Operation Manual
SYNERGY 2
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: SYN2STD2013 / APRIL-2013
Synergy 2 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
Dual Power Hydro-Stretch .............................................................................................. 15
Installation & Adjustments ............................................................................. 16
Machine Placement ........................................................................................................ 17
Machine Set-Up .............................................................................................................. 18
Frequency Drive Adjustments......................................................................................... 20
Photo Sensor Adjustment ............................................................................................... 31
Pre-Operation Adjustments ............................................................................................ 35
Dual Power Hydro-Stretch Adjustments ......................................................................... 37
Load Compression Testing ............................................................................................. 39
Optional Scale Package ................................................................................................. 40
Operation Instructions ................................................................................... 43
Operator Controls ........................................................................................................... 44
Wrap Pattern Descriptions .............................................................................................. 46
Film Loading ................................................................................................................... 47
Machine Operating Instructions ...................................................................................... 48
Film Cutting .................................................................................................................... 50
Maintenance ................................................................................................. 51
Preventative Maintenance .............................................................................................. 52
Maintenance Schedule ................................................................................................... 54
Trouble-shooting ........................................................................................... 55
Troubleshooting Guide ................................................................................................... 56
Power Problems ............................................................................................................. 57
Turntable Problems ........................................................................................................ 58
Film Carriage Problems .................................................................................................. 60
Film Delivery Problems ................................................................................................... 62
Technical References ................................................................................... 64
Recommended Spare Parts ........................................................................................... 65
Mechanical Drawings...................................................................................................... 66
Electrical Drawings ......................................................................................................... 74
Notes ............................................................................................................ 83
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Synergy 2 Turntable Stretch Wrapper Operation Manual
Table of Figures
Figure 1: Synergy 2 High Profile, Side View....................................................................... 11
Figure 2: Synergy 2 High Profile, Top View........................................................................ 12
Figure 3: Synergy 2 High Profile, Front View ..................................................................... 12
Figure 4: Synergy 2 Low Profile, Side View ....................................................................... 13
Figure 5: Synergy 2 Low Profile, Top View ........................................................................ 13
Figure 6: Synergy 2 Low Profile, Front View ...................................................................... 14
Figure 7: Dual Power Hydro-Stretch Components ............................................................. 15
Figure 8: Altivar 12 AC Drive Keypad ................................................................................. 20
Figure 9: Photoelectric Sensor, Top View, D.O., Not Sensing, Output ON ........................ 31
Figure 10: Photoelectric Sensor, Top View, D.O., Sensing, Output OFF ........................... 32
Figure 11: Thru Beam Photo Sensing Concept .................................................................. 32
Figure 12: Polarized Retro-Reflective Sensing Concept .................................................... 33
Figure 13: Diffuse Sensing Concept ................................................................................... 33
Figure 14: Ultrasonic Sensing Concept .............................................................................. 34
Figure 15: Product Height Detection Photo Eye Location .................................................. 35
Figure 16: PLC Potentiometer Adjustments ....................................................................... 36
Figure 17: Film Loading/Threading Diagram ...................................................................... 47
Figure 18: Top View of Package, Film Cut Location .......................................................... 50
Figure 19: Side View of Package, Film Tear Angle ............................................................ 50
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Highlight Industries, Inc.
Synergy 2 Turntable Stretch Wrapper Operation Manual
General
Information
General
Information
Synergy 2 Turntable Stretch Wrapper Operation Manual
Safety Messages
For the best result with the Synergy 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
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General
Information
Synergy 2 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
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General
Information
Synergy 2 Turntable Stretch Wrapper Operation Manual
Introduction and Warranty
Introduction
Thank you for your purchase of a Synergy 2 Turntable Stretch Wrapper! Designed for the
high volume industrial user, the Synergy 2 will stretch wrap any load to the maximum
stretch level of any film.
Limited Warranty
Highlight Industries, Inc. warrants its Synergy 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
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General
Information
Synergy 2 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 Synergy 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
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General
Information
Synergy 2 Turntable Stretch Wrapper Operation Manual
Revision History
Revision
1
2
3
Revision Comment
Initial Release
Changed Emergency Stop
Changed Disconnect and Terminal Blocks
UPDATED 20” CARRIAGE DRAWING
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
Date of Revision
April 2011
April 2012
April 2013
4/17/14-RDU
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Highlight Industries, Inc.
Synergy 2 Turntable Stretch Wrapper Operation Manual
Specifications
Specifications
Synergy 2 Turntable Stretch Wrapper Operation Manual
Specifications
Machine Dimensions
Length (inch)
Width (inch)
Height (inch)
Turntable Height from Floor (inch)
Operation Space (inch)
Maximum Pallet Size (inch)
Shipping Weight (lbs)
High Profile
Low Profile
110
116
48.50
60
91
91
13.4
3.8
125 x 70 x 100
50 x 50 x 80
1500
2100
Electrical Specifications






120VAC, 60Hz, Single Phase, 15Amp
NEMA 12 Rated Electrical Enclosure
Lockable Disconnect Switch
Off the Shelf Components
Industrial NEMA 12 Push Buttons
Allen Bradley Micrologix 1200 Programmable Logic Controller (PLC)
Turntable





4,000 lbs Maximum Turntable Load Capacity
12 RPM Maximum Turntable Speed
20-30 Loads Per Hour
¾ HP 3-Phase AC Motor
1 HP AC Frequency Drive
Film Carriage





Dual Belt Lift
Adjustable Raise and Lower Speeds
Automatic Package Height Detection
¾ HP 3-Phase AC Motor
1 HP AC Frequency Drive
Film Delivery





Dual Powered Hydro-Stretch
Adjustable Film Pre-Stretch
240% Average Stretch Level
10 Inch Diameter Roll Capacity
20 Inch Height Roll Capacity (or Optional 30 Inch Height)
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Specifications
Synergy 2 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: Synergy 2 High Profile, Side View
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Specifications
Synergy 2 Turntable Stretch Wrapper Operation Manual
Figure 2: Synergy 2 High Profile, Top View
Figure 3: Synergy 2 High Profile, Front View
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Specifications
Synergy 2 Turntable Stretch Wrapper Operation Manual
Figure 4: Synergy 2 Low Profile, Side View
Figure 5: Synergy 2 Low Profile, Top View
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Specifications
Synergy 2 Turntable Stretch Wrapper Operation Manual
Figure 6: Synergy 2 Low Profile, Front View
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Specifications
Synergy 2 Turntable Stretch Wrapper Operation Manual
Dual Power Hydro-Stretch
Over 70% of film breaks occur at the bottom of the product where the product and pallet
meet. Dual Power Hydro-Stretch®, a feature exclusive to Highlight Industries, Inc provides
two independent levels of pre-stretch: one for the bottom of the product, the other for the
rest of the product. This allows products to be wrapped tighter, at higher stretch levels, and
at lower costs.
Unlimited Film Stretch
Dual Power Hydro-Stretch® has the ability to stretch any gauge or any quality of film to its
ultimate stretch level. The stretch level of the Dual Power Hydro-Stretch® is unlimited
because it is not controlled by gears or pulleys. The flexibility of Dual Power HydroStretch® insures that whatever films are available today or tomorrow can be used to their
maximum efficiency.
Figure 7: Dual Power Hydro-Stretch Components
Film Force Control
The Film Force applied to the product on the Synergy 2 is directly proportional to the
stretch level set on the Hydro-Stretch unit. An increase in the stretch percentage will result
in the increase in force to load.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Highlight Industries, Inc.
Synergy 2 Turntable Stretch Wrapper Operation Manual
Installation &
Adjustments
Installation & Adjustments
Synergy 2 Turntable Stretch Wrapper Operation Manual
Machine Placement
Receiving and Inspections
The Synergy 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 Synergy 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 Synergy can be installed on any type of floor constructions that meets the weight
bearing and stress tolerance requirements.
Warning!
The Synergy 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
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Installation & Adjustments
Synergy 2 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.
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.
Warning!
It is very important that the machine be leveled. Uneven floors will cause
premature turntable support roller failure.
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. Check if the Film Carriage Belt Tension limit switch is properly tripped. This switch is
located under the lift belt in the upper tower enclosure.
3. 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 PLC,
located inside the electrical enclosure, and all sensors.
4. Pull the Emergency Stop button out. Power should now be applied to the AC
frequency drives. Press the Emergency Stop button again and ensure that power to
the Frequency Drives is removed.
Warning!
Ensure that the Emergency Stop button light is ON when the button is pushed
in and OFF when the button is pulled out.
PLC Input Checks
1. Press the Emergency Stop button in to ensure that the machine will not move
unexpectedly. Refer to the electrical schematics in the Technical References section
to correspond buttons and sensors to their designated input numbers.
2. Press each push button and activate each selector switch on the operator panel.
Check each for their corresponding input by looking at the indicator lights on the
front of the PLC.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Synergy 2 Turntable Stretch Wrapper Operation Manual
3. Block the Product Height Detection photo eye located on the side of the Film
Carriage. The input should be ON when the photo eye is NOT blocked and should
turn OFF when the photo eye becomes blocked.
4. Trip the Film Carriage Maximum Up/Down limit switch in both directions. The
corresponding inputs will be ON when the Film Carriage is NOT at an extreme
position, and should turn OFF when the limit switch becomes tripped.
5. Turn the turntable for at least one full revolution. Ensure that the turntable home
sensor input comes on, and that it comes on only once during the revolution. The
input may remain on for up to a quarter turntable revolution.
Warning!
Do NOT remove or modify the fixed upper and lower Film Carriage limit switch
stops.
Manual Function Checks
1. Pull the Emergency Stop button out to restore control power to the machine.
2. Use the selector switch on the operator panel to Raise the Film Carriage. The Film
Carriage should rise only while the switch is being activated and the Film Carriage
should automatically stop once the Film Carriage max up limit switch is tripped.
Adjust the speed of the Film Carriage as the carriage travels up and observe the
change in Film Carriage speed.
3. Use the selector switch on the operator panel to Lower the Film Carriage. The Film
Carriage should lower only while the switch is being activated and the Film Carriage
should automatically stop once the Film Carriage max down limit switch is tripped.
Adjust the speed of the Film Carriage as the carriage travels down and observe the
change in Film Carriage speed.
4. Press and hold the Turntable Jog/Home button. The turntable should rotate in low
speed. Press the Turntable Jog/Home button twice in quick succession. The
turntable should return to its home position and stop.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Installation & Adjustments
Synergy 2 Turntable Stretch Wrapper Operation Manual
Frequency Drive Adjustments
An AC Frequency Drive is a device that controls the 3-phase AC motor’s speed by varying
the frequency and voltage sent to the motor. The Synergy Turntable Stretch Wrapper uses
Schneider Electric Altivar 12 Adjustable Frequency Drives. Refer to the Electrical
Schematic Drive Parameters Technical References section for detailed drive parameter
settings. Refer to the drive manufacturer’s manual for more detailed drive information.
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.
Figure 8: Altivar 12 AC Drive Keypad
Keypad Description:
1. Value LED. When illuminated it indicates when a numeric value is being displayed.
2. Charge LED. When illuminated it indicates when drive capacitors are fully charged.
3. Unit LED. When illuminated it indicates when a unit, such as AMPS, is being
displayed.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Installation & Adjustments
Synergy 2 Turntable Stretch Wrapper Operation Manual
4. ESC button. Exits a menu or parameter, or aborts the displayed value and returns to
the previous value in the memory.
5. STOP button. Stops the motor. The run command will have to be cycled before the
motor will be allowed to run again.
6. RUN button. Starts running the motor if the drive is configured for control by the
drive keypad.
7. Jog Dial. Used for navigation of the menus. Turn clockwise or counterclockwise to
scroll through the menu list and is used for selection/validation when the dial is
pressed.
8. MODE button. Switches between the control/programming modes.
9. CONFIGURATION mode LED. When illuminated it indicates when a value can be
changed.
10. MONITORING mode LED. When illuminated it indicates when the display is
monitoring the current status of the drive.
11. REFERENCE mode LED. When illuminated it indicates when the display is showing
the speed reference value.
12. Four 7-Segment displays. The display of the drive for menus and settings.
Menu Structure
To access the monitoring parameters, press the wheel on the
face of the frequency drive. Using the wheel, scroll through the
menu until the display shows Non (Mon) for monitoring mode.
This gives the user access to all the monitoring parameters.
To access the complete set of drive parameters first press the wheel to access different
modes. Using the wheel, scroll to “COnF” and press the wheel again; this will access
different sets of parameters. Using the wheel, scroll to “FULL” and press the wheel; this will
give the user access to the complete parameter set.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Installation & Adjustments
Synergy 2 Turntable Stretch Wrapper Operation Manual
Monitoring Parameters
Code Name/Description
LFr
External reference value:
Unit
Hz
rFr
External keypad or local force mode configured. Forced local reference
FLOC page 61 set to LCC and Forced local assignment FLO page 61
different to nO.
Displays the speed reference coming from the remote keypad. This
value is not visible in factory setting.
Output Frequency:
Hz
LCr
This function provides the estimated motor speed. It corresponds to the
estimated motor 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
Motor Current:
A
ULn
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.
Main Voltage:
A
StAt
Line voltage from the point of view of the DC bus, motor running or
stopped.
Product Status:
N/A
rdY – Drive Ready
rUn – Drive Running
ACC – Acceleration in progress
dEc – Deceleration in progress
dCb – DC injection braking in progress
CLi – Current limit
nSt – Freewheel stop control
Obr – Auto-Adapted deceleration
CtL – Controlled stop on mains phase loss
tUn – Auto-tuning in progress
FSt – Fast stop active
nLP – No line power
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Installation & Adjustments
Synergy 2 Turntable Stretch Wrapper Operation Manual
Programming Functions
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 Schematic Drive Parameters page of the Technical
References section for the Highlight factory settings. Some of the most commonly adjusted
programmable functions (parameters) are listed below.
Note
Refer to the drive manufacturers Operation Manual or website for complete lists
and explanations of the programming parameters.
I_O Menu
Code SubCode
tCC
Type of Control:
Factory
Setting
2C
2C – 2-wire control
3C – 3-wire control
Analog Input 1 Type:
5U
r1
5U – 0-5VDC input voltage
10U – 0-10VDC input voltage
0A – 0-20mA current input
Relay Output 1 Assignment:
FLt
AO1-
AO1
nO – Not assigned
FLt – No error detected
rUn – Drive run
Analog Output 1 Assignment:
nO
AO1t
nO – Not Assigned
OCr – Motor current
OFr – Output Frequency
Analog Output 1 Type:
0A
AI1-
AI1t
Name/Description
10U – 0-10VDC
0A – 0-20mA
4A – 4-20mA
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Installation & Adjustments
drC Menu
Code SubCode
bFr
nPr
UnS
nCr
FrS
nSP
tFr
Ctt
Synergy 2 Turntable Stretch Wrapper Operation Manual
Name/Description
Adjustment
Range
50/60
0.5-1.2
100-480V
plate
10-400Hz
0-24000rpM
10-400Hz
Factory
Setting
50 Hz
1
230V
Varies
50 Hz
Varies
72 Hz
Std
UFr
PErF – Performance, Sensorless Vector
Std – Standard, Volts/Hertz
PUNP – Pump, low torque
IR Compensation:
25-200%
100%
SLP
StA
Optimizes torque at very low speeds
Slip Compensation
Frequency Loop Stability:
0-150%
0-100%
100%
20%
FLG
Adjusts overshoots and oscillations at the end
of acceleration or deceleration. A higher
number decreases oscillations
Frequency Loop Gain:
0-100%
tUn
Adjusts the slope of the speed increase. A
lower number decreases oscillations.
Motor Auto Tuning:
nO/YES/dOnE nO
Standard Motor Frequency
Rated Motor Power (% of drive rated HP)
Rated Motor Voltage
Rated Motor Current
Rated Motor Frequency
Rated Motor Speed
Maximum Frequency
Motor Control Type:
20%
Automatically tunes the drive to the motor
profile
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Installation & Adjustments
CtL Menu
Code SubCode
Fr1
Synergy 2 Turntable Stretch Wrapper Operation Manual
Name/Description
Speed Reference Channel 1:
Factory
Setting
AI1
CHCF
AI1 – Terminal analog input
LCC – Remote Display
Ndb – Modbus
AIU1 – Jog dial (wheel) on drive
Channel Configuration:
SIM
Cd1
SIN – Not separate mode. Speed and run commands from the
same source.
SEP – Separate mode. Speed and run commands from
different sources.
Command Channel 1 (run fwd/rev, stop):
tEr
Only appears if CHCF is set to SEP.
tEr – terminals
LOC – Local
LCC – Remote display
Ndb – Modbus
FUn Menu
Code SubCode
rPtACC
dEC
brA
Stt-
rrS
Stt
Name/Description
Acceleration Time (seconds)
Deceleration Time (seconds)
Decel Ramp Adaptation Assignment:
Adjustment
Range
0.0-999.9 s
0.0-999.9 s
Factory
Setting
3.0 s
3.0 s
YES
nO – Function inactive. (Used with dynamic
braking)
YES
–
Automatically
increases
the
deceleration time to prevent a DC bus
overvoltage
dYnA – Most rapid deceleration possible
without a dynamic braking resistor.
Type of Stop:
rNP
rNP – Ramp Stop
FSt – Fast Stop
nSt - Freewheel
Reverse Direction Assignment:
nO
nO – Function inactive
L1H – Input L1 active high
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Installation & Adjustments
AdC-
PSS-
CLISPL-
Synergy 2 Turntable Stretch Wrapper Operation Manual
AdC
L2H – Input L2 active high
L3H – Input L3 active high
L4H – Input L4 active high
Automatic DC Injection:
SdC1
tdC1
PS2
nO – function inactive
YES – Time limited DC injection
Ct – Continuous DC injection
Automatic DC Injection Current
Automatic DC Injection Time (seconds)
Second Preset Speed Assignment:
SP2
CL1
LSP
HSP
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
Current Limitation
Low Speed Setting (Hz)
High Speed Setting (Hz)
FLt Menu
Code SubCode
rSF
YES
0-120% if nCr
0.1-30 s
70%
0.5 s
nO
0-400 Hz
0.25-1.5 plate
0-HSP
LSP-tFr
10 Hz
varies
0 Hz
60 Hz
Fault Reset Assignment:
Factory
Setting
nO
nO – Function inactive
L1H – Input L1 active high
L2H – Input L2 active high
L3H – Input L3 active high
L4H – Input L4 active high
Automatic Restart:
nO
FLr
nO – Function inactive
YES – Automatic drive restart after fault condition
Max automatic restart time
Flying Restart (Catch on the fly):
5 min
nO
tHt-
Restarts the motor at the estimated speed the motor is already
going.
nO – Function inactive
YES – Function active
Motor Thermal Current
varies
Atr-
Atr
tAr
ItH
Name/Description
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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 digital keypad
display.
Note
Not all faults can be cleared by resetting from the drive keypad. Some faults
can only be cleared by cycling power on the drive, and some faults cannot be
reset at all.
Code
Name
Possible Cause
Remedy
CrF1
Precharge
Charging relay control fault or
charging resistor damaged
InFI
Unknown drive rating
InF2
Unknown or
incompatible power
board
Internal serial link
The power card is different from the
card stored
The power card is incompatible with
the control card
 Turn the drive off and then back
on again
 Check the connections
 Check the stability of the main
supply
 Contact your local Schneider
Electric
 representative
Contact your local Schneider
Electric representative
Contact your local Schneider
Electric representative
InF3
InF4
InF9
---InFb
Invalid
industrialization zone
Current
measurement circuit
Problem of
application Firmware
Internal thermal
sensor detected fault
InFE
Internal CPU
OCF
Overcurrent
Communication interruption
between the internal cards
Inconsistent internal data
Current measurement is not
correct due to hardware circuit
Invalid application firmware
update using the Multi-Loader tool
 The drive temperature sensor is
not operating correctly
 The drive is in short circuit or
open
Internal microprocessor
 Parameters in the Motor Control
menu (drC) are not set properly
 Inertia or load too high
 Mechanical locking
Contact your local Schneider
Electric representative
Contact your local Schneider
Electric representative
Contact your local Schneider
Electric representative
Flash again the application
firmware of the product
Contact your local Schneider
Electric representative
 Turn the drive off and then back
on again
 Contact your local Schneider
Electric representative
 Check the parameters
 Check the size of the
motor/drive/load
 Check the state of the
mechanism
 Connect line chokes
 Reduce the Switching
Frequencies (SFr)
 Check the ground connection of
drive, motor cable, and motor
insulation
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 Short-circuit or grounding at the
drive output
 Ground fault during running
status
 Commutation of motors during
running status
 Significant current leakage to
ground if several motors are in
parallel
Internal power component short
circuit detected at power on
Instability or over-speed associated
with the inertia of the application
OCF
SCF1
Motor short circuit
Ground short circuit
SCF4
IGBT short circuit
SOF
Over-speed
tnF
Auto-Tuning




LFFI
AI current lost fault
ObF
Over-braking
Detection if:
 Analog input AI1 is configured as
current
 AI1 current scaling parameter of
0% is greater than 3mA
 Analog input current is lower
than 2mA
Braking too sudden or driving load
OHF
Drive overheat
Drive temperature too high
OLC
Process overload
Process overload
OLF
Motor overload
Triggered by excessive motor
current
Motor not connected to the drive
One motor phase loss
Special motor
Motor is rotating
 Check the cables connecting
the drive to the motor, and the
motor insulation
 Connect motor chokes
Contact your local Schneider
Electric representative
 Check the motor
 Over-speed is 10% more than
the maximum frequency (tFr).
Adjust this parameter if
necessary
 Add a braking resistor
 Check the size of the
motor/drive/load
 Check the parameters of the
speed loop (gain and stability)
 Check that the motor/drive are
compatible
 Check that the motor is present
during auto-tuning
 If an output contactor is being
used, close it during auto-tuning
 Check that the motor is
completely stopped
Check the terminal connections
 Increase the deceleration time
 Install a module unit with a
braking resistor if necessary
 Check the line supply voltage to
be sure it is under the maximum
Check the motor load, the drive
ventilation, and the ambient
temperature. Wait for the drive to
cool down before restarting.
Check the process and the
parameters of the drive to be in
phase
Check the setting of the motor
thermal protection, check the
motor load
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OPF1
1 output phase loss
Loss of one phase at drive output
OPF2
3 output phase loss
 Motor not connected
 Motor power too low, below 6%
of the drive nominal current
 Output contactor open
 Instantaneous instability in the
motor current
OSF
Main overvoltage
PHF
Input phase loss
SCF5
Load short circuit
SLF1
Modbus
Communication
 Line voltage too high
 Disturbed line supply
 Drive incorrectly supplied or a
fuse blown
 Failure of one phase
 3-phase ATV12 used on a
single-phase line supply
 Unbalanced load
 This protection only operates
with the drive on load
 Short-circuit at drive output
 Short circuit detection at the run
order or DC injection order if
parameter IGBT test Strt is set
to YES
Interruption in communication on
the Modbus network
SLF2
SoMove
Communication
Communication interruption with
SoMove
SLF3
HMI Communication
Communication interruption with the
external display terminal
 Check the connections from the
drive to the motor
 In case of downstream
contactor, check the right
connection, cable, and contactor
 Check the connections from the
drive to the motor
 Test on a low power motor or
without a motor: In factory
settings mode, motor phase loss
detection is active Output Phase
loss detection OPL = YES to
check the drive in a test or
maintenance environment,
without having to use a motor
with the same rating as the
drive, deactivate motor phase
loss detection Output Phase
loss detection OPL = nO
 Check and optimize the
following parameters: IR
compensation (law U/F) UFr ,
Rated motor voltage UnS and
Rated motor current nCr and
perform an Auto-tuning tUn
Check the line voltage
 Check the power connection
and the fuses.
 Use a 3-phase line supply.
 Disable the fault by setting Input
Phase loss detection IPL
Check the cables connecting the
drive to the motor, and the motor’s
insulation
 Check the connections of
communication bus.
 Check the time-out (Modbus
time out ttO parameter
 Refer to the Modbus user
manual
 Check the SoMove connecting
cable.
 Check the time-out
Check the terminal connection
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SPIF
PI Feedback
detected fault
PID feedback below lower limit
ULF
Process underload
fault
tJF
IGBT overheat
 Process underload
 Motor current below the
Application Underload threshold
LUL parameter during a period
set by Application underload time
delay ULt parameter to protect
the application.
 Drive overheated
 IGBT internal temperature is too
high according to ambient
temperature and load
CFF
Incorrect
configuration
 HMI block replaced by an HMI
block configured on a drive with
a different rating
 The current configuration of
customer parameters is
inconsistent
CFI
Invalid configuration
CHI2
Download invalid
configuration
Invalid configuration
The configuration loaded in the
drive via the bus or communication
network is inconsistent. The
configuration upload has been
interrupted or is not fully finished.
Interruption of download operation
with Loader or SoMove
USF
Undervoltage
 Line supply too low
 Transient voltage dip
 Check the PID function
feedback
 Check the PI feedback
supervision threshold LPI and
time delay tPI
Check the process and the
parameters of the drive to be in
phase
 Check the size of the
load/motor/drive.
 Reduce the Switching frequency
SFr.
 Wait for the drive to cool before
restarting
 Return to factory settings or
retrieve the backup
configuration, if it is valid.
 If the fault remains after
reverting to the factory settings,
contact your local Schneider
Electric representative
 Check the configuration loaded
previously.
 Load a compatible configuration
 Check connection with Loader
or SoMove.
 To reset the default re-start the
download operation or restore
the factory setting
Check the voltage and the
parameters of Undervoltage Phase
Loss Menu USb
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Photo Sensor Adjustment
Basic Description
A photoelectric sensor is an electrical device that responds to a change in the intensity of
light. They look for specific light wave lengths that usually are only present in enough
concentration from a photoelectric light source. This helps reduce false flagging of the
photoelectric sensor from other light sources such as overhead lighting. Common
photoelectric sensors used by Highlight Industries, Inc. include thru-beam (opposed),
polarized retro-reflective, and diffuse.
Highlight Industries, Inc. uses Banner photoelectric sensors. Status indicator LED’s for
Power, Signal, and Output are clearly visible beneath a raised dome in the sensor’s
transparent cover. The Green Power LED indicator is illuminated whenever power is
applied to the sensor. The Red Signal LED illuminates when the sensor sees light and
flashes at a rate corresponding to the strength of the signal received. The faster the light
flashes the stronger signal the photoelectric sensor sees (more light being sensed). The
Amber LED illuminates whenever its output is ON.
Also located beneath the sensor’s cover are controls for light/dark operate and sensitivity
adjustment. A photo eye in Light Operate mode, or L.O., means that the sensors output will
be ON when the sensor sees light. Dark Operate, or D.O., means that the sensors output
will be ON when the sensor does NOT see light. Turn the small potentiometer clockwise to
increase light sensitivity, or turn it counterclockwise to decrease light sensitivity. A higher
sensitivity means that the sensor must see more light before it will detect the light.
To assist the machine with its operation, the photoelectric sensors should be aligned and
adjusted properly. Each photoelectric sensor sends a signal to the Programmable Logic
Controller to indicate its condition/status. Refer to the Electrical Schematics for the
identification, function, and style of each photo sensor.
Figure 9: Photoelectric Sensor, Top View, D.O., Not Sensing, Output ON
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Figure 10: Photoelectric Sensor, Top View, D.O., Sensing, Output OFF
Thru-Beam Sensing Concept
The thru beam sensing concept requires a separate emitter and receiver that are
positioned opposite each other so that the light from the emitter shines directly on the
receiver. An object is sensed when it interrupts the light beam.
Sensor alignment means positioning the sensor(s) so that maximum emitted light reaches
the receiver element. In opposed sensing, the emitter’s light is centered on the receiver’s
field of view. Use the sensor’s Red LED to check for optimal alignment.
Figure 11: Thru Beam Photo Sensing Concept
Polarized Retro-Reflective Sensing Concept
A retro-reflective sensor is a sensor that contains both light emitter and receiver circuitry. Its
emitter sends a light beam to a retro-reflective target, which reflects the light back to the
receiver. As in opposed-mode sensing, an object is sensed when it interrupts the beam.
A polarized photoelectric sensor means that light the sensor sees must be oriented in a
specific direction. The emitted light must then return to the sensor in the same orientation
that it was sent. Usually only a reflector is able to return enough light in the correct
orientation for the sensor to detect it. This makes the polarized sensor more immune to
stray light or from reflections of the emitted light off of other objects. Retro-reflective targets
are usually reflectors with a matrix of tiny corner-cube prisms, each with three mutually
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Synergy 2 Turntable Stretch Wrapper Operation Manual
perpendicular surfaces and a hypotenuse face. A light beam entering a corner-cube prism
through its hypotenuse face is reflected from the three surfaces and emerges back through
the hypotenuse face. The result is a light parallel to the entering beam. In this way, the
retro-reflective target returns the light beam to its surface.
Figure 12: Polarized Retro-Reflective Sensing Concept
Diffuse Sensing Concept
A diffuse type sensor contains both the light emitter and receiver circuitry. An object is
detected when the sensor captures the small percentage of emitted light that is reflected
back to the sensor from the surface of the object itself.
Diffuse mode is dramatically influenced by the reflectivity of the surface being sensed. A
bright white surface will be sensed at a longer range than will a dull black surface. Also,
most diffuse sensors can rely on a returned light signal only if the surface of a shiny target
is perfectly parallel to the sensor lens. This may be impossible with curved targets, such as
shiny cans, and presents a concern when detecting webs of metal foil or poly film where
web “flutter” may occur.
Figure 13: Diffuse Sensing Concept
Ultrasonic Sensing Concept
Ultrasonic sensors emit and receive sound at frequencies above the range of human
hearing (above 20 kHz). They sense objects by measuring the time it takes to reflect the
ultrasonic sound waves from the object’s surface and back to the receiver, or by detecting
an object’s presence when it interrupts the transmission of sound from the emitter to an
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Synergy 2 Turntable Stretch Wrapper Operation Manual
opposed receiver. Unlike infrared photoelectric sensing, which is based on an object’s
opacity or reflectivity to light, ultrasonic sensing depends on object’s density—it’s ability to
reflect or block sound. This makes ultrasonic sensing practical for detection of clear or
black materials and other objects that are difficult to detect with photoelectric sensors.
Figure 14: Ultrasonic Sensing Concept
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Pre-Operation Adjustments
Turntable Speed
The Turntable Speed potentiometer dial is located inside the electrical enclosure. This
controls the wrapping high speed only. Turn clockwise to increase, counter-clockwise to
decrease. Adjusting this will affect the film overlap. It is recommended to adjust this dial
first, before setting the film carriage speed. The maximum turntable speed is 12 rotationsper-minute (RPM).
Product Height Detection
The top of the product is detected using a diffuse photoelectric sensor, or optionally an
ultrasonic sensor. The film coverage over the top of the product provides additional load
security. The amount of top film coverage desired is based on the individual load profile. To
set the top of the product film coverage, simply loosen the knob located underneath the
photo sensor. Sliding the photo sensor assembly down will increase the amount of film
being applied over the top of the product. Whereas, sliding the photo sensor assembly
upwards will decrease the amount of film coverage over the top of the product.
Alternatively the overlap amount can be adjusted by using the first/top small potentiometer
located on the front of the PLC. Turning it clockwise will increase the time delay for the
sensor above product, resulting in more film overlap on top of the product. Turning it
counter-clockwise will decrease the time delay, triggering the film carriage to stop sooner.
This timer is helpful when trying to de-bounce the signal from the photo eye on the
carriage.
Figure 15: Product Height Detection Photo Eye Location
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Figure 16: PLC Potentiometer Adjustments
Turntable Deceleration Delay
At the end of every wrap cycle the turntable must first find its home position, and then starts
a timer in the PLC that delays the turntable from entering low speed before stopping the
turntable at home. If there is excessive turntable travel in low speed, or if the turntable
passes home before finally stopping the Turntable Deceleration Delay may need to be
adjusted. Also, if the turntable speed is changed, the Turntable Deceleration Delay may
also need to be adjusted.
The second/bottom potentiometer, located on the front face of the PLC (see figure above),
can be used to adjust this delay. Turning the potentiometer clockwise will increase the
delay time, making the turntable remain in high speed for a longer amount of time. Turning
the potentiometer counter-clockwise will decrease the delay, making the turntable slow
down sooner.
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Dual Power Hydro-Stretch Adjustments
To insure optimum performance from the brand and gauge of stretch film you have chosen,
the following steps will help guide you through the proper adjustments. Highlight Field Test
Kit, FTK-4000 is highly recommended for the professional calibration of the machine to
your film, and is available for purchase from Highlight Industries, Inc. Familiarize yourself
with the instructions found in the kit before the proceeding.
Hydro-Stretch Adjustment Methods
There are two (2) dials affecting the film stretch and film output speed from the carriage to
the load:
1. The Main (Release) Hydro-Stretch dial, located under the lockable film carriage top
cover, affects the film’s initial stretch and stretch on the main body of the package.
2. The Bottom (Relief) Hydro-Stretch dial, also located under the lockable carriage top
cover, works in conjunction with the “Main Hydro-Stretch” dial to produce a lower film
stretch for the bottom load where the pallet and load meet (where 90% of all film
breaks occur). Setting this dial to about 400 will cause the system to only use the
Main Hydro-Stretch value as the film stretch setting. As the Bottom Hydro-Stretch
setting is lowered, so will the stretch percentage of the film while the pallet is being
wrapped.
Hydro-Stretch Adjustment Guide
1. Observe the gauge of stretch film to be used. As a guide, commonly attained stretch
levels are 200% on 60-gauge, 250% on 80-gauge, and 280% on 135-gauge. Check
with your film supplier for the recommended level of stretch for your film.
2. Open the lockable cover of the carriage and set the “Main Hydro-Stretch” dial to 280;
set the “Auxiliary or Bottom Hydro-Stretch” dial to 130. These numbers do NOT
indicate film stretch percentage; they are used as markers so when a different film
gauge is used and the settings are changed accordingly, the operator can easily
return to previous film gauge settings.
3. Thread the film through the hydro-stretch rollers according to the threading diagram.
Allow the film to feed approximately five to ten seconds. This will insure no film
hang-ups and remove any damaged film. Grasp the tail of stretch film, and attach it
to the product.
4. Initiate a wrapping cycle by pressing the “Start” button on the operator panel.
5. Have another person to ‘walkout’ the stretch film for you. Place the stretch indicator
(provided in the Highlight Field Test Kit, FTK-4000) on the main film roll. Mark three
points on the film with the stretch indicator wheel as it feeds through the roller
system. Allow the marks to go all the way through and out of the roller system and
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Synergy 2 Turntable Stretch Wrapper Operation Manual
onto the package. Once the film is fully on the package, press the Emergency Stop
button to stop the machine.
6. Use a tape measure (also provided in the Highlight Field Test Kit, FTK-4000) to
measure the distance between the first and second, and second and third marks.
Record these measurements separately. The original distance between marks is 10
inches, so the film stretch ends up being the measured distance minus 10, then
times ten ( (Measured Distance - 10) x 10).
7. If higher film stretch is desired, set the “Main Hydro-Stretch” dial to a higher setting.
Increments of ten will generally increase the stretch considerably. If the film breaks,
then its maximum stretch level was reached and the “Main Hydro-Stretch” dial
should be at least 10 lower. This will usually yield the film’s maximum stretch. After
setting the “Main Hydro-Stretch” dial to a higher (or lower) setting, the “Film Force”
dial may have to be adjusted.
Film Breakage
Film breaks between the package and the large black roller in the Film Carriage indicate
the film stretch is set too high. Reduce the setting of the Main Hydro-Stretch dial to provide
less stretch to the film.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Load Compression Testing
Load compression tests were designed to allow you to measure the force of the film against
your product. These tests will allow you to fine tune the machine for the most secure
products.
1. Place a product in the center of the wrap area.
2. Attach the film to the product.
3. Initiate a wrapping cycle by pressing the Start button on the operator panel. To test
the load compression, allow the machine to complete one full cycle.
4. Using the tape measure provided in the Highlight Field Test Kit FTK-4000, determine
as close as possible the center of one side of the product.
5. Attach the scale provided in the Highlight Field Test Kit FTK-4000 kit to the center of
the package by pushing the pointed end of the hook all the way through the stretch
film. Grasp the other end of the scale, and pull it two inches away from the product.
6. Record the reading on the scale. To increase the load compression, rotate the Main
Hydro-Stretch dial clockwise to a higher reference number, or rotate counterclockwise to decrease the load compression.
7. Remove all the stretch film from the product.
8. Repeat the above steps if additional adjustments are needed.
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Optional Scale Package
The optional scale package allows the user to quickly measure the weight of a package
placed on the machine. To operate correctly and efficiently the scale needs to be
configured with the correct settings. Below are 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.
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Highlight Recommended Configuration Values
Note
Changing the scale parameters to values other than the Highlight
recommended values may result in poor scale operation.
Name/Code
Description
F1:
Graduations
Specifies the number of full-scale graduations. Value
should be consistent with legal requirements and
environmental limits on the useful system resolution.
F2: Span Gain Span Gain is related to A/D integration time. The larger
the span gain, the higher the internal resolution, but the
slower the update speed. Note that the scale must be recalibrated whenever this parameter is altered. See
Appendix C in the scales manual for more information.
F3: Zero Track Selects the range within which the scale will
Band
automatically zero. Note that the scale must be in a
standstill to zero the scale.
F4: Zero
Selects the range within which the scale may be zeroed.
Range
Note that the indicator must be in standstill to zero the
scale.
F5: Motion
Sets the level at which motion is detected by comparing
Band
the present display update with the previous one. If
motion is not detected for two seconds or more, scale is
in standstill and can process a Print or Zero command.
Maximum value varies depending on local regulations
F6: Digital
Averages weight readings to produce higher stability but
Filter
the slower the indicator’s response time. Choose 8
unless a very fast response is needed.
F7:Overload
Selects the desired formula which determines the point
Limit
at which the indicator shows overload. All selections are
based on the primary unit selected in F8.
F8: Calibration Selects the primary base unit to be used in the
Unit
calibration process. Also the default unit for normal
operation. 1 = pounds, 2 = kilograms.
F9: Display
Determines the desired weight increments. Value should
Divisions
be consistent with legal requirements.
F10: Decimal
Determines the location of the decimal point.
Point
F16:Zero
Places the scale in a Zero Calibration routine. See
Calibration
below.
F17:
Span Places the scale in a Span Calibration routine. See
Calibration
below.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
Highlight
Suggested
Value
5000
100
3
100
1
8
2%
1
1
0
See below.
See below.
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Scale Calibrating Procedure
Note
Highlight Industries, Inc. calibrates the scale before shipment using known
weights. The values stored in these settings are custom per scale and machine.
Do not change these values unless directed to do so by Highlight personnel.
Step 1: Navigate the scale menu to parameter “F 16.”
Step 2: Press the “ZERO” button ONCE. This enters the Zero Calibration Menu. The
display will momentarily show “C 0” followed by a value.
Step 3: After making sure that there are no test weights on the machine press the “ZERO”
button again. The display will zero.
Step 4: Press the “SET / NET” button to save the zero point value. The display will show
“EndC0” momentarily then revert to parameter F16.
Step 5: Navigate to parameter “F 17.”
Step 6: Press the “ZERO” button ONCE. This enters the Span Calibration Menu. The
display will momentarily show “C 1” followed by a value with one flashing digit. This value
will be zero with the decimal point parameter selected in F10.
Step 7: Place a known weight on the machine. Ensure that the test weight is below the
maximum capacity of the scale and above 1% of the maximum capacity of the scale.
Step 8: Key in the weight of the test weight using the buttons on the screen. Press the
“TARE / <<” button to select the digit to the left of the current position. Press “PRINT / >>”
to select the digit to the right of the current position. Press “UNITS” to increase the value of
the digit and press “ZERO” to decrease the value of a digit.
Step 9: Once the weight of the test weight is keyed in exactly, press the “SET / NET” button
to save the value. If the calibration was successful the display will read “EndC1”
momentarily, and then revert back to “F17”. If “Err0” is displayed the test weight is larger
than the full capacity of the scale. If “Err1” is displayed the test weight is below 1% of the
full capacity of the scale. If “Err2” is displayed the internal resolution of the scale is not high
enough to accept the calibration value
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Highlight Industries, Inc.
Synergy 2 Turntable Stretch Wrapper Operation Manual
Operation
Instructions
Operation Instructions
Synergy 2 Turntable Stretch Wrapper Operation Manual
Operator Controls
Warning!
If the Emergency Stop button is pressed while the turntable is rotating, the
turntable will NOT stop immediately, but rather it will decelerate and possibly
coast to a stop.
Operator Panel Button Controls
Layout
Emergency Stop
Bottom Counter
Top Counter
Bottom Counter
Set/Reset
Top Counter
Set/Reset
Function
The Emergency Stop button stops 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 out to
restore power to the machine.
The Bottom Counter displays the number of wraps to
be applied to the bottom of the product. To reset to
zero, press the Bottom Counter Set/Reset button twice
in quick succession or press and hold both the Top and
Bottom Counter Set/Reset buttons.
The Top Counter displays the number of wraps to be
applied to the top of the product. To reset to zero, press
the Top Counter Set/Reset button twice in quick
succession or press and hold both the Top and Bottom
Counter Set/Reset buttons.
Press the Bottom Counter button to increment the
bottom wrap counts. When illuminated, the button
indicates that the film carriage is at the max down
position.
To reset the counts to zero, press the Bottom Counter
Set/Reset button twice in quick succession or press
and hold both the Top and Bottom Counter Set/Reset
buttons.
Press the Top Counter button to increment the top
wrap counts. When illuminated, the button indicates
that the film carriage is at the max up position or the
height detection photo sensor no longer sees the
product.
To reset the counts to zero, press the Top Counter
Set/Reset button twice in quick succession or press
and hold both the Top and Bottom Counter Set/Reset
buttons.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Operation Instructions
Synergy 2 Turntable Stretch Wrapper Operation Manual
Table Home
The Table Home amber light illuminates when the
turntable is at its home position.
Cycle Start
Carriage
Auto/Banding
Carriage
Raise Lower
Turntable
Jog/Home
The Cycle Start button starts a wrapping cycle. A solid
green LED indicates the machine is ready for
operation. When the light flashes it indicates that the
film has broken or is out.
In a wrap cycle, selecting Carriage Banding will stop
the film carriage for wrap reinforcement. For normal
operation, select Carriage Auto.
The Carriage Raise/Lower selector switch manually
raises or lowers the film carriage. This function is
disabled when the wrap cycle is running.
The Turntable Jog/Home button manually jogs the
turntable while the button is being pressed. To send the
turntable to home, press the button twice in quick
succession.
Carriage Raise Speed
The Carriage Raise Speed potentiometer dial controls
the speed of the carriage while it travels upward.
Carriage Lower Speed
The Carriage Lower Speed potentiometer dial controls
the speed of the carriage while it travels downward.
Wrap Pattern
The Wrap Pattern selector switch selects the wrapping
pattern applied to the package during the wrap cycle.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Operation Instructions
Synergy 2 Turntable Stretch Wrapper Operation Manual
Wrap Pattern Descriptions
Wrap Pattern 1 (Top Wraps First – Bottom Wraps Second)
Wrap Pattern 1 is the standard pattern that all machines will ship with. The top wraps are
applied first, and the bottom wraps applied second.
1. When the machine starts if the carriage is not on the lower limit the carriage will
lower to the lower limit. During this time the turntable will rotate in low speed.
2. Once the carriage is on the lower limit the turntable accelerates to high speed and
the machine will spiral wrap up to the top of the package and stop.
3. Once the carriage stops, the turntable will find home and the top wraps will be
applied.
4. After the top wraps are complete the machine will spiral wrap down and make
contact with the bottom limit switch. The turntable will find the home position, and the
bottom wraps will be applied.
5. Once the bottom wraps are complete the turntable will find home, decelerate, and
stop at home.
Wrap Pattern 2 (Bottom Wraps First – Top Wraps Second)
The bottom wraps are applied first and the top wraps applied second.
1. When the machine starts if the carriage is not on the lower limit the carriage will
lower to the lower limit.
2. Once the carriage is on the bottom limit the bottom wraps will be applied.
3. After the bottom wraps are complete, the machine will spiral wrap up and apply the
top wraps.
4. Once the top wraps are complete, the machine will spiral wrap down and make
contact with the bottom limit switch. The turntable will find the home position,
decelerate, and stop at home.
Wrap Pattern 3 (Top Wraps First – Bottom Wraps Second, Up Slow)
The top wraps are applied first, and bottom wraps applied second; the turntable will be in
low speed while the carriage rises.
1. When the machine starts if the carriage is not on the lower limit the carriage will
lower to the lower limit. During this time the turntable will rotate in low speed.
2. Once the carriage is on the lower limit the turntable remains in low speed and the
machine will spiral wrap up to the top of the package and stop.
3. Once the carriage stops, the turntable will accelerate to high speed, find the home
position, and the top wraps will be applied.
4. After the top wraps are complete the machine will spiral wrap down and make
contact with the bottom limit switch. The turntable will find the home position, and the
bottom wraps will be applied.
5. Once the bottom wraps are complete the turntable will find home, decelerate, and
stop at home.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Operation Instructions
Synergy 2 Turntable Stretch Wrapper Operation Manual
Film Loading
Follow the procedure below to thread the film onto the Film Carriage.
Warning!
Be sure the Emergency Stop button is pressed before threading the film and
while the film is being threaded.
1. Load the film roll over the three-inch round metal core. Be sure the roll is completely
lowered and locked onto the bottom anti-rotation tab. Load the film so that the cling
will be against the package.
2. Pull six to eight feet of film off the film roll.
3. Follow the diagram below and thread the film tail all the way through the rollers.
4. After threading, grab the film tail, pull it out, and attach to the load.
Figure 17: Film Loading/Threading Diagram
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Operation Instructions
Synergy 2 Turntable Stretch Wrapper Operation Manual
Machine Operating Instructions
Only adjustments that can be made from the operator panel are described in this section.
For other machine adjustments see the Pre-Operation Adjustments section of the manual.
Film Carriage Speed
The wrapping and manual speeds of the carriage are controlled by potentiometer dials
located on the operator panel. Turn clockwise to increase, counter-clockwise to decrease.
The Carriage Speed Up and the Carriage Speed Down affect the amount of film overlap.
Carriage Raise/Lower
The carriage raise/lower selector switch can be used to manually raise or lower the film
carriage. The carriage will automatically stop at the upper and lower limits. The Carriage
Auto/Banding switch must be set to Auto for this function to operate. This function is only
active if the machine is not running a cycle, is paused, or is in a film out condition.
Carriage Auto/Banding
Every machine is equipped with a film carriage auto/banding selector switch. While in
banding mode, the film carriage will not move up or down manually or in the wrap cycle.
This function is active at any time.
If any particular package requires that reinforcing wrap bands be applied to the package
during the wrap cycle, then the operator can use the Carriage Banding feature. Once the
carriage reaches the desired height of the reinforcing wrap band, simply switch the
Carriage from Auto to Banding using the selector switch on the operator panel. To resume
the wrap cycle, simply switch the operation back to Carriage Auto.
Turntable Jog/Home
An Operator can manually jog the turntable by simply pressing the Turntable Jog/Home
button. To manually home the turntable, press the Turntable Jog/Home button twice in
quick succession. An indicator light on the button panel will illuminate when the turntable is
at home. This function is only active if the machine is not running a cycle, is paused, or is in
a film out condition.
Top and Bottom Counter Incrementing and Resetting
To increment either the top or bottom counters an operator must press the corresponding
increment button at a relatively slow pace. When this is done the counter will increment. If
the count exceeds 25, both the counter display and internal PLC counts will be reset back
to zero. To reset either counter the operator must press the corresponding button twice in
quick succession. This will cause both the counter display and the internal PLC count to be
reset.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Operation Instructions
Synergy 2 Turntable Stretch Wrapper Operation Manual
Manual Machine Reset
If the need to reset the machine arises, an operator should press and hold both the top and
bottom counter increment buttons at the same time. Once this is done, the turntable and
the film carriage will return to their home positions and the wrap cycle will be cleared. The
top and bottom counter displays will also be reset to zero so that the operator will be aware
that a machine reset has occurred.
Running a Wrap Cycle
1. To start a new wrap cycle, first place the product to be wrapped on the turntable,
thread the film through the carriage, and attach the film to the product.
2. Set the desired number of Top and Bottom wraps using the Top/Bottom Counter
Set/Reset buttons.
3. Select the desired Wrap Pattern to be applied to the product.
4. Press the Cycle Start button on the operator panel to initiate the wrap cycle.
Start of Cycle Reset
At the start of every cycle the machine will automatically reset the carriage to its lowered
position. This is done to ensure full film coverage on the package and to maintain a single,
consistent machine operation, no matter what the initial state of the machine is.
Emergency Stop
If there is a need to press the emergency stop button, all motive power will be removed.
The turntable will attempt to stop as fast as possible, but may coast to a stop. The
Emergency Stop condition will cause the machine to reset the wrap cycle, however, it does
not reset the counter displays.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Operation Instructions
Synergy 2 Turntable Stretch Wrapper Operation Manual
Film Cutting
Standard Film Cutting
After the product has been wrapped, it is suggested that the film be cut approximately 12
(twelve) inches past a corner and to wipe the film tail down or tuck it under another layer of
film.
Note
To cut the film a film knife can be used or an operator can tear the film at a 45degree angle to itself.
Figure 18: Top View of Package, Film Cut Location
45 deg
Pull
Figure 19: Side View of Package, Film Tear Angle
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Highlight Industries, Inc.
Synergy 2 Turntable Stretch Wrapper Operation Manual
Maintenance
Maintenance
Synergy 2 Turntable Stretch Wrapper Operation Manual
Preventative 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. Highlight Industries, Inc. cannot possibly know, evaluate, or advise the
various trades in all schedules of periodic maintenance. Accordingly, 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 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 daily:
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 loose cotter pins.
4. Check for oil leaks around the speed reducers.
5. Check for dry seals at the bearings.
6. Check for chain wear and proper tension on the power roller stretch sprockets. The
correct amount of chain tension can be checked by pulling the chain taut and having
3/8” slack.
7. Check for fraying lift belts on the film carriage lift system.
8. Check for loose electrical connections and for frayed cords and cables. Replace
immediately any damaged cords and cables.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Maintenance
Synergy 2 Turntable Stretch Wrapper Operation Manual
Turntable Bearing Lubrication Table
The main turntable bearing should be lubricated with clean grease that conforms to NLGI
EP-2 penetration. Wipe fittings clean before and after lubrication; rotate the turntable while
lubricating. Thereafter, use the following recommendation for periodic lubricating:
Shift Operation
Single Shift
Double Shift
Triple Shift
Times Per Year
4
8
12
Reducer
All gear reducers contain lubricating oil. A high-grade lubricant is required which is stable,
anticorrosive, and highly resistant to oxidation. Drain and replace the oil in these reducers
using the following recommended directions:
1. Remove the drain plug and drain the oil.
2. Replace the drain plug.
3. Remove the ‘level’ plug and ‘vent’ plug.
4. Fill the reducer through the ‘vent’ port.
5. Allow the excess to run out from the ‘level’ port.
6. Replace the ‘level’ plug.
7. Replace the ‘vent’ plug.
Power Hydro-Stretch System
The system should not require any maintenance. However, if a fluid leak occurs, refill with
Dextron 2 automatic transmission fluid.
Sprockets and Chains
All sprockets should be inspected for wear, and chains should be checked for proper
tension and lubrication on a periodic basis. To do this procedure, the chain guards will have
to be removed. If the slots in the reducer mount plate do not allow you to tension the chain,
the chain is probably stretched and in need of replacement. 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.
Miscellaneous Pivot and Rotating Bearings
All other bearings not mentioned previously should be greased bi-monthly using Mobile EP2 or equivalent.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Maintenance
Synergy 2 Turntable Stretch Wrapper Operation Manual
Maintenance Schedule
Part
Schedule
Turntable Reducer
Check for leaks and the overall condition of
the gear motor once a week.
Film Carriage
Reducer
Check for leaks and the overall condition of
the gear motor once a week.
Turntable Chain
Drive Tension
(For Synergy Low
Profile Only)
Carriage Lift Belt
All pivot bearings
Service With
Follow
manufactures
recommendations
Follow
manufactures
recommendations
Check and adjust every three months.
Check and tighten every six months.
Initially first 1,000 cycles; every 10,000 cycles
thereafter.
Mobil EP-2 grease
Note
For additional maintenance information about specific components on the
machine, refer to the components operation manuals shipped inside the main
enclosure.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Highlight Industries, Inc.
Synergy 2 Turntable Stretch Wrapper Operation Manual
Troubleshooting
Trouble-shooting
Synergy 2 Turntable Stretch Wrapper Operation Manual
Troubleshooting Guide
Warning!
Make sure that only qualified 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 three (3) minutes for the
DC bus capacitors to discharge. The frequency drive controller display and/or
LED’s are not accurate indicators of the absence of DC bus voltage.
Before You Start
The diagrams in this section will guide you in identifying typical problems while operating
the Synergy Turntable Stretch Wrapper, and provide you with corresponding solution(s).
Problems are divided in reference to the machine functions: power, turntable, film carriage,
and film delivery.
If further assistance is 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 to provide the following information:
1. Machine serial number
2. Date of purchase
3. Symptoms of any problems
General Troubleshooting Practices
1. Always adhere to the General OSHA or the State OSHA guidelines.
2. When working with machine wiring, take precautions to prevent contact with live
wires.
3. Ensure that all wiring is securely fastened and that all terminals are tightened down
properly.
4. Have a multi-meter nearby to be able to check for voltages and continuity on
different portions of the machine circuitry.
5. Use the schematics provided in this manual to trace wiring and find components on
the sub panel.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Trouble-shooting
Synergy 2 Turntable Stretch Wrapper Operation Manual
Power Problems
Problem
Possible Cause
The Emergency Stop button is
pressed.
The machine is not plugged in.
The Main Disconnect is turned
off.
Possible Solution
Pull the Emergency Stop button
out to restore power.
Plug the machine into a 120VAC,
15A outlet.
Turn the Main Disconnect on.
Make sure the belt tension switch
(located in the upper enclosure)
is tripped.
The main circuit breaker is tripped Turn the breaker back on, or
or off.
replace if necessary.
Ensure the circuit breakers before
and after the DC power supply
are on.
The 24VDC supply is off or
Use a voltmeter to check that the
malfunctioned.
power supply is receiving
120VAC and supplying 24VDC.
Replace if necessary.
The main contactor has
Check wiring to the contactor, or
malfunctioned.
replace if necessary.
The PLC power circuit breaker is Turn the breaker back on, or
off.
replace if necessary.
Check wiring to the PLC, or
The PLC has malfunctioned.
replace if necessary.
Turn the breaker back on, or
The drive circuit breaker is off.
replace if necessary.
Check wiring to the Frequency
The drive has malfunctioned.
Drive, or replace if necessary.
The Belt Tension switch is not
tripped.
The machine
does not power
up.
The PLC is not
on.
The display on a
Frequency Drive
is not on.
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Trouble-shooting
Synergy 2 Turntable Stretch Wrapper Operation Manual
Turntable Problems
Problem
Possible Cause
The Frequency Drive is not on
(the drive display is off).
The Frequency Drive is faulted.
The turntable is mechanically
restricted.
The turntable
does not rotate
manually.
The turntable motor is not wired
correctly.
The Turntable Jog/Home button
has malfunctioned.
The PLC has malfunctioned
The Frequency Drive has
malfunctioned.
The parameters in the Frequency
Drive are not set properly.
The Frequency Drive is not on
(the drive display is off).
The Frequency Drive is faulted.
The table does
not rotate during
the wrap cycle.
The turntable is mechanically
restricted.
The turntable motor is not wired
correctly.
Possible Solution
See the Power Problems section.
Record the fault code on the drive
display and refer to the Frequency
Drive Adjustments section of this
manual or the drive
manufacturer’s manual.
Check the condition of the motor,
chain, and rollers under the
turntable. Replace as necessary.
Check connections between the
Frequency drive and the motor.
Ensure the motor is wired for the
correct voltage. Replace the
motor as necessary.
Check wiring to the button and
replace as necessary.
Check wiring to the PLC and
replace as necessary.
Check wiring to the Frequency
Drive and replace as necessary.
Refer to the Electrical Schematics
in the Technical References
section of this manual for
Highlight Industries, Inc. factory
drive settings.
See the Power Problems section.
Record the fault code on the drive
display and refer to the Frequency
Drive Adjustments section of this
manual or the drive
manufacturer’s manual.
Check the condition of the motor,
chain, and rollers under the
turntable. Replace as necessary.
Check connections between the
Frequency drive and the motor.
Ensure the motor is wired for the
correct voltage. Replace the
motor as necessary.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Trouble-shooting
Problem
Synergy 2 Turntable Stretch Wrapper Operation Manual
Possible Cause
The Turntable Speed
potentiometer is set too low.
The table does
not rotate during
the wrap cycle.
(continued)
The Cycle Start button has
malfunctioned.
The PLC has malfunctioned
The Frequency Drive has
malfunctioned.
The parameters in the Frequency
Drive are not set properly.
The Turntable Deceleration Delay
is set too long.
The Turntable Home proximity
switch is malfunctioning.
The turntable
does not stop at
home.
The Frequency Drive deceleration
parameter (DEC) is set too low or
too high.
Possible Solution
Turn the potentiometer clockwise
to increase speed. Check wiring
to the potentiometer, and replace
if necessary.
Check wiring to the button and
replace as necessary.
Check wiring to the PLC and
replace as necessary.
Check wiring to the Frequency
Drive and replace as necessary.
Refer to the Electrical Schematics
in the Technical References
section of this manual for
Highlight Industries, Inc. factory
drive settings.
Decrease the Turntable
Deceleration Delay. See the PreOperation Adjustment section of
this manual for instructions.
Check the wiring to the proximity
switch and that it is adjusted
properly (only 8mm sensing
range). Replace as necessary.
If the drive deceleration parameter
is set too low the drive may fault
and the turntable may coast to a
stop. If the setting is too high, it
may pass the home position
before stopping. Refer to the
Electrical Schematics in the
Technical References section of
this manual for Highlight
Industries, Inc. factory settings.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Trouble-shooting
Synergy 2 Turntable Stretch Wrapper Operation Manual
Film Carriage Problems
Problem
Possible Cause
The corresponding Carriage
Speed potentiometer is set too
low.
The Carriage is set to Banding.
The Film Carriage
Raised/Lowered limit switch is
malfunctioning.
The Frequency Drive is not on
(the drive display is off).
The Film
Carriage does
not Raise or
Lower manually
or in the wrap
cycle.
The Frequency Drive is faulted.
The Carriage is mechanically
restricted.
The Carriage motor is not wired
correctly.
The PLC has malfunctioned
The Frequency Drive has
malfunctioned.
The parameters in the Frequency
Drive are not set properly.
The Carriage Raise/Lower
selector switch or the Cycle Start
button is malfunctioning.
Possible Solution
Turn the corresponding
potentiometer clockwise to
increase the speed. Check wiring
to the potentiometer and replace
as necessary.
Change the Carriage operation to
Auto using the selector switch on
the operator panel.
Ensure that the carriage limit
switch is clear of any obstruction
and moves smoothly. Check
wiring to the limit switch and
replace as necessary.
See the Power Problems section.
Record the fault code on the drive
display and refer to the
Frequency Drive Adjustments
section of this manual or the drive
manufacturer’s manual.
Check the condition of the motor
and belts. Replace as necessary.
Check connections between the
Frequency drive and the motor.
Ensure the motor is wired for the
correct voltage. Replace the
motor as necessary.
Check wiring to the PLC and
replace as necessary.
Check wiring to the Frequency
Drive and replace as necessary.
Refer to the Electrical Schematics
in the Technical References
section of this manual for
Highlight Industries, Inc. factory
drive settings.
Check wiring to the switch or
button and replace as necessary.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
60
Trouble-shooting
Problem
The Film
Carriage does
not Raise or
Lower during the
wrap cycle.
Synergy 2 Turntable Stretch Wrapper Operation Manual
Possible Cause
Possible Solution
The Turntable Home proximity
switch is malfunctioning.
Check the wiring to the proximity
switch and that it is adjusted
properly (only 8mm sensing
range). Replace as necessary.
The Product Height Detection
photo eye is positioned too high.
The Product Height Detection
photo eye does not see the load.
The Film
Carriage rises
some, but does
not rise to the
top of the
package.
The Package Height Detection
Delay potentiometer is set too
low. The sensor may not see the
load at all times. Use the
potentiometer to filter out these
dead spots.
Slide the Product Height
Detection photo eye lower.
Black or clear loads may require
an optional ultrasonic sensor
instead of the standard diffuse
sensor.
Check wiring to the sensor.
Replace the sensor as
necessary.
Turn the potentiometer clockwise
to increase the delay. See the
Pre-Operation Adjustments
section of the manual for
instructions.
Adjust position or sensitivity of
the sensor (see the Photo Sensor
Adjustments and/or PreOperation Adjustments section).
The Product Height Detection
Slide the Product Height
photo eye is positioned too low.
Detection photo eye higher.
Adjust the sensitivity of the
The Product Height Detection
sensor (see the Photo Sensor
photo eye is not adjusted properly
Adjustments and/or Preand always sees a ’package’.
Operation Adjustments section).
Turn the potentiometer counterclockwise to decrease the delay
The Package Height Detection
(make the carriage stop sooner).
Delay potentiometer is set too
See the Pre-Operation
high.
Adjustments section of the
manual for instructions.
The Product Height Detection
photo eye is not adjusted
properly.
The Film
Carriage rises
too far above the
package.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Trouble-shooting
Synergy 2 Turntable Stretch Wrapper Operation Manual
Film Delivery Problems
Problem
Possible Cause
The film is not threaded properly.
The film Quality is too low.
The Hydro-Stretch dials are not
set properly.
The film breaks
at the start of the
wrap cycle.
The Turntable is accelerating too
fast.
The Hydro-Stretch hydraulic tank
is empty or low.
The Bottom (Relief) HydroStretch solenoid is
malfunctioning.
The film is not threaded properly.
The film Quality is too low.
The film breaks
during the wrap
cycle.
The Hydro-Stretch dials are not
set properly.
The Hydro-Stretch hydraulic tank
is empty or low.
The Main (Release) HydroStretch solenoid is
malfunctioning.
Possible Solution
Use the Film Loading Diagram
located on the carriage to thread
the film correctly.
Use films that are free of holes or
snags.
See the Dual Power HydroStretch Adjustments section of
this manual to set the dials
correctly.
Refer to the Electrical Schematics
in the Technical References
section of this manual for
Highlight Industries, Inc. factory
drive settings.
Check the fluid level and fill if
necessary. Check for leaks.
Check wiring to the solenoid and
replace if necessary.
Use the Film Loading Diagram
located on the carriage to thread
the film correctly.
Use films that are free of holes or
snags.
See the Dual Power HydroStretch Adjustments section of
this manual to set the dials
correctly.
Check the fluid level and fill if
necessary. Check for leaks.
Check wiring to the solenoid and
replace if necessary.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Trouble-shooting
Problem
Synergy 2 Turntable Stretch Wrapper Operation Manual
Possible Cause
The Hydro-Stretch dials are not
set properly.
The film is not threaded properly.
The film is not
being stretched
during the wrap
cycle.
The film is slipping on the stretch
rollers
The Hydro-Stretch hydraulic tank
is empty or low.
The Main (Release) HydroStretch solenoid is
malfunctioning.
The Bottom (Relief) HydroStretch solenoid is
malfunctioning.
The Hydro-Stretch dials are not
set properly.
The film is being
stretched too
much during the
wrap cycle.
The film is not threaded properly.
The Hydro-Stretch hydraulic tank
is empty or low.
The Main (Release) HydroStretch solenoid is
malfunctioning.
The Bottom (Relief) HydroStretch solenoid is
malfunctioning.
Possible Solution
See the Dual Power HydroStretch Adjustments section of
this manual to set the dials
correctly.
Use the Film Loading Diagram
located on the carriage to thread
the film correctly.
Ensure the film cling will be on
the package side as the film is
wrapped around the package.
Ensure the main film mandrel
provides drag on the film. Tighten
the mandrel if it is too loose.
Check the fluid level and fill if
necessary. Check for leaks.
Check wiring to the solenoid and
replace if necessary.
Check wiring to the solenoid and
replace if necessary.
See the Dual Power HydroStretch Adjustments section of
this manual to set the dials
correctly.
Use the Film Loading Diagram
located on the carriage to thread
the film correctly.
Check the fluid level and fill if
necessary. Check for leaks.
Check wiring to the solenoid and
replace if necessary.
Check wiring to the solenoid and
replace if necessary.
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Highlight Industries, Inc.
Synergy 2 Turntable Stretch Wrapper Operation Manual
Technical
References
Technical References
Synergy 2 Turntable Stretch Wrapper Operation Manual
Recommended Spare Parts
The table below provides the recommended spare parts list for the Synergy 2 Turntable
Stretch Wrapper.
Machine
Section
HLI Part
Number Item Description
Carriage
Carriage
Carriage
Carriage
Carriage
H.P Turntable
H.P Turntable
H.P Turntable
H.P Turntable
L.P Turntable
L.P Turntable
Tower
Tower
Tower
Tower
Tower
300055
520085
520157
520029
305167
305153
305024
300506
301021
745175
301478
300448
305466
309120.2
309121.2
309122.2
Electrical
408463
Electrical
401984
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
Electrical
750055
403430
403428
403429
745890
406100
404248
408330
SOLENOID VALVE, N.O., 24 VDC
CARRIAGE ROLLER
Syn CARRIAGE CENTER GUIDE ROLLER
FILM MANDREL FRICTION PAD
BEARING, 1''
Swivel caster w/Timken Taper Bearing
CASTER, 8'' X 2'' 1 3/16 BORE CAST AL DRIVE WHEEL
BEARING, 2-BOLT FLANGE, 1-3/16 BORE
3/4hp GEARMOTOR – 28:1
CAM ROLLER ASS'Y FOR L.P.T.T.
3/4hp GEARMOTOR – 39.8:1
MOTOR, 3/4 HP, 3 PH 56C AC MOTOR
Reducer, Right Angle, custom shaft, 60:1
BELT, LIFT,CWA, 2" X 98.25",SYN
BELT, LIFT,CWA, 2" X 123",SYN – Optional
BELT, LIFT,CWA, 2" X 137.25,SYN – Optional
AC VECTOR DRIVE, ATV12, 115VAC INPUT 1 PH, 230VAC OUT
3PH
PHOTO EYE INFRA RED DIFFUSE, LONG RANGE, 10-30 DC,
M12 CONN.
POTENTIOMETER, 10K Single Turn Speed Pot (Double) Ass'y
PROX SW, 18mm, 8mm RANGE, 4 WIRE, 10-65VDC, NO/NC
PUSH/PULL, 40MM MUSHRM HD, 22mm, RED
PUSH BUTTON LIGHT, RED LED, 24VDC, 1NC/1NO
LIMIT SWITCH, BELT TENSION SWITCH ASSY.,
CONTACTOR, 18A, 24VDC COIL, 1NO 1NC AUX
POWER SUPPLY, 24VDC, 2.5 AMP, DIN RAIL MOUNT
LIMIT SWITCH, NEUTRAL POS. 2 NO AND 2 NC CONTACTS
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
Qty
1
4
2
1
4
2
1
3
1
5
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
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Technical References
Synergy 2 Turntable Stretch Wrapper Operation Manual
Mechanical Drawings
Low Profile System
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Low Profile Turntable
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Synergy 2 Turntable Stretch Wrapper Operation Manual
High Profile System
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High Profile Turntable
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Synergy 2 Turntable Stretch Wrapper Operation Manual
Tower
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
70
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Synergy 2 Turntable Stretch Wrapper Operation Manual
Film Carriage, Standard 20”
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Synergy 2 Turntable Stretch Wrapper Operation Manual
Film Carriage, Optional 30”
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Synergy 2 Turntable Stretch Wrapper Operation Manual
Hydro-Stretch Unit
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Technical References
Synergy 2 Turntable Stretch Wrapper Operation Manual
Electrical Drawings
H
IGHLIGHT
Electrical Schematics
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Synergy 2 Turntable Stretch Wrapper Operation Manual
H
IGHLIGHT
Technical References
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Synergy 2 Turntable Stretch Wrapper Operation Manual
H
IGHLIGHT
Technical References
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Technical References
Synergy 2 Turntable Stretch Wrapper Operation Manual
ALTIVAR 12 DRIVES PROGRAMMING PARAMETERS
Drive #
Function Controlled
Drive/Motor HP
Full Menu Code Code
I/O
tCC
AI1
AI1t
r1
tOL
LOC
AO1 AO1
AO1t
drC
bFr
nPr
CoS
UnS
nCr
FrS
nSP
tFr
Ctt
UFr
StA
FLG
tUn
CtL
Fr1
PSt
CHCF
Cd1
FUn
rPt
ACC
dEC
rPt
brA
Stt
Stt
rrS
AdC
AdC
SdC1
tdC1
CL1
CL1
SPL
LSP
HSP
FLt
rSF
AtR
Atr
tAr
FLr
tHt
ItH
SLL
CON
ADD
tbr
tFO
ttO
Use the wheel on the drive to navigate to
ConF, then FULL, and finally the
parameters listed below.
Description
Type of control (2 wire)
Analog Input Type
Relay Output r1
Application Overload Time Delay
Application Overload Threshold (% of nCr)
Analog Output Assignment
Analog Output Type
Standard Motor Frequency
Rated Motor Power
Rated Motor Cos Phi
Nominal Motor Voltage
Motor Plate Current Rating
Nominal Motor Frequency
Motor Speed Rating
Maximum Output Frequency
Motor Control Type
IR Compensation
Frequency Loop Stability
Frequency Loop Gain
Motor Auto Tuning
Speed Control Referece
Stop Key Priority
Motor Control/Channel Configuration
Command Channel 1
Acceleration Time (Seconds)
Deceleration Time (Seconds)
Ramp Shape Assignment
Decel Ramp Adaption Assignment
Type of Stop
Reverse Direction
Automatic DC Injection
Automatic DC Injection Current
Automatic DC Injection Time
Current Limitation
Low Speed (Min Hz)
High Speed (Max Hz)
Detected Fault Reset Assignment
Automatic Restart
Max Automatic Restart Time
Flying Restart
Motor Thermal Current
Modbus Communication Fault Management
Modbus Address
Modbus Baud Rate
Modbus Communication Format
Modbus Communication Time Out
0204
Turntable
0304
Film
Carriage
1/0.75
1/0.75
Default
Setting
Setting
2C
*
*
5U
*
*
FLt
*
*
0 sec
*
*
90%
*
*
nO
Ofr
Ofr
0A
10U
10U
50 Hz
60 Hz
60 Hz
PLATE
0.8
0.8
PLATE
*
*
230V
*
*
PLATE
3.2
3.2
50 Hz
60 Hz
60 Hz
PLATE
1725
1725
72 Hz
60.0
60.0
Std
*
*
100%
*
*
20%
*
*
20%
13
13
nO
YES/dOnE YES/dOnE
AI1
*
*
YES
*
*
SIM
*
*
tEr
*
*
3
2.0
1.0
3
1.0
0.3
Lin
*
*
YES
dYnA
dYnA
rMP
*
*
nO
L2H
L2H
YES
*
*
70%
*
*
0.5 sec
*
*
1.5 In
*
*
0 Hz
8.0
*
60 Hz
*
*
nO
*
*
nO
*
*
5 min
*
*
nO
YES
YES
PLATE
5
5
YES
*
*
OFF
1
1
19.2
*
*
8E1
*
*
10s
*
*
This table represents the Electrical Schematics Page 4
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Technical References
Synergy 2 Turntable Stretch Wrapper Operation Manual
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
78
Synergy 2 Turntable Stretch Wrapper Operation Manual
H
IGHLIGHT
Technical References
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Synergy 2 Turntable Stretch Wrapper Operation Manual
H
IGHLIGHT
Technical References
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Technical References
Synergy 2 Turntable Stretch Wrapper Operation Manual
Electrical Sub Panel Drawing
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Technical References
Synergy 2 Turntable Stretch Wrapper Operation Manual
Operator Button Panel
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
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Synergy 2 Turntable Stretch Wrapper Operation Manual
Notes
Notes
Synergy 2 Turntable Stretch Wrapper Operation Manual
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
84
Notes
Synergy 2 Turntable Stretch Wrapper Operation Manual
Highlight Industries, Inc. ● 2694 Prairie SW, Wyoming, Mi 49519 ● 1-800-531-2465
85