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1. Standard percentages are 200 low and 250 FON Relg high High Ratio O Safety Lock Low Ratio PAGE 4 OF 17 0411 IH 2957 FREQUENCY DRIVE An electronic frequency motor drive is a device that controls the 3 phase AC induction motor s speed by varying the frequency of the power sent to the motor The Predator Turntable Stretch Wrapper uses Schneider Electrical Altivar 12 Adjustable Frequency Drives ALTIVAR 12 DIGITAL KEYPAD DESCRIPTION The digital keypad includes the displays panel and the keypad The display panel provides the parameter display and shows the operation status of the AC drive The keypad provides programming and control interface DESCRIPTION 1 Value LED a b 2 Charge LED 3 Unit LED c 4 ESC button Exits a menu or parameter or aborts the displayed value to return to the previous value in the memory 5 STOP button Stops the motor could be hidden by door if function disabled Important See instructions for RUN STOP cover removal 6 RUN button Starts running if the function is configured could be hidden by door if function disabled 7 Jog dial For navigation when turned clockwise or counterclockwise and selection validation when pushed 8 MODE button Switches between the control programming modes The MODE button is only accessible with the HMI door open 9 CONFIGURATION mode LED b 10 MONITORING mode LED 11 REFERENCE mode L
2. FREQUENCY DRIVE CONTINUED PROGRAMMABLE FUNCTIONS factory settings Some of the most commonly adjusted programmable functions parameters are listed below All functions have been Highlight factory set and tested The factory settings listed in this manual are the drive manufacturer s factory setting not the Highlight Industries factory settings Refer to the Electrical explanations Schematic Drive Parameters page for the Highlight Cs NOTE Refer to the manufacturer s operation manual or website for complete lists and O MENU CODE SUB NAME DESCRIPTION FACTORY CODE SETTING tCC Type of Control 2C 2C 2 wire control 3C 3 wire control All Allt Analog Input 1 Type 5U 5U 0 5VDC input voltage 10U 0 10VDC input voltage OA 0 20mA current input rl Relay Output 1 Assignment FLt nO Not assigned FLt No error detected rUn Drive run AO1 AO1 Analog Output 1 Assignment nO nO Not Assigned OCr Motor current OFr Output Frequency AOlt Analog Output 1 Type 0A 10U 0 10VDC OA 0 20mA 4A 4 20mA drC MENU CODE SUB NAME DESCRIPTION ADJUSTMENT FACTORY CODE RANGE SETTING bFr Standard Motor Frequency 50 60 50Hz nPr Rated Motor Power of drive rated HP 0 5 1 2 1 Uns Rated Motor Voltage 100 480V 230V nCr Rated Motor Current plate Varies FrS Rated Motor Frequency 10 400Hz 50 Hz nsP Rated Motor Speed 0 24000rpM
3. N A Film Delivery Reducer Sealed lubricated with premium lubricant No maintenance required N A All Pivot Bearings N A N A cs NOTE Refer to electrical and mechanical component s operations manuals shipped inside the enclosure for additional maintenance information TROUBLESHOOTING WARNING Make sure that only qualified Gror personnel will perform inspection troubleshooting and part replacement HIGH VOLTAGE Disconnect all power including external control power that may be present before servicing the frequency drive controllers WAIT for 3 three minutes for the DC bus capacitors to discharge The frequency drive controller display and or LED s are not accurate This section will guide you in identifying typical problems while operating the Predator Turntable Stretch Wrapper and provide you with corresponding solution s If further assistance is required call the number listed on the indicators of the absence of DC bus voltage Machine not powering on Turntable is malfunctioning PAGE 15 OF 17 last page of this manual To receive quick and proper technical support please be prepared to provide the following information 1 Machine serial number 2 Date of purchase 3 Symptoms of any problem OPERATING ISSUE CAUSES RECOMMENDATIONS The electrical control box is not closed The film carriage loading door is not closed The film carriage foot safety switch is not clear The system is not p
4. on as the turntable passes the home position If not clear obstructions and adjust sensor fo pick up target Now does the indicator light turn on The film carriage dancer bar limit switch is not positioned correctly The indicator light does not turn on as the dancer bar is pulled The LED display is not on the film delivery frequency drive The frequency drive is not functioning Push the STOP button Wait 60 seconds and then pull the button out Is the fault cleared The frequency drive is not connected properly to the motor The parameters of the frequency drive are not correct The film delivery motor is not running None of the recommendations work Restore drive parameter setting Tighten power wiring the sensor replace if necessary Adjust potentiometer towards 100 to set speed Tighten wiring replace dial if necessary Remove obstruction and or clean limit switch head Tighten or replace limit switch as necessary Switch the film carriage circuit breaker on Refer to frequency drive manual for specific fault Tighten or replace wiring as necessary Restore drive parameters setting Check film carriage motor for mechanical restrictions Replace film carriage frequency drive Adjust the sensitivity of the sensor Tighten power wiring to the sensor replace if necessary Tighten power wiring to the sensor replace if necessary Adjust the sensitivity of the sensor Tighten pow
5. to ground if several motors are connected in parallel SEF Y IGBT short circuit e Internal power component short circuit detected e Contact your local Schneider Electric at power on representative SOF Overspeed e Instability e Check the motor e Overspeed associated with the inertia of the e Overspeed is 10 more than Maximum application Frequency amp Fr so adjust this parameter if necessary Add a braking resistor e Check the size of the motor drive load e Check parameters of the speed loop gain and stability PAGE 9 OF 17 0411 IH 2957 FREQUENCY DRIVE CONTINUED At drive power on only the supply is 10 over the maximum acceptable voltage level Power with no run order 20 over the maximum line supply e Disturbed line supply CODE NAME POSSIBLE CAUSES REMEDY EnF Auto tuning e Motor not connected to the drive e Check that the motor drive are compatible One motor phase loss e Check that the motor is present during auto tuning e Special motor e If an output contactor is being used close it e Motor is rotating being driven by the load for during auto tuning example Check that the motor is completely stopped LFF Al current lost fault Detection if e Check the terminal connection e Analog input All is configured as current All current scaling parameter of 0 Eri is greater than 3 mA e Analog input current is lower than 2 mA OOF Overbraking e Braking too sudden or driving loa
6. A SEATTLE 1 800 295 5510 PAGE 17 OF 17 uline com 0411 IH 2957
7. ED 12 Four 7 segment displays q If illuminated indicates that a value is displayed for example 0 5 is displayed for 0 5 b When changing a value the configuration mode LED and the value LED are on steady c If illuminated indicates that a unit is displayed for example AMP is displayed for Amps PAGE 5 OF 17 0411 IH 2957 FREQUENCY DRIVE CONTINUED MENU STRUCTURE To access the complete set of drive parameters first rer press the wheel to access different modes Using the To access the monitoring parameters press the wheel wheel scroll fo COnF and press the wheel again this on the face of the frequency drive Using the wheel will access different sets of parameters Using the wheel scroll through the list until the display shows Non Mon scroll fo FULL and press the wheel this will give the user for monitoring mode This gives the user access fo all the access to the complete parameter set monitoring parameters em K R ry ENT ED MONITORING PARAMETERS CODE NAME DESCRIPTION UNIT LFr External Reference Value Hz External keypad or local force mode configured Forced local reference FLOC set to LCC and forced local assignment FLO different to nO Displays the speed reference coming from the remote keypad This value is not visible in factory setting rFr Output Frequency Hz This function provides the estimated motor speed It corresponds to the estimated m
8. FORCEMENT WRAPS Automatic operation can be paused in order to apply reinforcement wraps to an additional top sheet or corner boards on the product Follow the procedure below 1 Press the Start button as normal to initiate cycle 2 As the carriage travels up switch the Turntable selector from Auto to Manual Both the turntable and the film carriage will pause 3 Apply the top sheet or corner boards to the product 4 Press the Start button to resume cycle Leave the Turntable selector switch in Manual position The turntable will now rotate 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 automatic operation If the Turntable selector is switched from Auto to Manual while the carriage is traveling down the carriage will travel back up and apply the top wraps before completing the wrap cycle This to ensure the top sheet applied during the manual operation is properly wrapped into the product AUTOMATIC FILM CUT The automatic film cut feature is always enabled in the automatic mode On the last wrap revolution the puncture solenoid located on the film carriage engages tearing a small hole in the film The powered film feed motor stops to allow the film force to load to increase the turntable rotates to its home position The punctured film is stretched u
9. MN H 2957 AUTOMATIC STRETCH WRAP DISPENSER uline com 1 800 295 5510 SYSTEM SPECIFICATIONS MACHINE DIMENSIONS Length 116 Width 65 Height 92 Turntable Diameter 65 Turntable Height from Floor 3 1 4 Wrapping Height 80 Operation Space 125 x 70 x 100 Maximum Load Size 56 X 56 x 80 Approximate Shipping Weight 1220 Ibs ELECTRICAL SPECIFICATIONS e 120 VAC 60 Hz Single phase 15 AMP NEMA 12 rated electrical panel e Operating temperature 32 F to 110 F e Lockable disconnect switch e NEC wiring standard e Programmable Logic Controller PLC with input output diagnostic lights TURNTABLE SYSTEM e Low Profile 2 HP 3 phase AC motor 2 HP AC frequency drive e 20 30 loads per hour spiral e 12 RPM turntable maximum speed e 4 000 Ibs turntable maximum load capacity FILM CARRIAGE ELEVATOR SYSTEM e 1 2 HP 3 phase AC motor 12 HP AC frequency drive PAGE 1 OF 17 e Adjustable raise and lower speeds e Automatic height detection photoelectric sensor FILM DELIVERY SYSTEM e 14 HP 3 phase AC motor 12 HP AC frequency drive e Adjustable film force e 200 250 average pre stretch level e 10 diameter roll capacity e 20 height roll capacity i CAUTION Motor control equipment and electronic controllers are connected to hazardous line voltages When servicing drive and controllers there may b
10. Varies tFr Maximum Frequency 10 400Hz 72 Hz Ctt Motor Control Type Std PErF Performance Sensorless Vector Std Standard Volts Heriz PUNP Pump low torque UFr IR Compensation 25 200 100 Optimizes torque at very low speeds SLP Slip Compensation 0 150 100 StA Frequency Loop Stability Adjusts overshoots and oscillations at the end of 0 100 20 acceleration or deceleration A higher number decreases oscillations FLG Frequency Loop Gain Adjusts the slope of the speed increase A lower number 0 100 20 decreases oscillations tUn Motor Auto Tuning Automatically tunes the drive to the motor profile nO YES dOnE no PAGE 7 OF 17 0411 IH 2957 FREQUENCY DRIVE CONTINUED CtL MENU CODE SUB NAME DESCRIPTION FACTORY CODE SETTING Fri Speed Reference Channel 1 All All Terminal analog input LCC Remote Display Ndb Modbus AIUI Jog dial wheel on drive CHCF Channel Configuration SIM SIN Not separate mode Speed and run commands from the same source SEP Separate mode Speed and run commands from different sources Cdl Command Channel 1 run fwd rev stop tEr Only appears if CHCF is set to SEP tEr terminals LOC Local LCC Remote display Ndb Modbut FUn MENU CODE SUB NAME DESCRIPTION ADJUSTMENT FACTORY CODE RANGE SETTING rPt ACC Acceleration Time seconds 0 0 999 9 s 3 05 dEC Deceleration Time seconds 0 0 999 9 s 3 05 brA Decel Ramp Adapiation Assignmen
11. al determines the speed of the turntable in both automatic and manual modes Turn clockwise to increase counter clockwise 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 increase counter clockwise to decrease The best product wrapping and proper dancer bar response is achieved when the dancer bar is set to between half and two thirds of its full extension This gives the proper force to load setting and allows a good proportion of the spring return travel on the dancer bar to be used when the turntable slows down at the end of cycle STOP The STOP button cuts machine operation and removes power to frequency drives In the event this button is pressed during the course of operation it is necessary to pull this button fully out to reset the machine WARNING If the STOP button is depressed while the turntable is rotating the turntable will NOT stop immediately but rather it will coast and decelerate to a stop POWER INDICATOR LIGHT The LED indicates that power is supplied to the machine 0411 IH 2957 MACHINE OPERATION FILM LOADING Follow procedure below to thread film onto the 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 t
12. bar to resume PLC S INPUT MODULE CHECKS 1 Open the electrical control box and insert the key latch onto the safety door switch 2 Depress push buttons and activate selector switches on the operator panel check for each corresponding input lights on the front face of PLC 3 Block the Product Height Detection photoelectric sensor located on the film carriage check for corresponding input light on the front face of PLC 4 Trigger magnetic proximity and limit switch sensors check each corresponding input lights on the front face of the PLC WARNING Do NOT remove or modify the fixed Gror upper and lower limit switch stops 5 Remove the key latch and close the electrical control box to resume 0411 IH 2957 PRE STRETCH ADJUSTMENT PRE STRETCH PERCENTAGE CHANGE 4 To ensure safety and correct operation of the stretch gears check the following items To change the pre stretch percentage follow the procedure below a The safety line is back to its home position following the profile of the knob 1 Turn the main disconnect switch off fety Li 2 Remove the knob cover on the film carriage saline 3 aS a xN Safety Lock P7 b The light indicates the selected pre stretch percentage 3 Push the safety lock and slide the knob to change the pre stretch percentage Lift the knob for the high percentage or lower the knob for low percentage
13. d too high e Increase the deceleration time e Install a module unit with a braking resistor if necessary e Check the line supply voltage to be sure that it is under the maximum acceptable 20 over maximum line supply during run status DHF Drive overheat e Drive temperature too high e Check the motor load the drive ventilation and the ambient temperature Wait for the drive to cool down before restarting See mounting and temperature conditions OEC Process overload e Process overload e Check the process and the parameters of the drive to be in phase OLF Motor overload Triggered by excessive motor current e Check the setting of the motor thermal protection check the motor load OPF 1 output phase loss e Loss of one phase at drive output e Check the connections from the drive to the motor e In case of using downstream contactor check the right connection cable and contactor OPF 2 3 output phase loss e Motor not connected e Check the connections from the drive to the motor Motor power too low below 6 of the drive nominal current e Test on a low power motor or without a motor In factory settings mode motor phase loss e Output contactor open detection is active Output Phase loss detection a GPL yES To check the drive in a test or e Instantaneous instability in the motor current p maintenance environment without having to use a motor with the same rating as the drive deactivate motor phase loss detection Output Phase loss
14. detection GPL nf e Check and optimize the following parameter IR compensation law U F UFr Rated motor voltage UnS and Rated motor current nEr and perform an Auto tuning Etn OSF Main overvoltage e Line voltage too high e Check the line voltage PAGE 10 OF 17 0411 IH 2957 FREQUENCY DRIVE CONTINUED CODE NAME POSSIBLE CAUSES REMEDY PHE Input phase loss e Drive incorrectly supplied or a fuse blown e Check the power connection and the fuses e Failure of one phase e Use a 3 phase line supply e 3 phase ATV12 used on a single phase line supply e Disable the fault by setting Input Phase loss detection PL n Unbalanced load e This protection only operates with the drive on load Cr S Load short circuit e Short circuit at drive output e Check the cables connecting the drive to the motor and the motor s insulation e Short circuit detection at the run order or DC injection order if parameter IGBT test SE is set to YES SLF i Modbus e Interruption in communication on the Modbus e Check the connections of communication bus communication network Check the time out Modbus time out 2 parameter e Refer to the Modbus user manual SLF 2 SoMove e Fault communicating with SoMove e Check the SoMove connection cable communication e Check the time out SLF FZ HMI communication e Fault communicating with the external display e Check the terminal connection terminal ULF Process underload e Process underl
15. e checked by pulling the chain taut and having 3 8 slack 6 Check for loose electrical connections and for frayed cords and cables Replace immediately any damaged cords and cables PAGE 14 OF 17 TURNTABLE BELT ADJUSTMENT Refer to figure below to adjust the turntable belt First loosen the four motor flange M10 screws Turn the M10 bolt on the adjuster tab until the belt is tensioned Retighten the four motor flange screws FILM CARRIAGE LIFT CHAIN ADJUSTMENT Refer to figure below to adjust the film carriage lift chain First loosen nut M12 on the adjustment bracket Turn the bottom bolt until desired tension is achieved Retighten nut M12 Note that the driving chain and adjustment bracket should be parallel with the moveable pulley base o EREDE Qe De Qe Ds an 7 ips 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 premature sprocket failure Any general purpose chain lube should be sufficient for lubrication Replace chain guards when preventative maintenance is complete 0411 IH 2957 MAINTENANCE SCHEDULE TABLE PART SCHEDULE 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
16. e exposed components with housings or protrusions at or above line potential Extreme care should be taken to protect against shock 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 Disconnect AC input power before checking componenis 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 Wiring work should be carried out only by qualified personnel There is a danger of electric shock or fire WARNING Loose clothing must NOT be worn Gror while the machine is in operation Stay clear of moving parts while the machine is running 0411 IH 2957 SYSTEM DESCRIPTION Tower Photo Sensor E Motor Cover lt Turntable cs 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 92 Machine Height 3 25 80 Wrapping Height PAGE 2 OF 17 ezIS e qojuN 99 Control Box Stretch Selector Cover Film Carriage Foot Security Pan Auto Film Cut Sol
17. enoid 101 5 Machine Length 35 5 12 5 2 i Hel pa lt 0411 IH 2957 SYSTEM SET UP MACHINE PLACEMENT Place the Automatic Stretch Wrap Machine 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 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 WARNING The Stretch Wrap Machine must be Gror anchored securely to the floor using the type of anchor recommended for your floor MACHINE SET UP 1 Place 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 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
18. er wiring to the sensor replace if necessary Adjust the switch so that it activates when the dancer bar is pulled Tighten siring to the sensor replace if necessary Switch the circuit breaker on Refer to frequency drive manufacturers manual for specific fault Tighten or replace wiring as necessary Restore drive parameters setting Check film carriage motor for mechanical restrictions Replace if necessary Replace film delivery frequency drive 0411 IH 2957 TROUBLESHOOTING CONTINUED The film does not stay The film is not threaded correctly Refer to film loading diagram attached to the product at start The film is not in good condition Use proper film The acceleration parameter on the film delivery frequency Restore parameters as listed on the electrical drive is not set properly schematics The acceleration parameter on the turntable frequency Restore parameters as listed on the electrical drive is not set properly schematics The film does not stay The film is not threaded correctly Refer to film loading diagram attached to the product in a wrapping cycle The film is not in good condition Use proper film The Film Force dial on the operator panel is not set Make a small adjustment at a time to set the correctly film force Resistance of potentiometer not equal to 5KO across Tighten wiring replace dial if necessary MAN CHICAGO ATLANTA DALLAS LOS ANGELES MINNEAPOLIS NYC PHIL
19. hrough the rollers 4 Close the film carriage and rotate the handle in the opposite direction to lock 5 Attach the film securely to the pallet Tying the end of the film in a knot often helps to secure the film to the pallet a N e Film Ty Sek S y X eS a l Security Door NORMAL SYSTEM START UP After the machine has been positioned and supplied with proper voltage you are ready to begin operation Read thoroughly and follow these steps to operate your system 1 Place product on the turntable 2 Make sure the turntable is at home position 3 Make sure the film carriage is situated at the max 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 Turntable and Film Carriage selector switches to Auto position 8 Press the Start button to initiate cycle PAGE 13 OF 17 STOP CONDITION Follow procedure below in the event of emergency Press the STOP button This cancels the current wrapping cycle and immediately stops the system 2 Correct the problem 3 Pull the STOP button out and then perform normal system start up procedure Co NOTE After pressing the E STOP button wait for at least 60 sixty seconds before pulling the button back out This will allow the frequency drives to completely go off APPLYING REIN
20. it at the designated wrap area 3 If the optional ramp H 2958 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 a ya 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 fo the floor y4 Gap m a i PAGE 3 OF 17 POWER AND SAFETY WIRING CHECKS 1 Using a voltage meter check the AC voltage coming to the system to insure proper voltage is present 2 Make sure the E STOP button is pressed in Turn the disconnect switch to ON position 3 Pull the E STOP button on the operator panel out Power should be applied to the frequency drives operating touch panel photoelectric sensors switches and LED s 4 Press the E STOP button Make sure all machine power is completely removed when the E STOP is depressed Pull the E STOP button out to resume 5 Open the film carriage door Make sure all machine power is completely removed when the carriage door is open Close the film carriage door to resume 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 security bar Make sure all machine power is completely removed when the carriage foot security bar is tripped Clear the
21. lugged into a 120VAC outlet Use a voltmeter to test supply voltage from the plant s outlet Is it reading 120VAC Use a voltmeter to test supply voltage from the plant s outlet Does it have continuity Turntable speed potentiometer dial not set high enough Resistance of potentiometer not equal to 5KQ across Is the LED display on the turntable frequency drive The frequency drive is not functioning Push the STOP button Wait 60 seconds and then pull the button out Is the fault cleared The frequency drive is not connected properly to motor The parameters of the frequency drive are not set correctly The turntable motor is not running None of the recommendations work Close the control box properly Close the carriage door properly Remove obstruction from the switch Plug machine into a 120VAC outlet Plug machine into a 120VAC outlet Replace the power cord to the machine Adjust potentiometer towards 100 to set speed Tighten wiring replace dial if necessary Check and switch on main circuit breaker Refer to frequency drive manual for specific fault Tighten or replace wiring as necessary Restore drive parameters setting Check turntable motor for mechanical restrictions Replace turntable frequency drive 0411 IH 2957 TROUBLESHOOTING CONTINUED Turntable does not stop at home Film carriage does not move The carriage does not raise in a wrapping cycle The carriage does
22. nction inactive YES Automatic drive restart after fault condition no tAr Max automatic restart time 5 min FLr Flying Restart Catch on the fly Restarts the motor at the estimated speed the motor is already going nO Function inactive YES Function active no tHt ItH Motor Thermal Current varies FAULT DETECTION The AC drive has a comprehensive fault diagnostic system that includes several different alarms and fault messages Once a fault is detected the corresponding protective functions will be activated The following faults are displayed as shown on the AC drive digifal keypad display NOTE Not all faults can be cleared by resetting at the keypad CODE NAME POSSIBLE CAUSES REMEDY GCF Overcurrent Parameters in the Motor Control Menu drl are Check the parameters nolconge e Check the size of the motor drive load Inertia orloadtoo high e Check the state of the mechanism Mechanical locking e Connect line motor chokes Reduce the Switching Frequency SFr e Check the ground connection of drive motor cable and motor insulation SEF Motor short circuit e Short circuit or grounding at the drive output e Check the cables connecting the drive to the motor and the motor insulation e Ground fault during running status ircui e Connect motor chokes SCF 3 Ground shori cirat e Commutation of motors during running status e Significant current leakage
23. not stop at the top of product in a wrapping cycle The carriage does not lower after the completion of top wraps count The film mandrel does not rotate PAGE 16 OF 17 Are the parameters of the frequency drive set properly Does the indicator light of the turntable home proximity switch turn on when the table is at home position If not clear obstructions and adjust sensor to pick up target Now does the indicator light turn on Film carriage speed is not set high enough Resistance of potentiometer not equal to 5KO across The carriage limit switch lever arm does not move freely The limit switch is not wired properly The LED display is not on the film carriage frequency drive The frequency drive is not functioning Push the STOP button Wait 60 seconds and then pull the button out Is the fault cleared The frequency drive is not connected properly to motor The parameters of the frequency drive are not set correctly The film carriage motor is not running None of the recommendations work The product height detection photoelectric sensor does not see the product The indicator light does not turn on as the turntable passes the home position If not clear obstructions and adjust sensor fo pick up target Now does the indicator light turn on The film carriage product height detection photo sensor does not have power The sensor sees objects other than the product The indicator light does not turn
24. ntil eventually cut 0411 IH 2957 MAINTENANCE As with all machinery proper attention and maintenance is the key to long component life maximum performance and safe operation By spending a few minutes reading and following these preventive measures you should reduce the downtime and prolong the life of your system It is important to understand that these maintenance schedules are minimum recommendations Anyone who maintains or services a stretch wrap machine must first satisfy himself herself as to the schedules of preventive maintenance based on cycling operation and environmental locations WARNING All maintenance operations require Gror the equipment to be powered down and locked out for personnel safety LOCK OUT TAG OUT PROCEDURES Be sure that anyone performing any type of maintenance on this equipment is familiar with and is adhering to the lock out tag out procedures set forth by the General OSHA or the State OSHA guidelines VISUAL CHECKS Visual checks should be conducted at least once per month 1 Keep the machine and surrounding area as clean as possible especially near moving components 2 Check for loose hardware especially set screws located in sprocket hubs bearing hubs and flanges 3 Check for oil leaks around the speed reducers Check for dry seals at the bearings Check for chain wear and proper tension on the power roller stretch sprockets The correct amount of chain tension can b
25. oad e Check the process and the parameters of the fault drive to be in phase e Motor current below the application underload threshold LU parameter during a perid set by application underload time delay UL parameter to protect the application EJF IGBT overheat Drive overheated e Check the size of the load motor drive e IGBT internal temperature is too high according Reduce the Switching frequency SFr to ambient temperature and load e Wait for the drive to cool before restarting PAGE 11 OF 17 0411 IH 2957 OPERATOR CONTROLS The operator panel for Predator XS is shown and described as follows START Predatorxs Power Pre Stretch The Start button START initiates all operations in automatic or manual modes When the system is in automatic mode the button LED stays on until the wrapping cycle is complete In manual mode the button LED _ _ flashes until the operation en is stopped WRAP RESET Switch to Reset and press the Start button to clear any operation The film carriage will lower to the bottom limit switch and the turntable will return to its home position TOP WRAPS BOTTOM WRAPS TURNTABLE FAM CARRUAGE TURNTABLE SPEED CARRIAGE SPEED uss er utse eer PLM FORCE gt STOP dai Switch to Up Only to select 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 pr
26. oduct apply top wraps and then stops Press the Start button again to lower the film carriage to the bottom limit switch Switch to Up Down to select automatic double wrap mode Press the Start button to begin cycle The film carriage will begin applying the bottom wraps travel upwards to top of the package apply top wraps and travel downwards to finish cycle TOP WRAPS Switch to the desired number of rotations for applying wraps to the top of the product BOTTOM WRAPS Switch to the desired number of rotations for applying wraps to the bottom of the product PAGE 12 OF 17 TURNTABLE To run an automatic mode switch to Auto and press the Start button To jog the turntable manually switch to Manual and press the Start button To stop the turntable switch to Auto or press the Stop button FILM CARRIAGE To run an automatic mode switch to Auto and press the Start button To raise or lower the film carriage manually switch to Manual Up or Manual Down and press the Start button To stop switch to Auto or press the Stop button TURNTABLE SPEED The Turntable Speed potentiometer dial determines the speed of the turntable in both automatic and manual modes Turn clockwise to increase counter clockwise to decrease Adjusting this will affect the film overlap The maximum turntable speed is 12 rotation per minute RPM CARRIAGE SPEED The Carriage Speed potentiometer di
27. otor frequency on the motor shaft In standard law the output frequency rFr is equal to stator frequency In performance law the output frequency rFr motor speed is equal to the estimated motor speed Range 400 to 400 Hz LCr Motor Current A Estimation of the effective motor current from phase current measurements with an accuracy of 5 During DC injection the current displayed is the maximum value of current injected in the motor ULn Main Voltage A Line voltage from the point of view of the DC bus motor running or stopped CODE NAME DESCRIPTION SEAL Q Product Status This parameter shows the state of the drive and motor roy Q Drive ready run Q Drive running the last six segments to the right of the code also indicate direction and speed EE Q Acceleration the last six segments to the right of the code also indicate direction and speed d amp c Q Deceleration the last six segments to the right of the code also indicate direction and speed Eb Q DC injection braking in progress CEI Q Current limit the four segments located on right down of display are blinking nSt Q Freewheel stop control Gor Q Auto adapted deceleration CLL Q Controlled stop on mains phase loss tun Q Auto tuning in progress FSE Q Faststop nt Q No line power When the control part is energized via the RJ45 connector and there is no power on the main input and no run order is present PAGE 6 OF 17 0411 IH 2957
28. t YES nO Function inactive Used with dynamic braking YES Aufomatically increases the deceleration time to prevent a DC bus overvoltage dYnA Most rapid deceleration possible without a dynamic braking resistor Stt Type of Stop rNP rNP Ramp Stop FSt Fast Stop nSt Freewheel ns Reverse Direction Assignment nO nO Function inactive L1H Input L1 active high L2H Input L2 active high L3H Input L3 active high L4H Input L4 active high AdC Automatic DC Injection YES nO function inactive YES Time limited DC injection Ct Continuous DC injection Automatic DC Injection Current 0 120 if nCr 70 Automatic DC Injection Time seconds 0 1 30 s 0 5 s PSS Second Preset Speed Assignment nO nO Function inactive L1H Input L1 active high L2H Input L2 active high L3H Input L3 active high L4H Input L4 active high Second Preset Speed Reference 0 400 Hz 10 Hz CLI Current Limitation 0 25 1 5 plate varies SPL Low Speed Setting Hz O HSP 0 Hz High Speed Setting Hz LSP tFr 60 Hz PAGE 8 OF 17 0411 IH 2957 FREQUENCY DRIVE CONTINUED FLt MENU CODE SUB CODE NAME DESCRIPTION FACTORY SETTING SF Fault Reset Assignment nO Function inactive L1H Input L1 active high L2H Input L2 active high L3H Input L3 active high L4H Input L4 active high no Atr Atr Automatic Restart nO Fu

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