter 7...

Page 94: ...RETCH PROX 1 700060 T T CAM FOLLOWER ASS Y 6 408117 DANCER BAR POTENTIOMETER 1 400637 CARRIAGE SAFETY LIMIT SWITCH 1 400639 CARR UPPER LOWER LIMIT SWITCH 1 300719 AUTO PUNCTURE SOLENOID 1 400643 LOAD...

Page 95: ...VIII Chapter 8 title HIGHLIGHT INDUSTRIES INC Predator XS Turntable Stretch Wrapper Operation Manual Notes Chapter 8...

Page 96: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VIII 1...

Page 97: ...PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL HIGHLIGHT INDUSTRIES INC 2694 PRAIRIE SW WYOMING MI 49519 1 800 531 2465 VIII 2...

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