Highlight PREDATOR XS User manual

OPERATION MANUAL
PREDATOR XS
TURNTABLE STRETCH WRAPPER
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: PREDXS-F/ FEB 2008

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
ii
SAFETY MESSAGES
SAFETY MESSAGESSAFETY MESSAGES
SAFETY MESSAGES
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 handy 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 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.

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
iii
General Precautions – Read These First!
HIGH VOLTAGE!
Motor control equipment and electronic controllers are connected to
hazardous line volta
ges. 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.
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!
Disconnect AC input power before checking components, performing
maintenance, cleaning up, and when the machine is not i
n 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.
WARNING
Loose clothing must
NOT be worn while the machine is in operation.
Stay clear of moving parts while the machine is running.

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
iv
INTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
Welcome
Congratulations on your purchase of Predator Turntable Stretch Wrapper! Designed for the high
volume industrial user the Predator 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 un-
authorized 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.”

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
v
About This Document
The purpose of this manual is to provide you with information necessary to install, operate,
troubleshoot and maintain the Predator Turntable Stretch Wrapper. The audience for this manual
should have knowledge of basic mechanical and electronic components, standard electrical wiring
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 and distribute 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 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 problem

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
vi
REVISION HISTORY TABLE
REVISION HISTORY TABLEREVISION HISTORY TABLE
REVISION HISTORY TABLE
No. Revision Comment Date of Issue Operation Manual No.
Initial Release November 2005 PREDXS
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. September 2006 PREDXS-B
3. Revision C
New carriage and turntable design January 2007 PREDXS-C
4. Revision D
New optional height detection method April 2007 PREDXS-D
5. Revision E
Added optional scale package June 2007 PREDXS-E
6. Revision F
Removed Q60 information
Added Ultrasonic information
February 2008 PREDXS-F

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
vii
TABLE OF CONTENTS
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY MESSAGES.........................................................................................................ii
INTRODUCTION................................................................................................................ iv
REVISION HISTORY TABLE............................................................................................. vi
TABLE OF CONTENTS......................................................................................................vii
LIST OF EXHIBITS.............................................................................................................ix
CHAPTER 1: GENERAL SYSTEM INFORMATION
System Specifications..............................................................................................I-1
System Overview Prints …….…………………………………………………….……. 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
Optional Height Detection Sensor…........................................................................II-19
Optional Scale Package...........................................................................................II-20
CHAPTER 3: OPERATIONS INSTRUCTIONS
Operator Controls.................................................................................................... III-1
Film Loading……………………………………………………………………………… III-3
Machine Operation...................................................................................................III-4
CHAPTER 4: MAINTENANCE
Preventive Maintenance.......................................................................................... IV-1
Maintenance Schedule Table.................................................................................. IV-4
CHAPTER 5: TROUBLESHOOTING
Troubleshooting Guide
Power Problem..............................................................................................V-2
Turntable Problem.........................................................................................V-3
Film Carriage Problem.................................................................................. V-5
Film Delivery Problem...................................................................................V-9

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
viii
CHAPTER 6: TECHNICAL REFERENCE
Turntable Frame Assembly......................................................................................VI-1
Turntable Frame Part List........................................................................................ VI-2
Optional High Profile Turntable 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
Control Box Assembly..............................................................................................VI-13
Control Box Part List................................................................................................VI-14
Electrical Schematics...............................................................................................VI-15
AC Frequency Drive Setting.................................................................................... VI-22
Electrical Sub-Panel Layout.....................................................................................VI-24
Electrical Sensors Layout........................................................................................ VI-26
CHAPTER 7: SPARE PARTS LIST
Recommended Spare Parts.....................................................................................VII-1
CHAPTER 8: NOTES

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
ix
LIST OF EXHIBITS
LIST OF EXHIBITSLIST OF EXHIBITS
LIST OF EXHIBITS
Exhibit 1-1: Predator XS Low Profile Overview Layout……………............………….......…I-3
Exhibit 1-2: Predator XS High Profile Overview Layout ………………………….............… I-4
Exhibit 1-3: Predator XS Low Profile Machine Description …..……............…………….… I-5
Exhibit 2-1: Ramp Positioning for Predator XS Low Profile….…………..…..........…...……II-2
Exhibit 2-2: Pre-Stretch Percentage Gear Set Swap……...……...……………..…..........…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: Description of Cutler Hammer AC Drive Digital Keypad …..........……………. II-11
Exhibit 2-7: Explanation of the LED Indicator on Cutler Hammer AC Drive……............….II-11
Exhibit 2-8: Schematic of the Film Feed Controller Card....................................................II-16
Exhibit 2-9: Description of the Film Feed Controller Card………………...………………….II-17
Exhibit 2-10: Recommended Settings for the Film Feed Controller Card Trim Pots ……..II-18
Exhibit 3-1: Film Threading Diagram ………..……………...........…..………………………. III-3
Exhibit 4-1: Turntable Belt Adjustment …...……..…………....……………………...........….IV-1
Exhibit 4-2: Film Carriage Lift Chain Adjustment …...……..………………...…………....….IV-3

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

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
I 1
SYSTEM SPECIFICATIONS
SYSTEM SPECIFICATIONSSYSTEM SPECIFICATIONS
SYSTEM SPECIFICATIONS
Machine Dimensions
Low Profile High Profile
Length (inch) 116 121
Width (inch) 65 88
Height (inch) 92 93
Turntable Diameter (inch) 65 48 Octagon
(58 Diagonal)
Turntable Height from Floor (inch) 3 ¼ 13 ½
Wrapping Height (inch) 80 70
Operation Space (inch) 125 x 70 x 100
Maximum Load Size (inch) 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 disconnect switch
•JIC wiring standard
•Programmable Logic Controller (PLC) with input/output diagnostic lights
Turntable System
•Low Profile: ½ HP 3-phase AC motor, ½ HP AC frequency drive
•High Profile: ¾ or 1 HP 3-phase AC motor, 1 HP AC frequency drive
•20-30 loads per hour (spiral)
•12 RPM turntable maximum speed
•4,000 lbs turntable maximum load capacity
Film Carriage/Elevator System
•½ HP 3-phase AC motor, ½ HP AC frequency drive
•Adjustable raise and lower speeds
•Automatic height detection photoelectric sensor

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
I 2
Film Delivery System
•¼ HP 3-phase AC motor, ½ HP AC frequency drive
•Adjustable 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 Drive Gear 17
301340 Lower Fixed Gear 46
301341 Upper Fixed Gear 42
301342 Slip Gear 46/42
NOTE
Actual measured pre-stretch level may vary depending on film type
(thickness) and film force applied to the load.

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
I 3
SYSTEM
SYSTEMSYSTEM
SYSTEM OVERVIEW PRINT
OVERVIEW PRINT OVERVIEW PRINT
OVERVIEW PRINTS
SS
S
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.

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

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
I 5
SYSTEM DESC
SYSTEM DESCSYSTEM DESC
SYSTEM DESCRIPTION
RIPTIONRIPTION
RIPTION
Shown below is the machine description.
Exhibit 1-3: Predator XS Low Profile Machine Description
Tower
Control Box
Stretch Selector
Cover
Photo Sensor
Film Carriage
Foot Security Pan
Auto Film Cut
Solenoid
Motor Cover
Frame
Turntable

II. Chapter 2
HIGHLIGHT INDUSTRIES, INC.
Predator XS Turntable Stretch Wrapper Operation Manual
Installation &
Adjustments
Chapter
2

PREDATOR XS TURNTABLE STRETCH WRAPPER OPERATION MANUAL
HIGHLIGHT INDUSTRIES, INC. ● 2694 PRAIRIE SW; WYOMING; MI 49519 ● 1 800 531 2465
II 1
MACHINE PLACEMENT
MACHINE PLACEMENTMACHINE PLACEMENT
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 truck 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
pallet loads. Make sure that there is sufficient room to load/unload the machine and that you do
not stretch the wiring cable. Remember, you will need to provide electrical service to a 120 VAC,
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.