Highlight Predator SS Operation Manual
Operation Manual
Predator SS
SIMPLIFIED STRETCH
LOW PROFILE
SERIAL 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 respond to your needs.
OPERATION MANUAL NUMBER: PREDSS_LP / DEC-2017
Predator SS Turntable Stretch Wrapper Operation Manual
Table of Contents
Table of Contents ............................................................................................................. 1
Table of Figures ................................................................................................................ 2
General Information ........................................................................................ 3
Safety Messages .............................................................................................................. 4
Introduction and Warranty ................................................................................................ 6
Revision History ................................................................................................................ 8
Specifications.................................................................................................. 9
Specifications ................................................................................................................. 10
System Overview Prints .................................................................................................. 11
System Description ......................................................................................................... 12
Installation & Adjustments ............................................................................. 13
Machine Placement ........................................................................................................ 14
Machine Set-Up .............................................................................................................. 15
Microprocessor Card ...................................................................................................... 18
Optional Scale Package ................................................................................................. 20
Operation Instructions ................................................................................... 23
Operator Controls ........................................................................................................... 24
Film Loading ................................................................................................................... 27
Machine Operating Instructions ...................................................................................... 29
Maintenance ................................................................................................. 30
Preventative Maintenance .............................................................................................. 31
Maintenance Schedule ................................................................................................... 34
Trouble-shooting ........................................................................................... 35
Self Test Troubleshooting ............................................................................................... 36
Troubleshooting Guide ................................................................................................... 39
Power Problems ............................................................................................................. 40
Turntable Problems ........................................................................................................ 41
Film Carriage Problems .................................................................................................. 42
Technical References ................................................................................... 43
Recommended Spare Parts ........................................................................................... 44
Electrical Drawings ......................................................................................................... 45
Mechanical Drawings...................................................................................................... 50
Notes ............................................................................................................ 64
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 1
Predator SS Turntable Stretch Wrapper Operation Manual
Table of Figures
Figure 1: Predator SS Low Profile Overview Layout .......................................................... 11
Figure 2: Predator SS Low Profile Machine Description..................................................... 12
Figure 3: Bracket in the Shipping Position .......................................................................... 16
Figure 4: Bracket in its Operating Position ......................................................................... 16
Figure 5: Microprocessor Card for the Predator SS ........................................................... 18
Figure 6: Operator Controls Diagram for the Predator SS .................................................. 24
Figure 7: Film Loading/Threading Diagram ........................................................................ 27
Figure 8: Turntable Belt Adjustment ................................................................................... 32
Figure 9: Film Carriage Lift Chain Adjustment .................................................................... 33
Figure 10: Self Test Error Display ...................................................................................... 37
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 2
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Highlight Industries, Inc.
Predator SS Turntable Stretch Wrapper Operation Manual
General
Information
General
Safety Messages
Information Predator SS Turntable Stretch Wrapper Operation Manual
For the best result with the Predator Turntable Stretch Wrapper, carefully read this manual
and all of the warning labels attached to the equipment before installing and operating it,
and follow instructions exactly. Keep this manual for machine 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
the equipment. Read the message and follow the instructions carefully.
Warning!
This symbol indicates a potentially hazardous situation which, if not
avoided, can result to bodily injury, or serious damage to the product.
Notes
This symbol indicates an area or subject of special merit, emphasizing
the equipment’s capabilities, common errors in operation or
maintenance, or other special instructions that can provide benefits to
users.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 4
General
Information Predator SS Turntable Stretch Wrapper Operation Manual
General Precautions – Read These First!
High Voltage!
Disconnect AC input power before checking components, performing
maintenance, cleaning up, and when the machine is not in use. Do NOT
connect or disconnect wires and connectors while power is applied to circuit.
High Voltage!
Wiring work should be carried out only by qualified personnel. Otherwise, there
is a danger of electric shock or fire.
High 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!
Motor control equipment and electronic controllers are connected to hazardous
line voltages. When servicing drives and controllers, there may be exposed
components with housings or protrusions at or above line potential. Extreme
care should be taken to protect against shock.
Warning!
Loose clothing must NOT be worn while the machine is in operation. Stay clear
of moving parts while the machine is running.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 5
General
Introduction and Warranty
Information Predator SS Turntable Stretch Wrapper Operation Manual
Introduction
Thank you for your purchase of a Predator SS Turntable Stretch Wrapper! Designed for the
high volume industrial user the Predator SS will stretch wrap any load to the maximum
stretch level of any film with full independent control of the film force. This allows even light
unstable loads to be wrapped at the lowest possible cost and the maximum load holding
force.
Limited Warranty
Highlight Industries, Inc. warrants its Predator manufactured by it, and sold pursuant to this
order, will be of merchantable quality, free from defects in material and workmanship as
determined at the date of shipment, by generally recognized, applicable and accepted
practices and procedures in the industry, for a period of three (3) years from the Highlight
invoice date, under normal use and service.
When the Purchaser gives Highlight written notice of any alleged defect within the
applicable warranty period, Highlight will, at its option repair or replace the same free of
charge F.O.B. its manufacturing plant, installation not included. Equipment replaced under
the warranty shall have the same warranty as new equipment but does not extend the
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, the equipment involved,
at Highlight’s option.
Highlight neither assumes nor authorizes any person to assume for it any other obligation
in connection with the sale of Highlight’s equipment.
This warranty shall not apply to any equipment which has been repaired or altered by unauthorized personnel in any way so as to, in the judgment of Highlight, affect serviceability,
or which has been subjected to misuse, negligence, accident, or to equipment made by
Highlight which has been operated in a manner contrary to Highlight’s instructions.
In no event regardless of the cause, shall Highlight be liable for penalties or penalty clauses
of any description or any damages resulting from loss of profits, use of products or for any
incidental indirect or consequential damages, even if advised of the possibility of such
damages. This limitation of Highlight’s liability will apply regardless of the form of action,
whether in contract or tort, including negligence. Any action against Highlight must be
brought within twelve (12) months after cause of action accrues.
“This warranty in lieu of all other warranties whether expressed, implied or statutory
including implied warranties of merchantability of fitness or extends only to the buyer or
customer purchasing from Highlight Industries, Inc or an authorized distributor.”
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 6
General
Information Predator SS Turntable Stretch Wrapper Operation Manual
About This Document
The purpose of this manual is to provide you with information necessary to install, operate,
troubleshoot, and maintain the Predator SS Turntable Stretch Wrapper. The audience for
this manual should have basic knowledge of mechanical and electronic components,
standard electrical wiring practices, and schematics symbols.
To guarantee safe operation of the equipment, carefully observe the safety messages
throughout this manual. Keep this operating manual and distribute it to all users for
reference.
Application Assistance
If any assistance is desired, contact the distributor from whom you have purchased the unit,
or call the number listed on the bottom of each page of this manual. To receive quick and
proper technical support for the equipment you have purchased, please be prepared to
provide the following information:
1. Machine Serial Number
2. Date of Purchase
3. Symptoms of any problems
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 7
General
Revision
Revision Comment
Date of Revision
Initial Release
October 2014
Updated load cell part number
Feb 2015-RDU
Updated 110” part numbers
April 2015-RDU
Added summing board cover to scale TT
Jan 2018-RDU
Revision History
Information Predator SS Turntable Stretch Wrapper Operation Manual
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 8
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Highlight Industries, Inc.
Predator SS Turntable Stretch Wrapper Operation Manual
Specifications
Specifications Predator SS Turntable Stretch Wrapper Operation Manual
LOW PROFILE
80” Wrap Height
110” Wrap Height
Length (inch)
98
98
Width (inch)
60
60
Height (inch)
91
132
Turntable Diameter (inch)
60
60
Turntable Height from Floor (inch)
3.25
3.25
Operation Space (inch)
105 x 75 x 120
105 x 75 x 132
Maximum Pallet Size (inch)
52 x 52 x 80
52 x 52 x 110
Shipping Weight (lbs)
1500
1700
Specifications
Machine Dimensions
Electrical Specifications
120VAC, 60Hz, Single Phase, 15Amp
Turntable
4,000 lbs Maximum Turntable Load Capacity
12 RPM Maximum Turntable Speed
20-30 Loads Per Hour
Optional Integrated Scale
Film Carriage
Adjustable Raise and Lower Speeds
Automatic Package Height Detection
Film Delivery
Infinite/Manual Film Force Adjustment
10 Inch Diameter Roll Capacity
20 Inch Height Roll Capacity (30 Inch Optional)
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 10
Specifications Predator SS Turntable Stretch Wrapper Operation Manual
System Overview Prints
Note
Shown below are STANDARD assembly drawings. It may not reflect your
purchased system, especially when optional items are added. Refer to the
Technical References section of the manual for more detailed information.
Figure 1: Predator SS Low Profile Overview Layout
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 11
Specifications Predator SS Turntable Stretch Wrapper Operation Manual
System Description
Figure 2: Predator SS Low Profile Machine Description
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 12
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Highlight Industries, Inc.
Predator SS Turntable Stretch Wrapper Operation Manual
Installation &
Adjustments
Installation & Adjustments Predator SS Turntable Stretch Wrapper Operation Manual
Machine Placement
Receiving and Inspections
The Predator Turntable Stretch Wrapper has gone through quality control tests at the
factory before shipment. Upon receiving, please do the following:
1. Inspect the entire machine for visual damage during shipment. If found, immediately
report this damage to the trucking line. Highlight Industries, Inc. has taken every
precaution during the packaging and loading of this equipment, however, it is YOUR
RESPONSIBILITY to inspect for damage before installation.
2. Make sure the part or serial number indicated on the machine corresponds with the
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 loads. Make sure that there is sufficient room to load/unload the machine and that you
do not stretch the power cable. Remember, you will need to plug the machine in to a
120VAC, 15-Amp outlet.
Floor Weight Bearing/Stress Tolerance
The floor must be able to bear the weight of the machine, the weight of the maximum load,
plus a safety factor. The floor must also be able to tolerate the stress of the machine’s
operation. If the fork trucks will operate on the same weight bearing area, add the weight of
the trucks to the weight bearing stress tolerance requirements.
The Predator can be installed on any type of floor constructions that meets the weight
bearing and stress tolerance requirements.
Warning!
The Predator must be anchored securely to the floor, using the type of anchor
recommended for your floor.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 14
Installation & Adjustments Predator SS Turntable Stretch Wrapper Operation Manual
Machine Set-Up
Unpacking and Moving the Machine
It is very important to read all instructions before undertaking any of these steps. The
following steps should help achieving a safe and quick machine set-up.
1. Place the skidded machine close to the designated wrap area. Remove all shipping
fasteners holding the machine to the pallet. The machine may be crated with the
tower tilted down with the motor cover and carriage removed for shipping purposes.
1.1. Stand up tower, pivoting about the pivot bracket at the base of the tower. Once
upright align 5 bolts at tower base to frame and tighten.
1.2. Remove 4 lower bolts from carriage mount bracket – leave the top 2 bolts loose but
in place. Align keyholes on carriage back over top 2 bolts in carriage mount bracket
and hang carriage. Install and tighten all 6 mounting bolts.
1.3. The carriage photo eye bracket may need to be unbolted from its shipping position
(Figure 3) to its operating position (Figure 4).
1.4. Mount motor cover in place over turntable and carriage lift motors with provided
fasteners.
1.5. Re-connect wiring to carriage if removed for shipping.
2. Place the forks of the forklift through the tubes provided on the base of the machine,
remove the machine from the shipping skids, and place it in the designated wrap
area.
3. If the OPTIONAL ramp (Part Number #600086) is purchased:
Select a ramp position as illustrated below. The ramp can be positioned anywhere in
a 180° rotation around the front of the turntable. There should be ¼” gap between
the turntable and the ramp. The ramp should be fully supported by the floor. Both the
ramp and the machine should be lagged to the floor.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 15
Installation & Adjustments Predator SS Turntable Stretch Wrapper Operation Manual
Figure 3: Bracket in the Shipping Position
Figure 4: Bracket in its Operating Position
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 16
Installation & Adjustments Predator SS Turntable Stretch Wrapper Operation Manual
Warning!
It is very important that the machine be leveled. Uneven floors will cause premature
turntable support roller failure.
Figure 5: Ramp Position for the Predator SS Low Profile
Power and Control Wiring Checks
1. Using a volt meter, check the AC voltage coming to the machine and insure the
proper voltage is present.
2. Make sure the Emergency Stop button on the operator panel is fully pressed in. Turn
the disconnect switch to the ON position. Power should be applied to the drive
board, operating touch-panel, photoelectric sensors, switches, and LED’s.
3. Press the Emergency Stop button. Make sure all machine power is completely
removed when the Emergency Stop button is depressed. Pull the Emergency Stop
button out to resume.
4. Open the electric control box. Make sure all machine power is completely removed
when the electrical control box is open. Close the electrical control box to resume.
5. Trip the carriage foot security bar. Make sure all machine power is completely
removed when the carriage foot security bar is tripped. Clear the bar to resume.
Warning!
Ensure that the Emergency Stop button light is ON when the button is pushed
in and OFF when the button is pulled out.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 17
Installation & Adjustments Predator SS Turntable Stretch Wrapper Operation Manual
Microprocessor Card
Microprocessor Card Description
Figure 5: Microprocessor Card for the Predator SS
S1: Operating voltage selector (220 VAC or 110 VAC)
Connector P1: Turntable/Film Carriage Relay Output
Connector P2: Power Input
Connector P3: Operator Panel Input
Connector P4/P10: Transformer Input/Output
Connector P5: Turntable Proximity Sensor Input
Connector P7: Film Carriage Limit Switches Input
Relay 1: Film Carriage Down
Relay 2: Film Carriage Up
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 18
Installation & Adjustments Predator SS Turntable Stretch Wrapper Operation Manual
Relay 3: Turntable/Film Carriage Stop
Relay 4: Power Input
Relay 5: Turntable Running
Fuse 1: Carriage Motor (5 Amp)
Fuse 2/2A: Power Input (10 Amp)
Fuse 3: Turntable Motor (5 Amp)
Fuse 6: Transformer Input (1 Amp)
Fuse 7: Transformer Output (1 Amp)
LED 1 is ON: Film Carriage Motor fuse is blown
LED 2 is ON: Turntable Motor fuse is blown
LED 3/3A is ON: Power Input fuse is blown
LED 7 is ON: Cycle starts
LED 8 is ON: Film Carriage is moving up
LED 10 is ON: Film Carriage is moving down
LED 11 is ON: Turntable is rotating
LED 15 is ON: Start Button is pushed
LED 16 is ON: Pause Button is pushed
LED 19 is ON: Package Height Photo Sensor is unblocked
LED 23 is ON: Carriage Max Up Limit Switch is not tripped
LED 24 is ON: Carriage Max Down Limit Switch is tripped
LED 25 is ON: Emergency Stop Button is not pushed
LED 26 is ON: Turntable Home/Count proximity switch is blocked
LED 36 is ON: Transformer Input/Output is blown
VR1: Film Carriage Max Speed setting
VR2: Turntable Max Speed setting
Replacing Microprocessor Card
1. Turn the disconnect switch to OFF position.
2. Removed the old microprocessor card by pulling all connectors off and loosening the
four mounting screws.
3. Install the new microprocessor card; connect all connectors and tighten the
mounting screws.
4. Turn the disconnect switch to ON position. The display should show “- -“. If not,
check all connectors and fuses again.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 19
Installation & Adjustments Predator SS Turntable Stretch Wrapper Operation Manual
Optional Scale Package
The optional scale package allows the user to quickly measure the weight of the package
placed on the machine. To operate correctly and efficiently the scale needs to be
configured with the correct settings. Below are the instructions on how to re-configure the
scale and the settings that have been pre-programmed. Re-configuring the scale is not
required unless there is a problem with the existing scale or a new scale is added to the
machine. Refer to the scale manual for more information.
Note
Changing the scale parameters to values other than the Highlight
recommended values may result in poor scale operation.
Navigating the Scale Menu
Step 1: Turn the scale display over so you are looking from above down at the back side of
the scale 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: Looking down at the scale, move the switch under the plate to the right.
Step 4: Turn the scale power back on.
Step 5: Press the “PRINT / >>” button until the desired setting appears on the screen.
Step 6: Press the “ZERO” button to enter the parameter set-up.
Step 7: Press the “PRINT / >>” button until the display reads the correct setting and press
the “SET / NET” button.
Step 8: Turn the power back off, move the switch under the plate to the left, and turn the
power back on.
Step 9: Replace the screws on the back cover and retighten the scale swivel grips on the
side.
Step 10: The scale is now ready to use.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465 20
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