20-PILOT Standard Manual G1000-013-00 r1 E1000-010 r1 25 06 19

INSTRUCTION
&
MAINTENANCE
MANUAL
LOW PROFILE
SEMI-AUTOMATIC
STRETCH WRAP
MACHINE & OPTIONS
PILOT STRETCHWRAPPER
services@pilotstretchwrapper.com
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3
RAPID CHECKLIST
Here is a simple and helpful procedure for starting the machine, but we also recommend that
the manual be thoroughly reviewed by a qualified service technician.

MANUAL SECTION
STEPS
FOR REFERENCE
Remove packaging materials and inspect for damage. Have the driver
acknowledge any damage before signing acceptance.
Section 4:2
IMPORTANT, you are responsible for any freight damage
claims with the carrier.
Erect the tower. Refer to the manual for assembly instructions. Section 4:3
Plug the machine to a standard 115V outlet. A 14 gauge extension cord
Section 4:5
may be used temporarily.
Manually jog the turntable and film carriage to check for binding or
Section 4:4 Item 7
unusual noise.
Load a roll of film and thread it according to the threading diagram
located on the top of film carriage. Remember to restore power by
Section 6:2
using the “Reset” switch on the control panel, and then press the blue
MANUAL FILM FEED button to momentarily activate the film feed.
Bring a test load to the machine… Section 6:1
Attach the film to the load. Section 6:3
Set Force‐to‐Load to 0… Section 5:1:11
Set the top & bottom wrap counts to 2… Section 5:2:4:2:1
Section 5:1:9 &
Set the film carriage raise and lower speeds to 3 5:1:10
Press the Cycle Start button… Section 5:1:5
Increase or decrease Force‐to‐Load until desired tension is achieved… Section 5:1:11
Section 5:1:9 &
Increase or decrease spiral speeds until desired overlap is achieved… 5:1:10
Increase or decrease top and bottom wrap counts accordingly. Section 5:2:4:2:1
Review the instructions in the manual to program the 3 separate wrap
Section 5:2:4:2
programs.
NOTE: For all trouble‐shooting issues, refer to the “Trouble‐Shooting Guide” in Section 10:0 of this
manual

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TABLE OF CONTENTS
1:0 BEFORE STARTING THE MACHINE......................................................... 9
2:0 SPECIFIC CAUTIONS AND WARNINGS................................................. 11
3:0 MACHINE DESCRIPTION ........................................................................ 13

3:1 Machine Specifications ........................................................................ 14
4:0 INSTALLATION ........................................................................................ 15

4:1 Moving the Machine ............................................................................. 15
4:2 Unpacking and Inspection ................................................................... 15
4:3 Knock-down Tower Assembly............................................................. 16
4:4 Pre-Operation Check and Final Assembly ......................................... 19
4:5 General Power Requirements.............................................................. 20
5:0 SET-UP AND OPERATING PROCEDURES ............................................ 21

5:1 Operating Controls – Exterior Control Panel ..................................... 21
5:1:1 Main Disconnect Switch (Optional) ................................................ 22
5:1:2 Emergency Stop Push-Pull Button................................................. 22
5:1:3 Power Off–On-Reset Selector Switch............................................ 22
5:1:4 Manual Film Feed Push-button...................................................... 22
5:1:5 Wrap Cycle START/PAUSE Keypad Button .................................. 23
5:1:6 Turntable JOG Keypad Button....................................................... 23
5:1:7 Film Carriage Elevator RAISE Keypad Button ............................... 23
5:1:8 Film Carriage Elevator LOWER Keypad Button............................. 23
5:1:9 Film Carriage RAISE SPEED Keypad Buttons .............................. 23
5:1:10 Film Carriage LOWER SPEED Keypad Buttons............................ 24
5:1:11 Film FORCE TO LOAD Keypad Buttons ....................................... 24
5:1:12 POWER Indicator Light.................................................................. 24
5:1:13 FAULT Indicator Light.................................................................... 24
5:2 Operator Interface Panel (HMI) ............................................................ 25
5:2:1 Initialization Screen........................................................................ 26
5:2:2 Control Power Disabled Screen..................................................... 26
5:2:3 Start-up Splash Screen.................................................................. 27
5:2:4 Main Menu Screen......................................................................... 27
5:2:4:1 Wrap Program Select Screen..................................................... 28
5:2:4:2 Machine Settings Screen............................................................ 28
5:2:4:2:1 Wrap Count Settings A (or B or C) Screen........................... 29
5:2:4:2:1.1 Top Wrap Revolutions Setting........................................ 29
5:2:4:2:1.2 Base Wrap Revolutions Setting...................................... 30
5:2:4:2:2 Photo-Eye Settings A (or B or C) Screen ............................. 30
5:2:4:2:2.1 Auto Load Height Photo-Eye Off / On Selection............. 30
5:2:4:2:2.2 Top of Load Film Overlap Setting ................................... 31
5:2:4:2:3 Wrap Mode Settings A (or B or C) Screen ........................... 31
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5:2:4:2:3.1 Base/Top Wraps First Mode Selection............................31

5:2:4:2:3.2 Up Only Wrap Mode Setting ...........................................32
5:2:4:2:3.3 Slow Start Revolutions Setting ........................................32
5:2:4:2:4 Film Force Settings A (or B or C) Screen..............................33
5:2:4:2:4.1 Reduced Bottom Film Force Selection ............................33
5:2:4:2:4.2 Delayed Film Force Revolutions Setting .........................34
5:2:4:2:5 Top Sheet Settings A (or B or C) Screen ..............................34
5:2:4:2:5.1 Pause Wrap Cycle for Top Sheet Application Selection..34
5:2:4:2:5.2 Distance to Lower Film Carriage After Pausing Setting ..35
5:2:4:3 Calibration Settings Screen.........................................................36
5:2:4:3:1 Language Selection ..............................................................37
5:2:4:3:2 Measures Selection...............................................................37
5:2:4:3:3 Turntable Start Speed Setting...............................................37
5:2:4:3:4 Turntable Run Speed Setting ................................................38
5:2:4:3:5 Turntable Realign Speed Setting ..........................................38
5:2:4:3:6 Realign Delay Setting............................................................39
5:3 Turntable Speed Adjustment................................................................39
5:4 Film Carriage Elevator Speed Set-Up ..................................................39
5:4:1 Film Carriage Elevator Raise Speed ..............................................39
5:4:2 Film Carriage Elevator Lower Speed..............................................40
5:5 Film Carriage Limit Switch Striker Adjustment ..................................40
5:6 Auto Load Height Sensing Photo-Eye Adjustment ............................41
5:7 Film Carriage Descent Obstruction Plate Safety Switch ...................41
6:0 WRAPPING A LOAD................................................................................ 43

6:1 Placing the Load on the Turntable.......................................................43
6:2 Threading the Prestretch Film Dispenser ...........................................43
6:3 Attaching the Film to the Load.............................................................45
6:4 Starting the Wrap Cycle (Initial Set-up) ...............................................45
6:5 Wrap Cycle Sequence of Operation.....................................................45
6:5:1 Up and Down (Cross-Spiral) Wrap Cycle – Top Wraps First..........45
6:5:2 Up and Down (Cross-Spiral) Wrap Cycle – Base Wraps First........46
6:5:3 Up Only (Simple-Spiral) Wrap Cycle – Base Wraps First ...............47
6:5:4 Film Fault Reset Sequence (Optional)............................................48
7:0 REMEDIAL ADJUSTMENT ...................................................................... 51

7:1 Turntable Soft-Start...............................................................................51
7:2 Load Toppling or Sliding ......................................................................51
7:3 Film Tearing & Puncturing....................................................................51
7:4 Uneven Top Surfaces............................................................................53
7:5 Auto Load Height Photo-Eye False Signals ........................................53
7:6 Top Sheet Application ..........................................................................53
7:7 Reinforcing Band Application ..............................................................55
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8:0 MAINTENANCE REQUIREMENTS .......................................................... 57

8:1 Lubrication ............................................................................................ 57
8:2 Maintenance Frequency Recommendations ...................................... 57
9:0 MAINTENANCE AND ADJUSTMENTS.................................................... 59

9:1 Film Carriage Lift Chain Adjustment .................................................. 59
9:2 Turntable Removal & Installation........................................................ 59
9:3 Turntable Drive Chain Adjustment...................................................... 60
9:4 Turntable Support Rollers ................................................................... 60
9:5 Film Carriage Limit Switch Lever Arm Adjustment ........................... 61
9:6 Auto Load Height Sensing Photo-Eye Adjustments.......................... 61
9:7 Variable Frequency Drives................................................................... 61
9:8 Turntable Positive Alignment Set-Up and Adjustment...................... 62
9:9 Turntable Accu-Count Proximity Sensor Adjustment ....................... 63
9:10 Dancer Proximity Sensor Installation & Adjustment ......................... 64
9:11 Carriage Height Pulse Proximity Sensor Adjustment ....................... 65
9:12 Film Carriage Safety Switch Adjustment............................................ 65
9:13 Prestretch Roller Cleaning Procedure ................................................ 67
9:14 Freeing Up a Jammed Film Carriage................................................... 67
10:0 TROUBLE-SHOOTING .......................................................................... 69

10:1 Trouble-shooting using Operator Interface Fault Messages ............ 69
10:1:1 Variable Frequency Drive Fault ..................................................... 70
10:1:2 Film Carriage Safety Switch Tripped Fault .................................... 71
10:1:3 Film Carriage Height Pulse Counter Sensor Fault ......................... 72
10:1:4 Wrap Cycle Watchdog Timer Fault ................................................ 73
10:1:5 Film Fault (Optional) ...................................................................... 74
10:2 Trouble-Shooting Guide....................................................................... 75
11:0 PARTS LISTS ........................................................................................ 85
12:0 COMPONENT MANUALS
13:0 MECHANICAL DRAWINGS
14:0 ELECTRICAL DRAWINGS
15:0 VFD PARAMETERS
16:0 SUPPLEMENTS
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1:0 BEFORE STARTING THE MACHINE
Please refer to the following checklist before contacting the machine vendor for
start-up assistance. This will prevent confusion and additional expense during
the start-up process.
1. Check for any freight damage, (hidden or apparent), and if found report it
to the carrier. It is the responsibility of the consignee to report any
damage incurred during shipment.
2. Uncrate and assemble the machine. Erect the tower according to the
instructions in Section 4:3.
3. The machine must operate on a level floor or the life of certain parts
will be reduced substantially!
4. DO NOT START THE MACHINE BEFORE REMOVING STRAPPING

SECURING THE TURNTABLE AND / OR THE TURNTABLE
SHIPPING BOLT, located on the face of the turntable on PILOT
machines!
5. Before operating the machine, remove any Styrofoam, strapping, or

shipping blocks from beneath the film carriage that may be present.
6. Actuate the Film Carriage Descent Obstruction Plate upwards and then
release, to ensure that the plate mechanism and safety switch assembly
are functioning freely. If the Descent Obstruction Plate becomes
jammed in the recessed position, the film carriage lower function
will become inoperable.
7. Connect the incoming electrical power supply and verify that the voltage
is correct, (refer to Section 4:5). Do not connect or attempt to operate
the machine without supplying proper and consistent electrical
input. Potential damage may occur that will void warranty.
8. Ensure that the two limit switches mounted on the film carriage operate
between the Upper and Lower Limit Switch Strikers. These strikers are
the adjustable chamfered blocks mounted to an aluminum rail on the
side of the tower. These strikers define the maximum travel of the
carriage. WITHOUT THESE STRIKERS AT THE TOP AND BOTTOM
TO TELL THE CARRIAGE TO STOP, THE CARRIAGE WILL OVER-
RUN ITS SAFE OPERATING RANGE, POTENTIALLY CAUSING
SERIOUS DAMAGE!
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9. During the winter months, gear-reducer lubricants will thicken when

exposed to cold weather during shipment. Allow the machine to warm up
to room temperature for 8 hours (minimum) before attempting to operate
the machine. FAILURE TO DO THIS MAY RESULT IN BLOWN FUSES
OR AC V/F DRIVE FAULTS!
10. If the machine is loaded by forklift truck, it is recommended that a stop

block be mounted to the floor in order to prevent the lift truck from
colliding with the turntable. (Suggestion: A 3” x 3” x 1/2” thick steel
angle bolted to the floor.)
11. READ THE MANUAL!

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2:0 SPECIFIC CAUTIONS AND WARNINGS
In the interest of promoting safe operating practices in the use of this equipment,
cautionary references are made throughout this manual in the format shown
below.
 NOTICE!
This designation indicates that a failure to observe can cause EQUIPMENT

MALFUNCTION!
 CAUTION!
This designation indicates that a failure to observe can cause DAMAGE TO

THE EQUIPMENT!
 WARNING!
This designation indicates that failure to observe can cause DAMAGE TO

THE EQUIPMENT AND / OR INJURY TO PERSONNEL!
The manufacturer strongly recommends that all personnel involved in

operating and maintaining this equipment be fully trained in the operational
and maintenance procedures described in this manual, and that this
manual be kept accessible to those personnel as a source of reference
information.
The manufacturer endeavors to supply the safest equipment possible. The

intention to provide only safe, quality packaging equipment to the customer is
enhanced by an on-going Product Safety program.
The manufacturer has no means of controlling the safe use of the equipment
other than through the features designed and built into the machinery and the
recommendations made in this manual. Ultimately the end-user must assume
final responsibility for the safety performance of this equipment and for
maintaining a safe working environment!
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3:0 MACHINE DESCRIPTION
The PILOT stretch-wrapping machine is a floor level (2.75” turntable elevation),

unit designed to be loaded either by fork-truck, or by a pallet jack or power-walkie
in conjunction with an optional access ramp. The machine operates on 115 volt
15 amp electrical service.
PILOT Low Profile

(shown with optional loading ramp)
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3:1 Machine Specifications
Power 115 volt, 1 Phase, 15 Amp (unshared) line service required. A

14 gauge power cord complete with a 115 volt 15 Amp 2-pole 3-
wire grounding type plug is provided.
Control The machine is controlled by microprocessor board with an

integrated Operator Interface Panel (HMI).
Motors All motors, unless otherwise specified, are 230 volts 3 phase,
TEFC, fractional to 1/2 HP.
Speed Turntable speed is manually controlled from 0 to 12 RPM by

adjustment of a speed setting parameter accessible through the
Operator Interface Panel (HMI).
The Film Carriage elevator speed is manually controlled from

minimum stall to maximum speed by keypad buttons located on
the control panel door. Separate speed adjustment is provided
for Raise and Lower speeds.
Drive Train The PILOT Turntable is driven from a right-angle oil-filled gear-
reducer and ANSI #50 direct chain drive. A center sprocket
connects to the turntable using four 12mm bolts.
The Film Carriage elevator is driven from a right-angle oil-filled

gear-reducer and ANSI #40 direct chain drive complete with
shock absorption mechanism that incorporates an “anti-fall”
safety mechanism to safeguard the operator and the equipment
in the unlikely event of a chain failure.
Environment The PILOT semi-automatic stretch wrapper is designed for

standard industrial environments with operating temperature
ranging from +50°F to +120°F (+10°C to +48°C).
Capacity Loading of 4,000 pounds turning, and 10,000 pounds static.

Standard design for pallet loads up to 50” square (71” maximum
diagonal dimension), to 80” overall height.
Film The PILOT semi-automatic stretch-wrapper accepts film up to

1.1 mils (28 microns) thick, wound on a standard 3” cores with a
roll diameter of 10” maximum and up to 20” maximum web
height.
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4:0 INSTALLATION
4:1 Moving the Machine
The PILOT Low Profile stretch-wrap machine may be fork-truck lifted from either
the front or rear. Simply insert the lift truck forks into the machine base frame
channels at either end, being careful not to hit the tower when tilting if lifting from
the tower side of the machine.
4:2 Unpacking and Inspection
Before applying power or operating the machine, a general inspection is

recommended to determine if any damage has taken place during transport.
IT IS THE END-USER’S RESPONSIBILITY TO REPORT ANY DAMAGE

INCURRED DURING SHIPMENT TO THE TRUCKING COMPANY!
In order to obtain a clear view of all elements of the machine, carefully remove all
packaging, strapping and blocking materials, as well as any shipping bolts.
1. Remove any strapping around the top of the turntable, securing it to the
machine base. Rotate the turntable clockwise and counter-clockwise
manually. Determine if the rolling action is both smooth and quiet.
2. Locate the optional ramp in the desired position. Ensure that the
mounting flanges on the ramp align with the corresponding holes on the
machine base. Insert the ramp mounting bolts, washers and lock-
washers and tighten securely.
3. Inspect any visible cables for crushed sections or loose fittings and
ensure that they are routed correctly and will not snag on anything.
4. Actuate the Film Carriage Descent Obstruction Plate upwards and then
release, to ensure that the safety stop plate mechanism and safety
switch assembly are functioning correctly. (Refer to Section 9:12).
 WARNING! Failure to thoroughly test the operation of the

Carriage Safety Switch may render the safety feature inoperable!
5. Operate all control panel push-buttons and switches. Their actions

should be crisp and free.
16
6. Check the carriage limit switch lever arms to ensure that they will contact
the limit switch strikers. Ensure that the upper and lower limit switch
strikers are positioned above and below the film carriage limit switches,
respectively.
 CAUTION! The film carriage limit switches must operate

between the upper and lower limit switch strikers to safely limit the
travel of the film carriage!
4:3 Knock-down Tower Assembly
Pilot machines will normally be shipped in “knocked-down” condition. The tower

is hinged where it attaches to the machine base and will be folded down flat for
shipment, supported by a shipping bracket that is inserted into one of the fork-lift
pick-up tubes in the base of the machine.
Erect the tower and secure it to the machine as follows:
1. Remove all packaging from the machine.
2. Round up the necessary personnel and a forklift truck or other lifting

device with which to raise the tower.
3. Insert the lifting eye-bolt into the top plate of the tower, if it is not already
installed. Attach a sling or cable through the eye-bolt at the top of the
tower. Next, lift the tower slightly until the lifting device takes up the
17
weight, and then remove the two shipping bolts securing the top of the
tower to the shipping bracket.
4. Once the tower is free of the shipping bracket, slowly and carefully raise
the tower. As the angle of the tower changes, keep advancing the lifting
equipment so that the sling or cable remains vertical.
 WARNING! At this stage the tower is not secured to the

machine base. From this point onward exercise extreme caution
so that the tower does not fall or topple forward at its pivot point!
5. Pivot the tower upward until it is resting flat on to the machine base, taking
care to avoid pinching the cable(s) located at the hinged section of the
tower! Install the four 12mm hex head bolts and lock-washers provided one
at a time into the threaded holes. Ensure that all hardware is securely
fastened before proceeding.
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6. Remove the sling and the eye-bolt, remove the shipping bracket from the
pick-up tube in the base of the machine and then test for proper machine
operation.
19
4:4 Pre-Operation Check and Final Assembly
1. Visually check all chains for proper tension and alignment.
2. Check the film carriage limit switch lever arms to ensure that they will
contact their respective limit switch strikers. Ensure that the upper and
lower limit switch strikers are positioned above and below the film
carriage limit switch lever arms, respectively.
 CAUTION! The film carriage limit switches must operate

between the upper and lower limit switch strikers to safely limit the
travel of the film carriage!
3. Inspect any external cables and ensure that they are unobstructed and
will not snag on anything. Ensure that the power cord is not routed
beneath the film carriage
4. Operate all control panel push-buttons and switches. Their actions

should be crisp and free. Open the control panel and verify that the
Master Control Relay is properly seated in its socket.
5. Turn on the Control Power by pulling out the red mushroom head E-Stop
button on the control panel and turning the Power Off–On–Reset switch
to the RESET position momentarily. Release the switch so it springs
back to the center “ON” position.
6. Manually jog the stretch wrap machine turntable through one revolution,
to ensure that it is unobstructed.
7. Before wrapping the first load, manually jog the film carriage up and
down to ensure that it stops properly at the top and bottom limits.
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4:5 General Power Requirements
Unless otherwise specified, the machine requires a 115 volt, 1 Phase, 60 Hz, 15
Amp (unshared) line service.
 CAUTION! Power the system only from an adequately

fused wall socket of the correct voltage. Do not use an extension
cord as a severe line power drop may occur, resulting in damage
to the electronic circuits!
If it is necessary to use an extension cord temporarily, a #14 AWG (minimum)

grounded type flexible cord to a maximum length of 10 feet would be acceptable.
However, extension cords are not recommended for permanent service.
The available line service voltage should be verified with a voltmeter at the
machine terminal strip, while the machine is operating under load, in order to
determine if the service is adequate.
The line voltage should not drop below 109 volts AC during full load
operation!
The line voltage should not exceed 126 volts AC at any time!
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5:0 SET-UP AND OPERATING PROCEDURES
5:1 Operating Controls – Exterior Control Panel
This section provides a description of the operator controls located on the

exterior panel of the control enclosure. The control panel front label incorporates
an Operator Interface Panel (HMI) and Keypad with various membrane-type
buttons in addition to an EMERGENCY STOP push-pull button, a POWER OFF-
ON-RESET selector switch, and a MANUAL FILM FEED push-button.
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5:1:1 Main Disconnect Switch (Optional)
The optional Main Disconnect Switch is used to disconnect the incoming power
from the control and motor circuits. In the “O” (Off) position, power is
disconnected. In the “I” (On) position power is connected. Holes in the
operating handle of the Main Disconnect Switch allow for the installation of a
padlock when the switch is turned to the “O” (Off) position.
5:1:2 Emergency Stop Push-Pull Button
This two-position red mushroom-head push-pull button is used to disable the

control power by de-energizing the Master Control Relay (MCR). When pulled
out, control power is made available to the Master Control Relay. Pushing the
Emergency Stop button in will interrupt power to the control and motor circuits
and causes all machine functions to come to an immediate halt.
 WARNING! The interior of the control panel remains

powered even when the Emergency Stop button is pushed in to the
STOP position. ALWAYS disconnect power before opening the
control panel!
5:1:3 Power Off–On-Reset Selector Switch
This three-position selector switch is used to turn on the control power. When
turned to the <RESET> position, the control power is reset and is indicated by
the illumination of the blue POWER ON light. When released, the switch will
spring back from this position to the center <ON> position. Turning the switch to
the <OFF> position will interrupt power to the control and motor circuits by de-
energizing the Master Control Relay (MCR) and causes all machine functions to
come to an immediate halt.

powered even when the power switch is turned OFF. ALWAYS
unplug the machine before opening the control enclosure!
5:1:4 Manual Film Feed Push-button
As a safety feature, the prestretch film dispenser is disabled from operating

whenever the machine is not performing a wrap cycle. In order to activate the
film feed to assist with attaching the film to the load, a Manual Film Feed push-
button is provided. Pressing this blue push-button temporarily enables the film
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feed for a few seconds, after which the film feed will again be disabled. If the film
feed is disabled before the operator has fed out sufficient film, then pressing the
button again will reactivate the film feed for another timed interval.
5:1:5 Wrap Cycle START/PAUSE Keypad Button
The green Wrap Cycle <START/PAUSE> button on the keypad performs the
following functions:
1. Pressing this button, if the machine is not already performing a wrap cycle,
starts the wrap cycle. All machine functions will progress in proper order
automatically without further input from the operator.
2. Pressing this button while the machine is already performing a wrap cycle
causes the wrap cycle to go into a PAUSE state and all machine motion to
come to a halt. The Wrap Cycle Pause condition is indicated by a
message on the Operator Interface Panel (HMI). Pressing this button
again will allow the wrap cycle to resume.
5:1:6 Turntable JOG Keypad Button
The <JOG> button, when pressed, causes the turntable to rotate at slow speed.
This function automatically stops when the button is released.
5:1:7 Film Carriage Elevator RAISE Keypad Button
Pressing the <RAISE> button causes the film carriage to ascend. This function
automatically stops when the film carriage upper limit switch comes in contact
with the upper limit striker, or when the button is released.
5:1:8 Film Carriage Elevator LOWER Keypad Button
Pressing the <LOWER> button causes the film carriage to descend. This
function automatically stops when the film carriage bottom limit switch comes in
contact with the lower limit striker, or when the button is released.
5:1:9 Film Carriage RAISE SPEED Keypad Buttons
The <RAISE SPEED> keypad buttons provide adjustment of film overlap by

varying the film carriage elevator motor speed while it is ascending. This is
adjustable from a slow crawl at <0> to a maximum speed to suit up to 20” wide
film. Pressing the <UP> arrow symbol keypad button increases the value
between <0> and <10>. Pressing the <DOWN> arrow symbol keypad button
decreases the value.
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5:1:10 Film Carriage LOWER SPEED Keypad Buttons
The <LOWER SPEED> keypad buttons provide adjustment of film overlap by

varying the film carriage elevator motor speed while it is descending. This is
adjustable from a slow crawl at zero to a maximum speed to suit up to 20” wide
film. Pressing the <UP> arrow symbol keypad button increases the value
between <0> and <10>. Pressing the <DOWN> arrow symbol keypad button
decreases the value.
5:1:11 Film FORCE TO LOAD Keypad Buttons
The <FORCE TO LOAD> setting, (sometimes referred to as “Film Tension”),

controls the output speed of the film web and is variable from a setting of zero,
(maximum film output speed), to values usually capable of breaking the stretch-
wrap material. Pressing the <UP> arrow symbol keypad button increases the
value between <0> and <10>. Pressing the <DOWN> arrow symbol keypad
button decreases the value.
 NOTICE! Film economy is determined by the prestretch

system’s prestretch ratio. The Force to Load setting controls the
tightness of the film web as it is delivered to the load only. Most
films will continue to tighten on the package for several hours after
wrapping due to film “memory”.
This should be adjusted to a setting where the prestretch dancer roller

mechanism is able to “float” between its stops. In this way, the prestretch system
can vary the output speed of the film web in order to compensate for the corners
of the load as it rotates and thereby maintain a constant level of tightness to the
load.
5:1:12 POWER Indicator Light
This blue LED indicator light will be illuminated whenever the control power is
enabled and the Master Control Relay (MCR) is energized. This must be
illuminated in order for the machine to operate.
5:1:13 FAULT Indicator Light
This red LED indicator light will flash whenever a fault condition has been
detected. Refer to information displayed on the Operator Interface Panel (HMI)
screen to determine the necessary action(s) required to correct the fault and
return to operating mode. Refer to Section 10:1 for a list of machine fault
conditions.
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5:2 Operator Interface Panel (HMI)
PILOT machines are equipped with an Operator Interface Panel, also referred to
as an HMI (Human-Machine Interface). The Operator Interface Panel is
integrated with the machine’s microprocessor control circuit board.
The Operator Interface Panel interfaces with the machine’s microprocessor

control system to display diagnostic messages, machine status messages, and
to access a menu system in which the machine presets and wrapping
parameters can be accessed and modified. The Operator Interface Panel is
equipped with six Function Key Buttons located below the LCD screen that are
used to navigate between displayed options, increment variable parameters and
enter or select the desired value or function.
The <UP> and <DOWN> arrow symbol keypad buttons are used to move the
cursor (>) vertically between lines on the displayed screen. The line that the
cursor is on will be displayed with a dark background to highlight that it is the
currently active selection. Holding these buttons down will cause them to scroll
continuously.
The <+> and <-> keypad buttons are used to increment or decrement numeric
values or switch between defined states, depending on the item selected.
Holding these buttons down will cause them to scroll continuously.
The <ESC> (Escape) keypad button is used to “escape” from the current screen
back to the previous screen.
26
The <ENT> (Enter) keypad button is used to select the currently high-lighted item
and perform the function indicated on that line. With the exception of language
selection, it is not necessary to press the <ENT> button to enter numeric values
or states if the <ESC> button is used to navigate away from the screen where a
variable value has been modified.
The Operator Interface Panel (HMI) is an LCD display with LED back-lighting.
After a period of inactivity the HMI will go into a screen-saver mode and the back-
light will turn off. Pressing on any keypad button or starting a wrap cycle will re-
enable the back-light.
5:2:1 Initialization Screen
When the machine is first plugged in an initialization screen is displayed briefly.

This will disappear within a few seconds.
INITIALIZING
VER. XX.X BUILD XXXXXX
Screen #1 – Initialization Screen
5:2:2 Control Power Disabled Screen
The CONTROL POWER DISABLED screen is displayed whenever power is

connected and the Master Control Relay (MCR) is disabled. Follow the displayed
instructions on this screen to re-enable the control power.
CONTROL POWER
DISABLED!
PULL OUT THE E-STOP

BUTTON, THEN TURN
THE POWER SWITCH
TO <RESET> TO
RE-ENABLE THE POWER.
Screen #2 – Control Power Disabled Screen

27
5:2:3 Start-up Splash Screen
The Start-up Splash screen appears briefly after the control power is turned on.
Once the control power has been enabled the Start-up Splash Screen will not
reappear unless the control power has been disabled for a minimum of 1 minute.
CONTROL
POWER
ENABLED
Screen #3 – Start-up Splash Screen
5:2:4 Main Menu Screen
The MAIN MENU screen is the default screen that will appear after the control
power is enabled and the Start-up Splash Screen has timed-out. The Main Menu
Screen has four selections for navigation to other screens where machine
functions and settings can be selected and modified. Use the <UP> and
<DOWN> arrow symbol buttons to move the cursor (>) to the appropriate line,
then press the <ENT> button to make the desired selection.
MAIN MENU
------------------------------
>WRAP PROGRAM SELECT
MACHINE SETTINGS
MACHINE CALIBRATION
WRAP CYLE COUNTER
A
Screen #4 – Main Menu Screen
A large letter A, B, or C is displayed at the bottom of the Main Menu screen to

indicate the currently selected Wrap Program (refer to Section 5:2:4:1).
28
5:2:4:1 Wrap Program Select Screen
The WRAP PROGRAM SELECT screen, accessed from the MAIN MENU
screen, has three lines that are used to select Wrap Program A, Wrap Program
B, or Wrap Program C. When a wrap cycle is started, the machine will perform
the pre-programmed wrap cycle using the parameters stored in the selected
program. A letter <A>, , or <C> representing the selected wrap program will
be displayed at the bottom of the Main Menu screen.
WRAP PROGRAM SELECT

------------------------------
>PROGRAM <A>
PROGRAM 
PROGRAM <C>
Screen #5 – Wrap Program Select Screen
5:2:4:2 Machine Settings Screen
The MACHINE SETTINGS screen, accessed from the MAIN MENU Screen, has
three links that are used to navigate to the Program <A>, Program , or
Program <C> Settings screens where the machine presets and wrapping
parameters for each wrap program can be accessed and modified.
MACHINE SETTINGS
------------------------------
>PROGRAM <A> SETTINGS
PROGRAM SETTINGS
PROGRAM <C> SETTINGS
Screen #7 – Machine Settings Screen
Use the <UP> and <DOWN> arrow symbol keypad buttons to move the cursor
(>) vertically to the desired Program <A>, or <C> Settings line, then press
the <ENT> (Enter) keypad button to go to the selected Program Settings screen.
29
The PROGRAM <A> (or or <C>) SETTINGS screens contain five links that
are used to navigate to other screens where specific machine presets and
wrapping parameters can be accessed and modified. The Program <A> Settings
screen is shown below. The Program and <C> Settings screens are
identical.
PROGRAM <A> SETTINGS

------------------------------
>WRAP COUNT SETTINGS
PHOTO-EYE SETTINGS
WRAP MODE SETTINGS
FILM FORCE SETTINGS
TOP SHEET SETTINGS
Screen #8 – Program <A> Settings Screen
5:2:4:2:1 Wrap Count Settings A (or B or C) Screen
This screen is used to set the number of wrap revolutions that will be applied to
the base and top of the load during the wrap cycle. The Wrap Count Settings
<A> screen is shown below. Wrap Count Settings and <C> screens are
identical.
WRAP COUNT
SETTINGS <A>
------------------------------
>TOP WRAP REVOLUTIONS :02
BASE WRAP REVOLUTIONS :02
Screen #9 – Wrap Count Settings <A> Screen
5:2:4:2:1.1 Top Wrap Revolutions Setting
The TOP WRAP REVS. setting is used to program the number of wrap
revolutions that will be applied to the top of the load during the wrap cycle. To
adjust the Top Wrap Revolutions preset value, move the cursor (>) to this line
and then use the <+> or <-> keypad buttons to increment or decrement the
value. A Top Wrap Revolution preset value from <1> to <12> can be entered.
30
5:2:4:2:1.2 Base Wrap Revolutions Setting
The BASE WRAP REVS. setting is used to program the number of wrap
revolutions that will be applied to the bottom of the load during the wrap cycle.
To adjust the Base Wrap Revolutions preset value, move the cursor (>) to this
line and then use the <+> or <-> keypad buttons to increment or decrement the
value. A Base Wrap Revolution preset value from <1> to <12> can be entered.
5:2:4:2:2 Photo-Eye Settings A (or B or C) Screen
This screen is used to enable or disable the Auto Load Height Sensing Photo-eye
(when operating in semi-automatic mode) and to adjust the amount of film that
will overlap the top of the load. Photo-Eye Settings <A> screen is shown below.
Photo-Eye Settings and <C> screens are identical.
PHOTO-EYE SETTINGS <A>

------------------------------
>AUTO LOAD
HEIGHT EYE :ON
TOP OF LOAD
FILM OVERLAP :08
Screen #10 – Photo-Eye Settings <A> Screen
5:2:4:2:2.1 Auto Load Height Photo-Eye Off / On Selection
The AUTO LOAD HEIGHT EYE selection is used to toggle the Auto Load Height
Sensing Photo-Eye parameter <ON> or <OFF>.
In most cases it is desirable to set this to the <ON> state, which allows the
machine to automatically adjust for varying load heights. Adjust the upper limit
switch striker to its highest position when using the Auto Load Height Photo-Eye.
(Refer to Section 5:5)
In the event that it becomes necessary to adjust the film carriage elevator height
manually, (due to uneven load top layer, voids in the load or photo-eye
malfunction), set this to the <OFF> state and adjust the upper limit switch striker
position manually. (Refer to Section 5:5)
31
To modify the Auto Load Height Sensing Photo-Eye setting, move the cursor (>)
to this line and then use the <+> or <-> keypad buttons to toggle the value
between <ON> and <OFF>.
5:2:4:2:2.2 Top of Load Film Overlap Setting
The TOP OF LOAD FILM OVERLAP setting is used to preset the amount of film
that will overlap the top of the load.
During the wrap cycle, after the Auto Load Height Sensing Photo-Eye (1PE)
detects the top of the load, pulses from the Carriage Height Pulse Sensor (5PX)
are counted until the number of pulses counted is equal to the distance
represented by the Top of Load Film Overlap value, at which time the film
carriage elevator stops ascending.
This parameter is adjustable from a minimum value of 0 inches (or 0 cm) to a

maximum value of 20 inches (or 50 cm). To adjust the Top of Load Film Overlap
preset value, move the cursor (>) to this line and then use the <+> or <-> keypad
buttons to increment or decrement the value.
5:2:4:2:3 Wrap Mode Settings A (or B or C) Screen
The Wrap Mode Settings Screen is used to set the wrap mode parameters.
Wrap Mode Settings <A> screen is shown below. Wrap Mode Settings and
<C> screens are identical.
WRAP MODE SETTINGS <A>

------------------------------
>BASE/TOP WRAPS
FIRST MODE :TOP
UP ONLY
WRAP MODE :OFF
SLOW START REVOLUTIONS :00
Screen #11 – Wrap Mode Settings <A> Screen
5:2:4:2:3.1 Base/Top Wraps First Mode Selection
PILOT stretch wrap machines have the capability of operating in either a Top
Wraps First wrap mode or a Base Wraps First wrap mode.
When the machine is in Top Wraps First wrap mode, the film carriage elevator
will ascend to the top of the load immediately at the start of the cycle.
32
When the machine is in Base Wraps First wrap mode, the film carriage elevator
will only ascend after the preset base wrap revolutions have been completed.
To modify the BASE/TOP WRAPS FIRST MODE setting, move the cursor (>) to
this line and then use the <+> or <-> keypad buttons to toggle the value between
<BASE> and <TOP>.
5:2:4:2:3.2 Up Only Wrap Mode Setting
PILOT stretch wrap machines have the capability of operating in either an Up

And Down wrap mode or an Up Only wrap mode.
When the machine is in Up And Down wrap mode, the load is wrapped from
bottom to top and then back to bottom applying a convolute wrap. (This is
sometimes referred to as “Cross-Spiral” wrap mode.)
When the machine is in Up Only wrap mode, the load is wrapped from bottom to
top only. (This is sometimes referred to as “Simple-Spiral” wrap mode.) An Up
Only wrap cycle is always performed as a Base Wrap First style of wrap cycle,
irrespective of the BASE/TOP WRAPS FIRST MODE setting, so when the
machine is in Up Only wrap mode the film carriage elevator will only ascend after
the preset base wrap revolutions have been completed.
 NOTICE! When using the UP ONLY wrap mode, it will be

necessary to activate the Film Carriage Lower keypad button to
return the carriage to the lower limit, before starting the next cycle!
To modify the UP ONLY WRAP MODE setting, move the cursor (>) to this line
and then use the <+> or <-> keypad buttons to toggle the value between <OFF>
and <ON>.
5:2:4:2:3.3 Slow Start Revolutions Setting
The SLOW START REVOLUTIONS setting is used to enter a value that will
force the turntable to run using the Start Speed setting for the preset number of
revolutions.
This feature can beneficial when wrapping unstable products that will not sustain
the full turntable speed before some layers of film have been applied to the load.
This parameter is adjustable from a minimum value of 0 to a maximum value of

25 revolutions. To adjust the SLOW START REVOLUTIONS preset value, move
the cursor (>) to this line and then use the <+> or <-> keypad buttons to
increment or decrement the value.
33
5:2:4:2:4 Film Force Settings A (or B or C) Screen
This screen is used to enable or disable the Reduced Bottom Film Force
parameter, and to adjust the number of Delayed Film Force Revolutions that will
be counted at the start of the wrap cycle before enabling the Force to Load
setting. Film Force Settings <A> screen is shown below. Film Force Settings
 and <C> screens are identical.
FILM FORCE
SETTINGS <A>
------------------------------
>REDUCED BOTTOM
FILM FORCE :OFF
DELAYED FILM
FORCE REVOLUTIONS :00
Screen #12 – Film Force Settings <A> Screen
5:2:4:2:4.1 Reduced Bottom Film Force Selection
The REDUCED BOTTOM FILM FORCE selection is used to toggle the Reduced
Bottom Film Force parameter <ON> or <OFF>.
Loads with protruding pallet corners may cause the film to break when wrapping
the base of the load. By reducing the Film Tension (Force to Load) while the
base of the load is being wrapped, this can be prevented.
When the Reduced Bottom Film Force parameter is set to the <ON> state, and
the film carriage has reached its bottom limit after descending from the top of the
load, the Force To Load setting on the keypad is disabled. Once the base wrap
revolutions are complete and the film carriage has ascended clear of the pallet,
the keypad Force To Load setting will be re-engaged and film will be applied to
the load at the selected value for the duration of the wrap cycle.
To modify the Reduced Bottom Film Force setting, move the cursor (>) to this
line and then use the <+> or <-> keypad buttons to toggle the value between
<ON> and <OFF>.
34
5:2:4:2:4.2 Delayed Film Force Revolutions Setting
The DELAYED FILM FORCE REVOLUTIONS setting is used to program the

number of wrap revolutions that will be counted from the beginning of the wrap
cycle before the keypad Force To Load setting is enabled.
Lightweight loads may tend to slide or topple due to the dragging effect of the
film, during the initial revolutions of the wrap cycle. By using the Delayed Film
Force Revolutions parameter to reduce the Film Tension (Force To Load) for a
preset number of revolutions, the load can be effectively stabilized during the
initial revolutions of the wrap cycle. Once the preset number of turntable
revolutions have been counted, the Force To Load setting will be engaged and
film will be applied to the load using the keypad Force To Load value for the
remainder of the wrap cycle.
This parameter is adjustable from a minimum value of 0 to a maximum value of 9

revolutions. To adjust the Delayed Film Force Revolutions preset value, move
the cursor (>) to this line and then use the <+> or <-> keypad buttons to
increment or decrement the value.
5:2:4:2:5 Top Sheet Settings A (or B or C) Screen
This screen is used to enable or disable the Top Sheet Pause parameter, and to
adjust the distance the film carriage will descend when the Top Sheet Pause is
initiated. Top Sheet Settings <A> screen is shown below. Top Sheet Settings
 and <C> screens are identical.
TOP SHEET SETTINGS <A>

------------------------------
>PAUSE WRAP CYCLE FOR
TOP SHEET APPLICATION :OFF
DISTANCE TO LOWER FILM

CARRIAGE AFTER PAUSING :50
Screen #13 – Film Force Settings <A> Screen
5:2:4:2:5.1 Pause Wrap Cycle for Top Sheet Application Selection
The PAUSE WRAP CYCLE FOR TOP SHEET APPLICATION selection is used
to toggle the Top Sheet Pause parameter <ON> or <OFF>.
35
In some cases it is desirable to cover the top of the load with a top sheet of
polyethylene film, and then wrap the edges of the top sheet into the load for
security.
When the PAUSE WRAP CYCLE FOR TOP SHEET APPLICATION parameter
is set to the <ON> state, and the film carriage has reached the top of the load
after having applied film from the bottom to the top of the load in a spiral pattern,
a top Sheet Pause will be triggered, causing the wrap cycle to “pause” and all
machine motion to come to a halt. The Top Sheet Pause condition will be
indicated by a message on the Operator Interface Panel (HMI).
Once the machine has come to a stop, manually place a top sheet over the top of
the load and adjust it as necessary so that the sides of the top sheet drape down
the sides of the load evenly.
Once the Top Sheet has been applied, pressing the green wrap cycle
<START/PAUSE> button will allow the wrap cycle to resume. As the wrap cycle
continues, the top sheet will be wrapped into the load by the layers of film that
are applied over the draped edges of the top sheet.
To modify the PAUSE WRAP CYCLE FOR TOP SHEET APPLICATION setting,
move the cursor (>) to this line and then use the <+> or <-> keypad buttons to
toggle the value between <ON> and <OFF>.
5:2:4:2:5.2 Distance to Lower Film Carriage After Pausing Setting
The DISTANCE TO LOWER FILM CARRIAGE AFTER PAUSING setting is

used to program a preset distance that the film carriage will descend when a Top
Sheet Pause is initiated.
If a value greater than <0> is entered for this parameter, then when the Top
Sheet Pause is initiated, the film carriage will descend. As the film carriage
descends, pulses from the Carriage Height Pulse Sensor (5PX) are counted until
the number of pulses counted is equal to the distance represented by the
DISTANCE TO LOWER FILM CARRIAGE AFTER PAUSING value, at which
time the film carriage elevator stops descending
The purpose of this parameter is to move the film carriage and stretch film to a
level below the top sheet, so that when the wrap cycle is resumed, and the film
carriage ascends back up to the top of the load, the top sheet will be wrapped
into the load
This parameter is adjustable from a minimum value of 0 inches (or 0 cm) to a

maximum value of 30 inches (or 75 cm). To adjust the DISTANCE TO LOWER
36
FILM CARRIAGE AFTER PAUSING preset value, move the cursor (>) to this
line and then use the <+> or <-> keypad buttons to increment or decrement the
value.
5:2:4:3 Calibration Settings Screen
The CALIBRATION SETTINGS screen, accessed from the MAIN MENU screen,
is used to set the parameters related to the overall calibration of the machine.
Values entered in the Calibration Settings are used for all wrap programs.
In order to prevent unauthorized personnel from adjusting critical operating

parameters, access to the Calibration Settings screen is password protected.
When the MACHINE CALIBRATION line is selected on the MAIN MENU screen,
the RESTRICTED ACCESS screen will appear, and correct entry of a password
in this screen is required before the Calibration Settings screen can be displayed.
RESTRICTED ACCESS
-----------------------------
PASSWORD: 0000
Screen #14 – Password Entry Screen
A factory standard password is used for PILOT machines. This password cannot
be changed, so it should be safeguarded to prevent unauthorized access to the
Calibration Settings. Contact your Pilot Stretchwrappers authorized sales
representative to obtain this password. Identification may be requested to
ensure that the person requesting the password has the proper authorization
within their organization.
Use the <UP> and <DOWN> arrow symbol keypad buttons to move the cursor
horizontally between the digits of the password. The digit that the cursor is on
will be displayed with a dark background. Use the <+> or <-> keypad buttons to
increment or decrement the individual password digit values. Once the correct
password has been entered press the <ENT> button to accept the password
entry. If the correct password was entered the CALIBRATION SETTINGS
screen will be displayed. If an incorrect password is entered the MAIN MENU
screen will be displayed. If no keypad activity is detected within a five seconds of
entering the RESTRICTED ACCESS screen, the MAIN MENU screen will be
displayed.
37
CALIBRATION SETTINGS
------------------------------
>LANGUAGE :ENGLISH
MEASURES :IMPERIAL
TURNTABLE START SPD.:033
TURNTABLE RUN SPEED :090
T/TABLE REALIGN SPD.:010
REALIGN DELAY :2.9
Screen #15 – Calibration Settings Screen
5:2:4:3:1 Language Selection
The LANGUAGE selection is used to set the Language displayed on the

Operator Interface (HMI) display screen.
To adjust the Language selection, move the cursor (>) to this line and then use
the <+> or <-> keypad buttons to scroll through the available languages. To
accept an alternate language selection, after you have scrolled to the desired
selection, press the <ENT> button. Once this is done, all the Operator Interface
Panel (HMI) menu screens and status and fault messages will be displayed in
the new language.
5:2:4:3:2 Measures Selection
The MEASURES selection is used to set the units of measure affecting certain
parameters related to distance.
To modify the Measures selection, move the cursor (>) to this line and then use
the <+> or <-> keypad buttons to toggle the value between <IMPERIAL> and
<METRIC> units of measure.
After changing the Measures selection, all wrap parameters that reference
distance measurement will need to be re-entered to correspond to the revised
units – i.e. if changing from an Imperial “inch” distance setting to a Metric “cm”
distance setting, the parameter’s preset value will need to be increased by a
factor of 2.5 in order to produce the same result.
5:2:4:3:3 Turntable Start Speed Setting
The TURNTABLE START SPD. setting is used to preset the Turntable Start
Speed value.
38
If a value higher than <0> is entered in the Slow Start Revolutions parameter, the
turntable will operate at the Start Speed setting for the preset number of
revolutions.
This parameter is adjustable from a minimum value of 10 percent to a maximum

value of 60 percent of full speed. To adjust the Turntable Start Speed preset
value, move the cursor (>) to this line and then use the <+> or <-> keypad
5:2:4:3:4 Turntable Run Speed Setting
The TURNTABLE RUN SPEED setting is used to preset the Turntable Run
Speed value. The Turntable Run Speed setting determines the speed that the
turntable motor will operate at during the wrap cycle, after any Start Speed
revolutions have been counted, and until part way into the final revolution.
Adjustable from 1 to 12 R.P.M. to suit loads of varying stability, it is typically

factory preset to 10 R.P.M. (1 revolution every 6 seconds.)

value of 100 percent of full speed. To adjust the Turntable Run Speed preset
5:2:4:3:5 Turntable Realign Speed Setting
The T/TABLE REALIGN SPD. setting is used to preset the Turntable

Realignment Speed value.
The Turntable Realignment Speed setting is only active in the final revolution of
an automatic wrap cycle, after the Realign Delay timer has timed-out, and sets
the value for the slow speed used to control realignment of the turntable back to
the home (starting) position. This is typically factory preset to approximately 1-
1/2 R.P.M. Once this is set, it should not require any further adjustment. If the
realignment of the turntable ever requires adjustment, refer to Section 9:8 for the
correct procedure.
The Turntable Realignment Speed setting is also engaged when manually

jogging the turntable.

value of 20 percent of full speed. To adjust the Turntable Realign Speed preset
buttons to increment or decrement the value. The factory default setting is <10>.
39
5:2:4:3:6 Realign Delay Setting
The REALIGN DELAY setting is used to preset the Turntable Realign Delay
Timer value.
The Turntable Realign Delay Timer is used to delay the transition from Turntable
Run Speed to Turntable Realign Speed during the final revolution of the wrap
cycle.
By delaying this transition in speed, the amount of time it takes for the turntable
to realign back to the home (starting) position is minimized. Refer to the
Turntable Positive Alignment Set-Up and Adjustment procedure in Section 9.8 for
details on how this timer’s preset value should be adjusted.
This parameter is adjustable from a minimum value of 0.0 to a maximum value of

9.9 seconds. To adjust the Turntable Realign Delay preset value, move the
cursor (>) to this line and then use the <+> or <-> keypad buttons to increment or
decrement the value.
5:3 Turntable Speed Adjustment
The Turntable Run Speed is adjustable from approximately 1 RPM to 12 RPM.

Access the Turntable Run Speed setting (refer to Section 5:2:4:3.4) in the
CALIBRATION SETTINGS screen and then adjust the Turntable Run Speed to
the desired level.
Cycle the machine to observe the modified setting. Re-adjust as necessary.
5:4 Film Carriage Elevator Speed Set-Up
PILOT series stretch-wrappers are equipped with independent speed controls for
the film carriage raise and film carriage lower functions.
5:4:1 Film Carriage Elevator Raise Speed
The film carriage elevator raise speed is used to control the amount of overlap
between the layers of film while the film carriage is ascending. Adjust the film
carriage elevator raise speed using the Film Carriage Raise Speed keypad
buttons (refer to Section 5:1:9) until the desired film web overlap is achieved. (A
four to six inch overlap between layers is recommended for most applications.)
40
When operating in semi-automatic mode it is recommended that the film carriage

elevator raise speed be adjusted to a fast setting in order to stabilize the top of
the load early in the wrap cycle.
5:4:2 Film Carriage Elevator Lower Speed
The film carriage elevator lower speed is used to control the amount of overlap
between the layers of film while the film carriage is descending. Adjust the film
carriage elevator lower speed using the Film Carriage Lower Speed keypad
buttons (refer to Section 5:1:10) until the desired film web overlap is achieved.
(A four to six inch overlap between layers is recommended for most
applications.)
5:5 Film Carriage Limit Switch Striker Adjustment
The film carriage is designed to run vertically between the adjustable upper and
lower limit switch strikers.
It is not necessary to adjust the position of the upper limit switch striker in order
to suit each different load height because the Auto Load Height Sensing Photo-
eye (1PE) automatically detects the top of the load and stops the film carriage at
the correct height. The upper limit switch striker should therefore be located at
its highest allowable position to act as an over-ride in the event of photo-eye
malfunction or if a load exceeding the wrap height capability of the machine is to
be wrapped.
The lower limit switch striker only needs to be adjusted if it is desirable to prevent
the film from being applied to the pallet or to provide some roping of the film at
the bottom of the load.
 CAUTION! When making limit switch striker adjustments,

ensure that at all times the upper limit switch striker is positioned
ABOVE the film carriage top limit switch lever arm and that the
lower limit switch striker is positioned BELOW the film carriage
bottom limit switch lever arm. Failing to ensure this may result in
the film carriage overrunning its allowable range of travel causing
damage to the film carriage drive mechanism!
To adjust a limit switch striker, use the appropriate size Allen (hex) key to loosen
the socket head screws, slide the striker vertically in its track to the desired
position and then securely re-tighten the screws.
41
5:6 Auto Load Height Sensing Photo-Eye Adjustment
The Auto Load Height Sensing Photo-Eye is used to automatically detect the top
of the load in order to accommodate varying load heights.
The Auto Load Height Sensing photo-eye eliminates the necessity of relocating
the upper limit switch striker in order to accommodate varying load heights. It is
usually desirable to overlap the top of the load by three to four inches with the
film web. The degree of overlap is a function of the photo-eye signal and the Top
of Load Film Overlap setting in the Photo-Eye Settings screen (refer to Section
5:2:4:2:2.2).
In order for the photo-eye to control the upper stopping position of the film
carriage the Auto Load Height Photo-Eye function must be set to <ON> in the
Photo-Eye Settings screen (refer to Section 5:2:4:2:2.1).
5:7 Film Carriage Descent Obstruction Plate Safety Switch
PILOT stretch wrap machines are equipped with a Film Carriage Descent
Obstruction Plate and Carriage Safety Switch.
The purpose of the Film Carriage Descent Obstruction Plate Safety Switch is to
disable the wrap cycle and the film carriage elevator descent, in the event that
the Descent Obstruction Plate is obstructed, (i.e. by some foreign object located
between the bottom of the film carriage and the floor), during the wrap cycle or
when the film carriage elevator is being manually lowered using the Film Carriage
LOWER keypad button.
When the Film Carriage Descent Obstruction Plate is actuated, the Carriage
Safety Switch contacts open, disabling the Automatic Wrap Cycle and the film
carriage elevator lower function. This condition will be indicated by the red
flashing Fault light on the control panel and by an error message displayed on
the Operator Interface Panel (HMI).
To reset the machine after the film carriage safety switch has been tripped,
manually raise the film carriage using the Film Carriage Elevator RAISE keypad
button (refer to Section 5:1:7), or cycle the power by turning the Power Off–Reset
switch to the <OFF> position and then back to the <RESET> position. (Refer to
Section 10:1:2 for more detail on this fault condition.)
42
43
6:0 WRAPPING A LOAD
6:1 Placing the Load on the Turntable
Center the load to be wrapped on the turntable and ensure that it is securely
situated before proceeding. The best wrap results will be achieved if the loads
are positioned evenly in the center of the turntable.
 WARNING! When loading by forklift truck, avoid collisions

between the lift truck and the machine structure!
6:2 Threading the Prestretch Film Dispenser
Raise the film carriage to a comfortable height and place a roll of film on the film
mandrel. Twist the film into a rope and then, referring to the threading diagram
on the following page, thread the film as follows:
1. With your right hand, grasp the prestretch safety door handle while
pressing the latch release lever with your thumb.
2. Carefully allow the safety door to pivot forward until it stops in the open
position.
3. Loop the roped film around the back side of the diverter roller on the left-
hand side of the carriage adjacent to the where the film roll mandrel is
located.
4. Pull the roped film across the space between the open door and the
polyurethane coated rollers, and across the front of the spring-loaded
dancer roller on the right-hand side of the carriage.
5. Gently push the door closed until the latch is firmly engaged.
44
Prestretch Film Dispenser Threading Diagram
The film feed is disabled when the machine is at rest. Press the blue MANUAL
FILM FEED push-button on the control panel to temporarily enable the film feed,
and then gently pull the film tail towards the turntable. This action will cause the
Dancer Roller to pivot and the machine will begin to dispense film. If the film
feed shuts off before sufficient film has been fed, then pressing the MANUAL
FILM FEED button again will reactivate the film feed for another timed interval.
45
6:3 Attaching the Film to the Load
Press the blue MANUAL FILM FEED push-button on the control panel to
temporarily enable the film feed and draw approximately three to five feet of
material from the prestretch carriage. Rope the end of the film and attach to any
convenient point on the load or pallet.
6:4 Starting the Wrap Cycle (Initial Set-up)
Place the load to be wrapped onto the turntable. (Refer to Section 6:1.)
Set the Top Wrap Revolutions preset value, (refer to Section 5:2:4:2:1.1), Base
Wrap Revolutions preset value, (refer to Section 5:2:4:2:1.2), Carriage Raise
Speed, (refer to Section 5:1:9) and Carriage Lower Speed, (refer to Section
5:1:10), to the desired values. Turn the Force to Load Control knob to zero.
Press the green CYCLE START / PAUSE push-button momentarily, to start the
wrap cycle. As the load rotates, gradually increase the Force to Load setting
until the desired film tension level is obtained. This setting should be acceptable
for subsequent loads if the length and width of the load do not vary greatly.
 NOTICE! Film economy is determined by the film

dispenser’s prestretch ratio. The setting of the Force to Load
Control knob controls the tightness of the film web as it is delivered
to the load only. Most films will continue to tighten on the load for
several hours after wrapping due to film “memory”.
6:5 Wrap Cycle Sequence of Operation
6:5:1 Up and Down (Cross-Spiral) Wrap Cycle – Top Wraps First
To operate the machine in Up and Down – Top Wraps First mode, the “Base
Wraps First Mode” parameter must be set to the TOP FIRST state on the
Operator Interface Panel (HMI) (refer to Section 5:2:4:2:3.1), and the “Up Only
Wrap Mode” parameter must be set to the UP AND DOWN state on the Operator
Interface Panel (HMI) (refer to Section 5:2:4:2:3.2).
Set the Top and Base wraps to the desired values. Set the Force to Load and
Carriage Speed controls to the desired levels. Ensure the film is attached to the
load.
46
 NOTICE! “Top Wraps First” wrap mode is disabled when

the Up Only Wrap Mode is set to the “Up Only” state!

1. Press the CYCLE START / PAUSE button momentarily. The turntable

starts to rotate. The film carriage ascends, winding the film around the
load in a spiral pattern. (Minor adjustment to the Force to Load setting
may be required.)
2. When the top of the load is reached the film carriage ascent stops and
the top of the load is wrapped.
3. As the turntable rotates, pulses produced by the Turntable Position Pulse

sensor (1PX) are counted (in the microcontroller), to determine when
each 360° revolution of the turntable has been completed.
4. Upon completion of the preset top wrap revolutions, the film carriage
descends, winding the film around the load in a spiral pattern across the
layers of film previously applied.
5. When the film carriage reaches the bottom limit switch, the film carriage
descent stops and the base of the pallet is wrapped.
6. Upon completion of the preset base wrap revolutions, less one, the
turntable begins the final revolution of the cycle. The Turntable Realign
Delay timer starts and after timing-out, the turntable decelerates to the
speed set by the Turntable Realign Speed setting (refer to Section
5:2:4:3:5), prior to aligning to the home position and stopping.
6:5:2 Up and Down (Cross-Spiral) Wrap Cycle – Base Wraps First
To operate the machine in Up and Down – Base Wraps First mode, the “Base
Wraps First Mode” parameter must be set to the BASE FIRST state on the
Operator Interface Panel (HMI) (refer to Section 5:2:4:2:3.1), and the “Up Only
Wrap Mode” parameter must be set to the UP AND DOWN state on the Operator
Interface Panel (HMI) (refer to Section 5:2:4:2:3.2).
load.
47


starts to rotate. (Minor adjustment to the Force to Load setting may be
required.)

sensor (1PX) are counted (in the microcontroller), to determine when
each 360° revolution of the turntable has been completed.
3. When the preset bottom wrap revolutions are complete, the film carriage
ascends, winding the film around the load in a spiral pattern.
the top of the load is wrapped.
5. Upon completion of the preset top wrap revolutions, the film carriage
descends, winding the film around the load in a spiral pattern across the
layers of film previously applied.
6. When the film carriage reaches the bottom limit switch, the turntable
begins the final revolution of the cycle. The Turntable Realign Delay
timer starts and after timing-out, the turntable decelerates to the speed
set by the Turntable Realign Speed setting (refer to Section 5:2:4:3:5),
prior to aligning to the home position and stopping.
6:5:3 Up Only (Simple-Spiral) Wrap Cycle – Base Wraps First
To operate the machine in Up Only – Base Wraps First mode, the “Up Only Wrap
Mode” parameter must be set to the UP ONLY state on the Operator Interface
Panel (HMI) (refer to Section 5:2:4:2:3.2). It is not necessary to program the
machine control to “Base Wraps First” wrap mode (Refer to Section 5:2:4:2:3.1).
load.

48

starts to rotate. (Minor adjustment to the Force to Load setting may be
required.)

sensor (1PX) are counted (in the microcontroller)), to determine when
each 360° revolution of the turntable has been completed
3. When the preset bottom wrap revolutions are complete, the film carriage
ascends, winding the film around the load in a spiral pattern.
the top of the pallet is wrapped.
5. Upon completion of the preset top wrap revolutions, less one, the
turntable begins the final revolution of the cycle. The Turntable Realign
Delay timer starts and after timing-out, the turntable decelerates to the
speed set by the Turntable Realign Speed setting (refer to Section
5:2:4:3:5), prior to aligning to the home position and stopping.
 NOTICE! When using the UP ONLY wrap mode, it will be

necessary to activate the Film Carriage Lower keypad button to
return the carriage to the lower limit, before starting the next cycle!
6:5:4 Film Fault Reset Sequence (Optional)
If the machine is equipped with the optional Broken Film Detection feature, then
in the event that the film breaks or runs out during the wrap cycle, the dancer bar
on the prestretch film carriage springs back to its retracted position, shutting off
the Prestretch film dispenser drive (3VFD).
This will then cause the Frequency Threshold Attained output (3VFD-LO+) on the
Prestretch drive to deactivate. After a time-delay to verify the absence of film
tension, the machine will initiate a Film Fault Reset Cycle and signals the fault
condition by flashing the red FAULT indicator light on the control panel and
displaying a diagnostic message on the Operator Interface Panel (HMI).
1. A film fault is detected. The turntable continues running. The Film

Carriage Raise and Lower outputs are disabled, causing the film carriage
to stop.
2. The turntable reaches its home position at which time it begins its final
revolution. The Turntable Realign Delay timer(in the microcontroller)
starts (refer to Section 5:2:4:3:6) and after timing-out, the turntable
49
decelerates to the speed set by the Turntable Slow Speed setting prior to
reaching the turntable home position and stopping.
3. Upon reaching the turntable home position the turntable stops,

completing the Film Fault Reset Cycle.
50
51
7:0 REMEDIAL ADJUSTMENT
7:1 Turntable Soft-Start
Turntable Soft-Start (or acceleration) is controlled by the turntable AC Variable

Frequency Drive
Turntable start-up speed may be affected by a wide range of load weights and
stability factors. If the load twists, distorts, or spills during the first few moments
of turntable rotation, this may indicate that the acceleration time is set too low.
(Refer to Section 9:8.)
7:2 Load Toppling or Sliding
Lightweight loads may tend to slide off the turntable or topple due to the dragging
effect of the film.
A few modifications may be required in order to achieve satisfactory operation:
1. Increase the Delayed Film Force Revolutions setting (refer to section

5:2:4:2:4.2) to allow the load to be stabilized during the initial revolutions
of the wrap cycle.
2. Decrease the Force to Load setting (refer to Section 5:1:11) to allow the
film web to feed out with less compressive force (film tension).
3. Select a film of thinner gauge requiring less force to load to make it elastic.
4. Select a film of softer composition that will behave in a more gentle

fashion.
5. Decrease the Turntable Run Speed setting. (Refer to Section 5:2:4:3:4)
7:3 Film Tearing & Puncturing
If the film is tearing or puncturing, determine whether the film is being damaged
before leaving the prestretch, or after leaving the prestretch and as it is applied to
the load.
If the film is being damaged before leaving the prestretch try the following:
52
1. Check the roll of film for any signs of damage such a bad edge caused
by the roll being dropped.
2. Check all the roller surfaces that the film web passes over for any signs
of cutting, imperfections or a build-up of film.
 WARNING! PINCH POINTS Be careful to keep hands,

hair and loose clothing well clear of the polyurethane coated
prestretch rollers and aluminum pinch rollers while power is
applied!
3. If the roll of film does not appear to have been damaged and there are
no detectable imperfections on the prestretch rollers, nip rollers or
dancer rollers, it may be necessary to change the prestretch ratio to a
lower prestretch percentage, or select a higher quality film.
If the film is being damaged after leaving the prestretch and as it is applied to the
load try the following adjustments:
4. Decrease the Force to Load setting (refer to Section 5:1:11) to allow the
film web to feed out with less compressive force (film tension).
5. For loads inset far from the corners of the pallet, manually raise the film
carriage and then adjust the carriage lower limit striker upward to place
the bottom edge of the film web above the offending pallet corner(s).
 CAUTION! Ensure that at all times the lower limit switch

striker is positioned BELOW the film carriage limit switches lever
arm. Failing to ensure this may result in the film carriage
overrunning its allowable range of travel causing damage to the
film carriage drive mechanism!
 NOTICE! These techniques may also be used with slip-

sheet or carton clamp material handling systems if the pallet is not
to be held captive to the load!
53
7:4 Uneven Top Surfaces
Loads with an uneven number of cartons on the top may require the Auto Height
Control Photo-eye to be over-ridden in order to make the top of the load secure.
Turn the Auto Load Height Photo-Eye parameter <OFF> (refer to Section
5:2:4:2:2.1). The wrapping of the top of the load will now be controlled by the
carriage upper limit switch signal instead of the photo-eye signal. Lower the
upper limit switch striker to a position will allow the film to ride up over the top
corners of the load by three to four inches. (The use of a top sheet is
recommended.)
The carriage upper limit switch striker will over-ride the Auto Load Height Photo-
eye function. To return to the photo-eye operating mode, reposition the upper
limit switch striker back to its highest position and turn the Auto Load Height
Photo-Eye function <ON> (refer to Section 5:2:4:2:2.1).
 CAUTION! Ensure that at all times the upper limit switch

striker is positioned ABOVE the film carriage limit lever arm.
Failing to ensure this may result in the film carriage overrunning its
allowable range of travel causing damage to the film carriage drive
mechanism!
7:5 Auto Load Height Photo-Eye False Signals
The Auto Load Height Photo-eye uses an infrared beam reflected off the surface
of the load surface to trigger its output. Some products being wrapped may
cause a false “bounce-back” due to color or inherent shininess, which confuses
the machine and leads to improper top wrap function.
False signals may be able to be “tuned-out” through an adjustment of the photo-

eye distance, (or sensitivity), setting located on the photo-eye (refer to Section
9:7 for details) and / or the Top of Load Film Overlap setting (refer to Section
5:2:4:2:2.2).
7:6 Top Sheet Application
In some cases it is desirable to cover the top of the load with a top sheet of
polyethylene film, and then wrap the edges of the top sheet into the load for
security.
54
If it is necessary to install a top sheet, this can be easily accomplished by

selecting the Pause Wrap Cycle for Top Sheet Application parameter <ON> in
the Top Sheet Settings screen (refer to Section 5:2:4:2:5.1), under the
appropriate Program A (or B, or C) Settings.
When the Pause Wrap Cycle for Top Sheet Application parameter is set to the
<ON> state, and the film carriage has reached the top of the load after having
applied film from the bottom to the top of the load in a spiral pattern, a top Sheet
Pause will be triggered, causing the wrap cycle to “pause” and all machine
motion to come to a halt. The Top Sheet Pause condition will be indicated by a
message on the Operator Interface Panel (HMI).
Once the machine has come to a stop, manually place a top sheet over the top of
the load and adjust it as necessary so that the sides of the top sheet drape down
the sides of the load evenly. After the Top Sheet has been applied, pressing the
green Wrap Cycle <START/PAUSE> button will allow the wrap cycle to resume.
As the wrap cycle continues, the top sheet will be wrapped into the load by the
layers of film that are applied over the draped edges of the top sheet.
55
7:7 Reinforcing Band Application
In some cases it is desirable to add reinforcing bands of film between the top and
bottom of the load as the film carriage is ascending or descending in order to
further stabilize the load.
This is easily accomplished by pressing the <ENT> keypad button when the film
carriage is at the desired height, while the film carriage is ascending or
descending during the wrap cycle, as indicated on the Operator Interface (HMI)
screens.
WRAP CYCLE
IN PROGRESS
------------------------------
THE FILM CARRIAGE IS

ASCENDING TO WRAP
THE TOP OF THE LOAD.
PRESS <ENT> TO
REINFORCE WRAP.
WRAP CYCLE
IN PROGRESS
-----------------------------
THE FILM CARRIAGE IS

DESCENDING TO WRAP
THE BASE OF THE LOAD.
PRESS <ENT> TO
REINFORCE WRAP.
Screen #17 & #18 – Film Carriage Ascending & Descending Screens
This causes the film carriage elevator to “pause”, while the turntable continues to
rotate, resulting in the application of reinforcing bands of film between the top
and bottom of the load. The Carriage Pause condition is indicated by a message
on the Operator Interface Panel (HMI).
56
WRAP CYCLE
IN PROGRESS
-----------------------------
-
THE FILM CARRIAGE

IS PAUSED.
PRESS <ENT> TO
RESUME, OR
WAIT 10 SECONDS.
Screen #19 – Film Carriage Paused Screen
Pressing the <ENT> keypad button while the film carriage is paused will disable
the pause condition and the film carriage elevator will resume traveling.
Alternately, after ten seconds the Carriage Pause function will self-cancel and the
film carriage elevator will resume traveling without further input from the operator.
57
8:0 MAINTENANCE REQUIREMENTS
8:1 Lubrication
When operating in normal environments the machine will require periodic

lubrication and maintenance as described in the following section. Use standard
industrial lubricants on a regular basis in proportion to the usage of the machine
and the cleanliness of the surroundings.
Unless otherwise specified, lubricating oils and greases should be regular

machine grade.
 Caution! Refer to the individual gear-reducer maintenance

instructions for correct lubricant specifications.
8:2 Maintenance Frequency Recommendations
Item Operation Frequency

Turntable Support Rollers Inspect Quarterly
Turntable Drive Gear- Change Oil Refer to
Reducer Component Mfr.’s
Specifications
Turntable Drive Chain Lubricate & Adjust Tension Within the first 100
operating hours,
then quarterly
Turntable Gear-Reducer Inspect & Tighten Set- Quarterly
Sprocket screws
1PX Turntable Pulse Inspect, Check / Adjust Quarterly
Proximity Sensor Sensing Distance, Tighten
Locking Nuts if required.
Film Carriage Elevator Drive Change Oil Refer to
Gear-Reducer Component Mfr.’s
Specifications
5PX Carriage Pulse Inspect, Check / Adjust Quarterly
Proximity Sensor Sensing Distance, Tighten
Locking Nuts if required.
58
Item Operation Frequency

Carriage Safety Switch Test Operation & Adjust As Monthly
Required
Carriage Lift Chain Lubricate & Adjust Tension Quarterly
Carriage Lift Sprockets Inspect & Tighten Mounting Quarterly
/ Set-screws
Carriage Limit Switch Arms Inspect Quarterly
Prestretch Roller Bearings Inspect & Tighten Set- Monthly
screws
Prestretch Chains Lubricate & Adjust Tension Monthly
Prestretch Sprockets Inspect & Tighten Set- Monthly
screws
 CAUTION! Inspect and tighten the turntable drive chain

after the first 100 operating hours. Follow the above-
recommended schedule thereafter.
 CAUTION! Recommended lubrication and inspection

frequency is based upon single shift operation. Adjust lubrication
and preventative maintenance accordingly for increased usage or
operation in a harsh environment.
 NOTICE! Some bearings are sealed-for-life rather than

regreasable. No maintenance is required or anticipated for the life
of the equipment.
59
9:0 MAINTENANCE AND ADJUSTMENTS
9:1 Film Carriage Lift Chain Adjustment
To adjust the carriage lift chain, first lower the film carriage to its halfway position
and remove the tower chain guard.
Visually inspect the carriage lift chain and shock-dampening spring. The chain
should be taut on the bottom side where it attaches to the carriage, (about 3/4”
side to side movement possible), with the spring slightly compressed.
If the chain is too loose the carriage movement will become somewhat jerky as
the carriage raises or lowers.
To adjust the lift chain, adjust the two-clevis nuts above the spring until the
desired tension is achieved. Then, securely tighten the two-clevis nuts against
each other to prevent loosening.
 CAUTION! Do not over-tighten the chain! Excessive

chain tension will overload the carriage lift gear-reducer.
Ensure that the sprockets are aligned parallel and centered with the chain at the
pick-up points. Run the carriage manually while holding the carriage cable away
from the tower guard mounting posts and verify that the lift motion is free of
binding and vibration.
 WARNING! Never remove the carriage lift chain without

first blocking the carriage for support!
9:2 Turntable Removal & Installation
The Low Profile turntable is fitted to the center sprocket assembly using four
12mm flat-head bolts.
To remove the turntable, first remove the four flat head bolts securing the
turntable to the center sprocket assembly. Install a 3/8” eye-bolt into the tapped
hole in the center of the turntable, hook up a chain or sling, and then lift the
turntable off with a fork-lift truck or chain fall.
To replace the turntable reverse the procedure, ensuring that the edge of the
turntable is aligned to the surrounding deck, and then slowly rotate the turntable
60
by hand until the holes in the turntable are aligned with the tapped holes in the
turntable center sprocket assembly. Reinstall the four flat-head bolts and tighten
securely.
9:3 Turntable Drive Chain Adjustment
A direct chain drive system is used to rotate the Low Profile turntable. To adjust
the chain, first remove the chain guard deck plate located on the base of the
machine between the tower and the turntable to expose the turntable chain
tensioner sprocket. Loosen the two hex head bolts securing the tensioner
sprockets slotted mounting block and then using a pry bar, move it forward, until
the desired chain tension is achieved. The chain should be taut, but not over-
tight. Securely tighten the two hex head bolts to lock the tensioner block in
position, and then replace the chain guard deck plate.
 CAUTION! Do not over-tighten the chain! Excessive

chain tension will overload the turntable gear-reducer.
 CAUTION! Operate the turntable. It should be relatively

quiet and should rotate without excessive chain noise or slapping.
Readjust the chain tension as necessary.
9:4 Turntable Support Rollers
The Low Profile Turntable support rollers consist of a precision ball bearing
inserted into a plastic wheel cover. The rollers are installed in sets of three, on a
common axle, in multiple cradles on the machine base plate beneath the
turntable. These rollers will require no maintenance unless damaged by
excessive impact loads or over-loading of the machine.
To access the turntable support rollers, remove the turntable as previously

described. The support rollers can be removed in sets of three, by lifting the
roller and axle assembly upwards and out the cradle. Spacers are installed
between the rollers and the cradle to prevent the rollers from binding. To remove
the rollers and spacers, remove the anti-rotation spring pin and then slide them
off of the end of the support axle.
Replacement support rollers should be reinstalled by reversing the procedure.

Ensure that the proper quantity of spacers are installed between the rollers, and
are properly oriented in the cradle and that all of the rollers within the cradle are
able to turn freely.
61
9:5 Film Carriage Limit Switch Lever Arm Adjustment
The Top and Bottom Film Carriage Limit Switches are mechanical limit switches
of standard design and may require some attention from time to time. Position
the arm so that is will travel through the appropriate angle when struck, and not
suffer from rebound or over-traveling.
Replace bent or broken lever arms. Check that all hardware securing the switch
components together and to the machine are intact, and tightly secured. Test the
switch for crisp action, and replace it if required.
9:6 Auto Load Height Sensing Photo-Eye Adjustments
The Auto Load Height Sensing Photo-eye uses an infrared beam reflected off the
load surface to trigger its output. Some products being wrapped may cause a
false “bounce-back” due to color or inherent shininess, which confuses the
machine and leads to improper top wrap function.
False signals may be able to be “tuned-out” through an adjustment of the photo-

eye distance (or sensitivity) setting located on the photo-eye.
The distance setting controls the intensity of the photo-eye beam and how far out
it can detect an object. If it is set too high, objects beyond the load being
wrapped on the turntable may be detected, preventing the carriage from stopping
at the top of the load. If it is set too low, the load being wrapped on the turntable
may not be detected, preventing the carriage from ascending or causing it to only
ascend part way before stopping. Adjust the distance setting lower or higher
accordingly to tune-out these problems. (Refer to Section 12:0 for specific
details provided in the photo-eye manufacturer’s component literature.)
9:7 Variable Frequency Drives
The Turntable, Film Carriage Elevator, and Prestretch are all driven by variable
speed AC motors. Each of these motors is controlled by its own Variable
Frequency Drive, (commonly known as a VFD), located inside the control panel.
All VFD parameters have been pre-calibrated at the factory and should not
require adjustment.
Should adjustment be required, reference Section 15:0 for the recommended

VFD parameters and Section 12:0 for specific details provided in the VFD
manufacturer’s component literature.
62
 WARNING! Adjustments to VFD parameters should only

be performed by a qualified technician!
 WARNING! All VFD parameters have been pre-calibrated

at the factory and should not require adjustment.

powered even when the Power Off–On–Reset switch is turned to
the OFF position. ALWAYS disconnect power before opening
the control panel!
9:8 Turntable Positive Alignment Set-Up and Adjustment
If the turntable is not aligning correctly to its home position at the end of the
automatic wrap cycle, it may be necessary to adjust the Turntable Positive
Alignment settings.
The components related to the Turntable Positive Alignment feature include:
 The Turntable Run Speed and Turntable Realign Speed Control Parameters
(Refer to Sections 5:2:4:3:4 & 5:2:4:3:5)
 The Realign Delay Setting (Refer to Section 5:2:4:3:6)
 The Turntable Accu-Count Proximity Sensor (1PX) located beneath the
turntable. (Refer to Section 9:9)
Set-up or adjust the Turntable Positive Alignment as follows:

unplug the machine before opening the control panel!
1. Place a load on the turntable that is representative of the heaviest load

typically to be wrapped.
2. Set the Realign Delay parameter to a value of 0.0 second.
3. Set the Turntable Realign Speed parameter to a value of 10.
4. If necessary, adjust the Turntable Run Speed parameter to set the desired
running speed of the turntable. This is typically factory-set to
63
approximately 10 RPM, (1 revolution every 6 seconds). Changing the

Turntable Run Speed setting affects the positive alignment.
5. Cycle the machine. When the machine begins its final revolution, the
Realign Delay Timer will time-out and the turntable will decelerate to a low
speed.
 NOTICE! The ideal setting for the Turntable Realign Speed

is a slow creep speed. This speed should be sufficient to move the
turntable with a heavy load placed on it, but slow enough that there
is no inertia that will cause the turntable to coast past the home
position when the wrap cycle is complete!
6. The turntable will continue to rotate at the Realign Speed until it reaches
the home position, at which time the wrap cycle is complete and the
turntable will stop.
7. If it is taking too long for the turntable to reach home position, increase the
Realign Delay Timer setting, (parameter), over the course of the next few
cycles until a setting is achieved that allows the least amount of time
necessary for the turntable to reach the home position, but without
coasting past. Keep in mind that the turntable must operate at the
Realign Speed setting for long enough to lose all the inertia from the
turntable before it reaches the Turntable Home Position.
9:9 Turntable Accu-Count Proximity Sensor Adjustment
PILOT machines are equipped with a Turntable Accu-Count Proximity Sensor

located on the base of the machine, beneath the turntable.
The inductive proximity sensor used is a non-contact type switch that senses the
teeth on the Turntable Center Sprocket.
The sensor used has a nominal sensing distance of 5 mm (3/16”). The sensor
must be mounted close enough to the sprocket teeth so that it will energize when
it detects a tooth and de-energize as the space between the sprocket teeth is
presented to the sensor. The pulses produced by the rotation of the sprocket are
counted by the microprocessor controller. The PILOT LP machine is equipped
with a seventy (70) tooth sprocket, so 70 pulses represents one rotation of the
turntable.
Adjust the position of the Turntable Position Pulse Sensor by loosening the two
jam nuts securing the proximity sensor to its mounting bracket. Move the
proximity sensor in or out as required and re-tighten the jam nuts.
64
 WARNING! When re-tightening the proximity sensor jam

nuts, ensure that there is some clearance space between the face
of the proximity sensor and the sprocket teeth!
9:10 Dancer Proximity Sensor Installation & Adjustment
The Dancer Proximity Sensor controls the prestretch film delivery system speed
and the starting & stopping of the prestretch motor.
The Dancer Proximity Sensor detects a steel eccentric target (or cam) that is
mounted to the dancer bar pivot shaft. As the dancer bar pivots and the distance
between the cam and the Dancer Proximity Sensor increases, the prestretch
motor will turn on and gradually increase in speed. With the dancer bar in its fully
retracted position, the prestretch motor should come to a complete stop.
If it should become necessary to replace or adjust the Dancer Proximity Sensor,

proceed as follows:
1. Raise the film carriage to a good working height and then remove power
from the machine.
2. Remove the prestretch carriage cover.
3. If the prestretch motor is not shutting off completely when the dancer bar
is in the retracted position, adjust the position of the Dancer Proximity
Sensor closer to the cam by loosening the two jam nuts securing the
proximity sensor to its mounting bracket. Move the proximity sensor
closer to the eccentric target and re-tighten the jam nuts.

of the proximity sensor and the cam!
4. If the prestretch motor is not starting the motor soon enough when the
dancer bar is pulled away from its retracted position, adjust the position
of the Dancer Proximity Sensor further from the cam by loosening the
two jam nuts securing the proximity sensor its mounting bracket. Move
the proximity sensor further from the target and re-tighten the jam nuts.
5. Alternately, rotating the cam slightly on the dancer bar pivot shaft may
improve the start-up point of the prestretch motor. Loosen the set-screw
securing the cam to the dancer bar pivot shaft and rotate the cam slightly
65
clockwise. It may be necessary also to re-adjust the distance between

the Dancer Proximity Sensor and the cam after doing this.
6. Re-connect power to the machine and test the operation. Re-adjust as

necessary, and when everything is satisfactory replace the prestretch
carriage cover.
 WARNING! PINCH POINTS Be careful to keep hands,

hair and loose clothing well clear of the polyurethane coated
prestretch rollers and aluminum pinch rollers while power is
applied!
9:11 Carriage Height Pulse Proximity Sensor Adjustment
The Carriage Height Pulse Sensor (5PX) generates a pulse for every 1/2”
(1.25cm) of film carriage travel. These pulses are used to determine the position
of the film carriage at various stages of the wrap cycle and will determine when
other functions of the cycle commence or finish.
The sensor used on PILOT machines has a nominal sensing distance of 1.5mm
(1/16”). The sensor must be mounted close enough to the sprocket teeth so that
it will energize when it detects a tooth and de-energize as the space between the
sprocket teeth is presented to the sensor. The pulses produced by the rotation of
the sprocket are counted by the microprocessor controller.
Adjust the position of the Turntable Position Pulse Sensor by loosening the two
jam nuts securing the proximity sensor to its mounting bracket. Move the
proximity sensor in or out as required and re-tighten the jam nuts.

of the proximity sensor and the sprocket teeth!
9:12 Film Carriage Safety Switch Adjustment
PILOT series stretch wrap machines are equipped with a Descent Obstruction
Plate. The Descent Obstruction plate is designed to “trip” the Film Carriage
Safety Switch in the event that it becomes obstructed. The Film Carriage Safety
Switch is a rotary lever safety limit switch with positive-break contacts, and may
require some attention from time to time.
66
The Film Carriage Safety Switch is mounted onto an adjustable sliding bracket,
which is slotted to allow diagonal adjustment. This sliding bracket is mounted to
the film carriage frame bottom gusset. The actuation / de-actuation point of the
Film Carriage Safety Switch is adjusted by loosening the adjustable sliding
bracket and moving the Film Carriage Safety Switch diagonally to increase or
decrease the pre-load on the actuator arm. The following illustration depicts the
nominal limit switch mounting location and actuator arm angle. The Film
Carriage Safety Switch should be adjusted so that the switch actuates with
minimal upward motion at each corner of the Descent Obstruction Plate.
FILM CARRIAGE FRAME

FILM CARRIAGE SAFETY SWITCH
CARRIAGE FRAME BOTTOM GUSSET
ADJUSTABLE SLIDING BRACKET
ACTUATOR ARM
DESCENT OBSTRUCTION PLATE
The Descent Obstruction Plate must actuate the Film Carriage Safety Switch if
struck at any point on its surface area.
After any adjustment is made to the Film Carriage Safety Switch, it is imperative
that the Descent Obstruction Plate be tested by actuating it on all four corners
and center to confirm that the Film Carriage Safety Switch will “trip”, irrespective
of where the Descent Obstruction Plate is actuated.
Failure to thoroughly test the operation of the Film Carriage Safety Switch
after performing any adjustment may render this safety feature inoperable!
 WARNING! Adjustments to the Film Carriage Safety

Switch should only be performed by a qualified technician!
67
 WARNING! Thoroughly test the operation of the Descent

Obstruction Plate and Film Carriage Safety Switch after performing
any adjustments!
9:13 Prestretch Roller Cleaning Procedure
Many cleaning agents can permanently damage the Prestretch Roller

polyurethane coating. If cleaning of the polyurethane-coated prestretch rollers
becomes necessary, the recommended procedure is as follows.
Into a bucket of warm water, add a few drops common dish detergent and mix
thoroughly. Then, with the aid of a common “fingernail” cleaning brush, scrub the
prestretch rollers thoroughly. Rinse the prestretch rollers thoroughly with plain
water and dry completely.
 WARNING! No Solvent or Naphtha based products should

be used to clean the polyurethane-coated prestretch rollers!
9:14 Freeing Up a Jammed Film Carriage
If the film carriage travels past its top limit its carrier mechanism inside the tower
can run into the top of the tower and become jammed. If this happens it may
lock-up the carriage lift gear-reducer, preventing it from being lowered.
To help alleviate this problem, a mechanical stop bolt is installed through the top
plate of the tower. This bolt can be backed off to release the jam condition.
To free up a jammed film carriage proceed as follows:
1. Remove the two screws holding the blue tower top cap, and remove the
top cap.
2. Locate the single 10mm hex head stop bolt on the top plate of the tower
and loosen it a few turns.
3. Press the Film Carriage <LOWER> keypad button and let the film carriage
travel downward.
4. Once the film carriage has lowered sufficiently, release the Film Carriage
<LOWER> keypad button and then tighten the mechanical stop bolt back
down.
68
5. Perform a visual inspection to try and determine why the film carriage
over-traveled in the first place. It could be due to the top limit switch
striker having been relocated below the Carriage Top Limit Switch (2LS)
(refer to Section 5:5), or it could be due to a problem with the Film
Carriage Height Pulse Counter Sensor (5PX) (refer to Section 9:11: &
Section 10:1:3).
69
10:0 TROUBLE-SHOOTING
10:1 Trouble-shooting using Operator Interface Fault Messages
PILOT stretch wrap machines are programmed to be able to detect a number of

different fault conditions and display corresponding fault messages and
diagnostic information on the Operator Interface Panel, also referred to as an
HMI (Human-Machine Interface).
In addition to the displayed messages, the red Fault indicator light on the control
panel label will flash when a fault condition has been detected.
Typically the fault conditions are annunciated using multiple screens that will
alternate until the fault condition is acknowledged. An initial screen describes the
fault condition, and a subsequent screen or screens will display detailed
diagnostic and corrective information about the fault condition.
Fault screens use a standardized format that, in addition to the displayed

message, may give instructions for use of the buttons beneath the HMI screen
area, as follows:
<ESC> – pressing this button will acknowledge and reset the fault condition, and
causes the display to return to the Main Menu screen (if the fault is of a type that
does not need to be retained in memory until alternate action is taken by the
operator).
<ENT> – if the message display screen offers a course of action to correct the
cause of the fault condition, it will instruct you to initiate the process by pressing
this button
70
10:1:1 Variable Frequency Drive Fault
PILOT machines are equipped with three variable frequency drives to control the
motors on the machine – one for the Turntable motor (1VFD), one for the Film
Carriage Elevator motor (2VFD), and one for the Prestretch film dispenser motor
(3VFD).
Each of these variable frequency drives has an alarm output contact connected
to the machine controller. In the event of a fault occurring with a variable
frequency drive, the variable frequency drive’s alarm contact will de-energize,
which will in turn cause a fault condition to be displayed on the Operator Interface
Panel (HMI) screen. Apart from identifying which of the drives has faulted, the
messages are identical so only the Turntable Variable Frequency Drive fault
screens are shown here.
TURNTABLE
V/F DRIVE FAULT
DETECTED!
PRESS EMERGENCY STOP

WAIT 10 SECONDS THEN
RESET THE POWER.
IF PROBLEM PERSISTS
CHECK FOR ERROR
MESSAGE DISPLAYED ON
#1VFD INSIDE PANEL.
PRESS <ESC>
TO RETURN TO THE
MAIN MENU.
Screen #20 & #21 – Turntable V/F Drive Fault Screens
If the fault cannot be reset by cycling the power, then the actual fault code
displayed on the variable frequency drive inside the control panel should be
noted. A chart of these fault codes appears in the Variable Frequency Drive
manufacturer’s manual located in section 12.
71
10:1:2 Film Carriage Safety Switch Tripped Fault
PILOT stretch wrap machines are equipped with a Descent Obstruction Plate
and Film Carriage Safety Switch (4LS) located beneath the Film Carriage.
The purpose of the Film Carriage Safety Switch (4LS) is to disable the wrap cycle
and the film carriage descent function in the event that the Descent Obstruction
Plate becomes obstructed, (i.e. by a foreign object located between the bottom of
the film carriage and the base of the machine). This can be triggered during the
wrap cycle or when the film carriage is being manually lowered using the Film
Carriage Lower button.
FILM CARRIAGE
DESCENT OBSTRUCTION
SAFETY SWITCH
TRIPPED!
MANUALLY RAISE
THE FILM CARRIAGE,
THEN REMOVE ANY
OBSTRUCTION FROM
UNDERNEATH IT.
PRESS <ESC>
TO RETURN TO THE
MAIN MENU.
Screen #22 & #23 – Descent Obstruction Safety Switch Fault Screens
When the Film Carriage Descent Obstruction Plate is actuated, the Carriage
Safety Switch (4LS) contacts “open”, disabling the Auto Wrap Cycle and Film
Carriage Lower functions of the machine. In the event that the film carriage
safety switch is tripped, this condition will be indicated by the error messages
shown above and the red flashing Fault light.
To reset the machine after the film carriage safety switch has been tripped, press
the <ESC> button, then manually raise the film carriage using the Raise button,
or cycle the power by turning the Power Off–On–Reset switch to the OFF
position and then back to the RESET position.
72
10:1:3 Film Carriage Height Pulse Counter Sensor Fault
If the Film Carriage Height Pulse sensor (5PX) remains either on or off for longer
than preset watchdog times (approximately 3 to 5 seconds) during operation of
the film carriage elevator function in a Wrap Cycle, the sensor is presumed to be
out of adjustment or defective, or the film carriage elevator is not physically
moving, and this fault condition will be triggered.
FILM CARRIAGE
HEIGHT PULSE
COUNTER SENSOR
FAULT DETECTED!
ENSURE THAT THE FILM

CARRIAGE DRIVE IS
RUNNING, THEN
CHECK THAT SENSOR
5PX IS CORRECTLY
ADJUSTED AND FUNCTIONING.
PRESS <ESC>
TO RETURN TO THE
MAIN MENU.
Screen #24 & #25 – Film Carriage Height Pulse Counter Sensor Fault Screens
Possible causes of this fault condition are a defective or improperly adjusted

Carriage Height Pulse sensor (5PX), a defective or improperly programmed Film
Carriage Elevator Drive (2VFD), or as a result of the Film Carriage becoming
jammed against its upper or lower end of travel.
73
10:1:4 Wrap Cycle Watchdog Timer Fault
All the while the wrap cycle is in progress, except during a Cycle Pause request
or a Film Carriage Pause (Reinforce Wrap) request, the Wrap Cycle Watchdog
timer in the machine controller records the elapsed cycle time. If the elapsed
cycle time reaches the preset value in the timer, the wrap cycle will immediately
be aborted and the message screens below will be displayed. The timer’s preset
value is nominally set to 360 seconds (6 minutes).
THE WRAP CYCLE
WATCHDOG TIMER
HAS TIMED-OUT!
DETERMINE CAUSE FOR

CYCLE RUNNING FOR
TOO LONG, THEN
CORRECT THE FAULT.
PRESS <ESC>
TO RETURN TO THE
MAIN MENU.
Screen #26 & #27 – Wrap Cycle Watchdog Timer Fault Screens
Possible causes of this fault condition could be a defective Turntable or Film

Carriage Variable Frequency Drive (VFD), or a sensor failure that prevents the
wrap cycle from stepping through its sequence properly. It is also conceivable
that the Wrap Cycle Watchdog Timer could time-out before the cycle is
completed if the operator programs the machine to put on a high number of wrap
revolutions with the turntable and film carriage speeds set very low.
74
10:1:5 Film Fault (Optional)
Film Fault Detection is an optional feature. A film fault is caused by a loss of film
tension during the wrap cycle, usually due to the film breaking or running out
during the Wrap Cycle. A film fault can be detected any time after the second
turntable revolution has been completed, and up until the time that the turntable
goes into its deceleration phase in the final revolution of the wrap cycle.
FILM FAULT
DETECTED!
MACHINE RESETTING
TO HOME POSITION
Screen #28 – Film Fault Detected Screen #1
The screen above is displayed when a Film Fault has been detected and the
machine is in the process of resetting back to home position.
FILM FAULT DETECTED!
RELOAD THE FILM,

THEN PRESS THE <START/PAUSE>
BUTTON TO REWRAP THE LOAD.
PRESS <ESC>
TO RETURN TO THE
MAIN MENU.
Screen #29 – Film Fault Detected Screen #2
The screen above is displayed after a Film Fault has been detected and the
machine has completed resetting to home position.
Refer to Section 6:5:4 for a description of the Film Fault Reset sequence.
75
10:2 Trouble-Shooting Guide
In the event of a machine malfunction, the suggestions listed in this section will
assist in determining the cause of a failure and possible remedies.
Many of the corrective actions recommended here require technical ability. Only
qualified and fully trained personnel should perform the corrective actions
listed in this trouble-shooting guide!
PROBLEM DETECTED POSSIBLE CAUSE CORRECTIVE ACTION

1. Power light is not illuminated. Optional Main Disconnect Turn the Optional Main
HMI (Operator Interface Switch is turned to the O (Off) Disconnect Switch to the 
Panel) screen is not position (On) position.
Illuminated. The machine is unplugged Plug the machine back in to
from the electrical supply the electrical supply power
power socket socket.
Electrical power source Turn on the electrical supply
supplying the machine is source or reset electrical
dead supply circuit breaker or fuse.
Blown main fuse #1FU Replace fuse #1FU with one
of same type and rating.
(Slow-blow)
Blown 24 Volt DC power Replace fuse #5FU with one
supply input fuse #5FU of same type and rating.
(Fast-blow)
Defective 24 Volt DC power Replace the 24 Volt DC
supply #1PS power supply #1PS.
Defective SWCB Replace the defective SWCB
microprocessor control board microprocessor control board.
2. Power On light is not The Power Off–On–Reset Turn the Power Off–On–
illuminated. switch is turned to the OFF Reset switch to the RESET
position position momentarily to
restart the control power.
The Emergency Stop Push- Pull out the E-Stop button,
Button is pushed in and then turn the Power Off–
On–Reset switch to the
RESET position momentarily
to restart the control power.
A power failure has occurred Turn the Power Off–On–
Reset switch to the RESET
position momentarily to
restart the control power.
76
3. Fault Light and optional Variable Frequency Drive Refer to the Operator
Machine Busy (red) status Fault detected Interface (HMI) screen for
indicator beacon light is information on which Variable
flashing Frequency drive is faulted,
and follow the on-screen
instructions.
The film carriage Descent Remove the obstruction and
Obstruction Plate safety manually raise the film
switch (4LS) was tripped carriage, or cycle the power.
A Film Carriage Height Confirm that sensor #5PX is
Sensor (5PX) Fault was working and is adjusted
detected correctly. If sensor is okay,
check Film Carriage Drive
and Carriage Speed settings
(refer to Section 5:4:1: &
5:4:2) to ensure that the Film
Carriage drive is operating.
The Wrap Cycle Watchdog Repeat the cycle to find the
Timer elapsed during a wrap cause of machine cycle time
cycle over-run.
Film Fault detected (optional Correct film fault condition,
feature) reload the film and rewrap the
load. (Refer to Section 6:5:4
& Section 10:1:5)
4. Turntable does not run in a Turntable is jammed Try rotating the turntable by
wrap cycle or with Turntable hand. If it will not move,
Jog button check for signs of mechanical
binding or jamming.
Turntable Variable Frequency Turn off the power and wait
Drive (1VFD) faulted 10 seconds, then reset the
power. If the fault condition
persists, check for a fault
message on #1VFD inside
the control panel. (Refer to
Section 10:1:1)
Turntable Speed setting is too Increase the Turntable Speed
low setting. (Refer to Section
5:2:4:3:3 & Section 5:2:4:3:4)
Turntable drive sprocket or If motor appears to be
motor key missing, or chain running, but turntable does
has fallen off not rotate check that turntable
sprocket key and key
between the motor shaft and
the gear-reducer input shaft
are intact. Replace keys if
missing. Ensure that
turntable chain is on.
Defective Turntable Gear- If motor is running, but
Reducer turntable does not rotate and
all keys and drive chain are
intact, replace gear-reducer.
77

Turntable does not run in a Improperly programmed Ensure that the Turntable V/F
wrap cycle or with Turntable Turntable V/F Drive Drive (1VFD) parameters are
Jog button correctly programmed.
…continued… (Refer to the V/F Drive
Parameter list in Section 15)
Defective Turntable Motor Check for AC voltage at the
motor terminals. If voltage is
present but motor will not run,
repair or replace motor).
5. Turntable is noisy Turntable is binding or Try rotating turntable by

jamming hand. If it will not move,
check for signs of mechanical
binding or jamming.
Machine is installed on an Relocate machine to a flat,
uneven surface clean, level surface.
Turntable drive chain is too Adjust turntable drive chain
slack tension. (Refer to Section
9:3)
Turntable support rollers Replace turntable support
worn out rollers. (Refer to Section 9:4)
6. Turntable runs too slowly or Turntable Speed setting is too Increase the Turntable Speed
stalls when wrapping a heavy low setting. (Refer to Section
load 5:2:4:3:3 & Section 5:2:4:3:4)
Load weight exceeds the Do not wrap loads that
capacity of the machine exceed the rated weight
capacity of the machine!
Machine is installed on an Relocate machine to a flat,
uneven surface clean, level surface.
Overhanging pallet is rubbing Pallet may be in poor
on the surround deck condition or inadequate to
properly support the load on
the LP turntable. Restack the
load on a better pallet.
Turntable support rollers Replace turntable support
worn out rollers. (Refer to Section 9:4)
7. Turntable runs too fast Turntable Speed setting is too Decrease the Turntable
high Speed setting. (Refer to
Section 5:2:4:4:5)
8. Turntable will not shut off Wrap cycle not sequencing Refer to “Wrap Cycle not
properly Sequencing Properly” trouble-
shooting later in this section.
78
9. Film Carriage will not raise or Film Carriage Speed Increase the Carriage Speed
lower setting(s) too low setting. (Refer to Sections
5:1:9 & 5:1:10)
Improperly adjusted Film Adjust the Film Carriage
Carriage Safety Switch Safety Switch. (Refer to
Section 9:12)
The film carriage Descent Raise film carriage to working
Obstruction Plate is jammed height and move film carriage
in the up position Descent Obstruction Plate
from side to side & back and
forth by hand to allow the
plate to drop into the down
position. There should be
some play between the
carriage frame and the safety
stop plate. If the film carriage
Descent Obstruction Plate
cannot be moved at all, check
for signs of mechanical
binding or jamming.
Defective Carriage Safety Disconnect Carriage Safety
Switch Switch and check with an
ohmmeter. Replace if
defective.
Film Carriage is jammed Move carriage from side to
side and back and forth by
hand. There should be some
play between the carriage
guide wheels and the tube on
which they run. If the
carriage cannot be moved at
all, check for mechanical
binding or jamming. If the
carriage is jammed against
the roof of the tower, release
the stop bolt to relieve the
jam and manually lower the
film carriage. (Refer to
Section 9:14)
Film Carriage Elevator Turn off the power and wait
Variable Frequency Drive 10 seconds, then reset the
(2VFD) faulted power. If the fault condition
Section 10:1:1)
Improperly programmed Film Ensure that the Film Carriage
Carriage Elevator V/F Drive Elevator V/F Drive (2VFD)
parameters are correctly
programmed. (Refer to the
V/F Drive Parameter list in
Section 15)
79

Film Carriage will not raise or Defective Film Carriage Check for AC voltage at the
lower Elevator Motor motor terminals. If voltage is
…continued… present but motor will not run,
repair or replace motor.
10. Film Carriage will not raise Photo-eye is detecting voids Increase the Top Overlap
during wrap cycle in the load setting (refer to section
5:2:4:2:2.2) and decrease film
Carriage Raise Speed (refer
to section 5:1:9). If that does
not solve the problem, then
restack load or wrap with
photo-eye over-ridden.
Improperly set-up photo-eye Check photo-eye settings.
Standard photo-eye has
“Light-On” operation. (Refer
to Section 9:6)
Defective photo-eye Check photo-eye status
indicators and operation
during cycle. If photo-eye is
not responding properly and
settings are correct, replace
photo-eye.
Wrap cycle not sequencing See “Wrap Cycle not
properly Sequencing Properly” trouble-
11. Film Carriage will not lower Wrap cycle not sequencing See “Wrap Cycle not
during wrap cycle properly Sequencing Properly” trouble-
12. Film Carriage raises and Carriage Speed setting(s) are Increase the Carriage Speed
lowers too slowly too low setting(s). (Refer to sections
5:1:9 & 5:1:10)
13. Film Carriage raises and Carriage Speed setting(s) are Decrease the Carriage Speed
lowers too fast and / or speed too fast setting(s). (Refer to sections
cannot be varied 5:1:9 & 5:1:10)
14. Film Carriage Lift movement Carriage Lift Chain requires Lubricate or tension the
is jerky lubrication or tensioning chain. (Refer To Section 9:1)
15. Prestretch will not run Film is threaded incorrectly Thread film correctly. (Refer
to section 6:2)
Manual Film Feed button was Press the Manual Film Feed
not pressed prior to button to enable manual
attempting to manually feed feeding of the film. (Refer to
film sections 5:1:4 & 6:3)
80
Prestretch will not run The Emergency Stop Push- Pull out the E-Stop button,
…continued… Button is pushed in and then turn the Power Off–
On–Reset switch to the
RESET position momentarily
to restart the control power.
Power Off / On / Reset switch Turn the Power Off / On /
is in to the Off position Reset switch to the Reset
position and release to the
On position.
Film Force to Load setting is Decrease the Film Force to
too high Load setting. (Refer to
section 5:1:11)
Dancer Proximity Sensor and Adjust distance between
/ or Target Cam incorrectly Dancer Proximity Sensor and
adjusted cam. Adjust position of cam if
necessary. (Refer to Section
9:10)
Dancer Proximity Sensor Check for 24 Volts DC across
Defective terminals #16 & #18 on
SWCB microprocessor board
plug J9-CARR with Dancer
Bar retracted & Film Force to
Load pot set at zero.
Then, check for 0 Volts DC
across terminals #17 & #18
on SWCB microprocessor
board plug J9-CARR with
Dancer Bar retracted & Force
to Load setting at zero,
increasing to approximately
10 Volts DC as the Dancer
Bar is pulled out to the fully
extended position.
If correct readings are not
attainable, replace defective
Dancer Proximity Sensor.
81

Prestretch will not run Prestretch Variable Turn off the power and wait
…continued… Frequency Drive (3VFD) 10 seconds, then reset the
faulted power. If the fault condition
Section 10:1:1)
Improperly programmed Ensure that the Prestretch
Prestretch V/F Drive V/F Drive (3VFD) parameters
are correctly programmed.
(Refer to the V/F Drive
Parameter list in Section 15)
Defective Prestretch Motor Check for AC voltage at the
replace motor).
16. Prestretch runs too fast and / Dancer Proximity Sensor and Adjust distance between
or speed cannot be varied / or Target Cam incorrectly Dancer Proximity Sensor and
9:10)
Dancer Proximity Sensor Check for 24 Volts DC across
Defective terminals #16 & #18 on
SWCB microprocessor board
plug J9-CARR with Dancer
Bar retracted & Film Force to
Load pot set at zero.
Then, check for 0 Volts DC
across terminals #17 & #18
on SWCB microprocessor
board plug J9-CARR with
Dancer Bar retracted & Force
to Load setting at zero,
increasing to approximately
10 Volts DC as the Dancer
Bar is pulled out to the fully
extended position.
If correct readings are not
attainable, replace defective
Dancer Proximity Sensor.
Defective Prestretch Motor Check for AC voltage at the
replace motor).
17. Prestretch continues to run Dancer Bar not returning fully Replace Dancer Bar
after the film has been cut to home position due to spring(s).
broken, weak or missing
spring(s)
82

Prestretch continues to run Dancer Bar not returning fully Adjust Dancer Bar Assembly
after the film has been cut to home position due to hardware to eliminate end
…continued Dancer Bar roller or film clamping of dancer roller
diverter roller not turning bearings, or replace roller(s).
freely
Dancer Bar not returning fully With dancer bar springs
to home position due to removed, the Dancer Bar
binding or misalignment of Assembly should be able to
Dancer Bar Assembly and swing freely. Adjust dancer
pivot bushings bar hardware to eliminate end
clamping of Dancer Bar
Assembly. Ensure that pivot
bushings are straight.
Dancer Proximity Sensor and Adjust distance between
/ or Target Cam incorrectly Dancer Proximity Sensor and
9:10)
… Dancer Proximity Sensor Replace defective Dancer
Defective Proximity Sensor. (Refer to
Section 9:10)
18. Prestretch is noisy Prestretch sprockets and / or Check prestretch sprocket

chain(s) loose or misaligned set-screws and tighten.
Ensure sprockets are level.
Adjust prestretch chains by
loosening motor and / or
prestretch chain idler
sprocket and taking-up slack
in chains(s).
19. Wrap Cycle not Sequencing Blown Fuse F2, F4, F6 or F9 Replace fuse F2, F4, F6 or
Properly on SWCB Microprocessor F9 with one of same type and
board rating.
SWCB Microprocessor board Verify that all terminal plugs
hardware problem are securely installed on to
the SWCB
19A. Wrap Cycle will not start Blown Power Supply Input Replace fuse #5FU with one
fuse #5FU of same type and rating.
(Fast-blow)
19B. Film Carriage does not raise Auto Load Height Sensing Check Photo-eye for correct
during wrap cycle Photo-eye not “seeing” the operation and set-up. (Refer
load to Section 9:6)
83

19C. Film Carriage overshoots the Auto Load Height Sensing Turn Auto Load Height
top of the load being wrapped Photo-eye turned OFF Sensing Photo-eye ON.
(Refer to section 5:2:4:2:2.1)
Top Overlap Setting incorrect Adjust Top Overlap Setting to
provide the desired amount of
film over top of the load.
(Refer to section 5:2:4:2:2.2)
Carriage Height Pulse Sensor Adjust Carriage Height Pulse
#5PX out of adjustment Sensor so that it detects teeth
on the carriage lift chain top
idler sprocket.
Carriage Height Pulse Sensor Replace defective Carriage
#5PX is defective Height Pulse Sensor
19D. Film Carriage does not lower Turntable Accu-Count Adjust the Turntable Accu-
during wrap cycle Proximity Sensor #1PX Count Proximity Sensor.
requires adjustment (Refer to Section 9:9)
Turntable Accu-Count Replace Turntable Accu-

Proximity Sensor #1PX is Count™ Proximity Sensor
defective
A foreign object is lodged The film carriage Descent
between the bottom of the Obstruction Plate has been
film carriage and the base of actuated. Manually raise the
the machine film carriage and remove the
obstruction.
The film carriage Descent Raise film carriage to working
Obstruction Plate is jammed height and move film carriage
in the up position Descent Obstruction Plate
from side to side & back and
forth by hand to allow the
plate to drop into the down
position. There should be
some play between the
carriage frame and the safety
stop plate. If the film carriage
Descent Obstruction Plate
cannot be moved at all, check
for signs of mechanical
binding or jamming.
Improperly adjusted Carriage Adjust Carriage Safety Switch
Safety Switch (Refer to Section 9:12)
Defective Carriage Safety Disconnect Carriage Safety
Switch Switch and check with an
ohmmeter. Replace if
defective.
84

19E. Turntable does not re-align at Turntable Realign Speed not Perform Turntable Positive
Home Position properly set correctly Alignment Set-up. (Refer to
Section 9:8)
Turntable Accu-Count Adjust the Turntable Accu-
Proximity Sensor #1PX Count Proximity Sensor.
requires adjustment (Refer to Section 9:9)
Turntable Accu-Count Replace Turntable Accu-

Proximity Sensor #1PX is Count Proximity Sensor
defective
85
11:0 PARTS LISTS
The parts lists shown in this section are for the end-user’s reference in identifying
components of the machine. When a malfunction is traced to a failed
component, the part number for that component will aid in the procurement of a
replacement part.
The description of each component in the parts list is generic. In order to identify
the item exactly, the manufacturer and manufacturer’s part number (along with
any other nameplate data) should be obtained from the item itself.
Those items that are marked “Y” in the SP (Spare Parts) column are
recommended as spare parts to be stocked by the end-user.
PILOT_manual_r0.doc
Section 11 - Page 1
MATERIAL LIST
PILOT SERIES LOW PROFILE SEMI-AUTOMATIC STRETCH WRAP MACHINE
Machine Assembly Dwg: G1000-013-00-R1 Electrical Drawing: E1000-010 Rev. 1

DWG LOCATION QTY. U/M SP PART NUMBER DESCRIPTION
ITEM #
2 PILOT LP - BASE & TURNTABLE DRIVE - MECHANICAL ASSEMBLY

G2300-177-00-R0
2.1 Machine Base 1 ea. G2300-177-01-00 Pilot Turntable Base Weldment
2.2 Turntable Deck Plate 1 ea. F4148 Turntable Deck Plate
2.19 Turntable Deck Plate/ Drive 6 ea. H1401 Button Head Socket Screw M5 x 12mm Long
Cover Hardware
2.3 Turntable 1 ea. C3314 Turntable - 57" Diameter x 1/4" Thick - Bolt-On
Design
2.20 Turntable Hardware 4 ea. H1387 Flat Head Socket Screw M12-1.75 x 25mm Long,
Black
2.13 Turntable Support Wheel - 12 ea. Y S236-W
Gang of 3 Assembly - each
consisting of:
2.13.1 Turntable Support Wheels 3 ea. S153 (W167) Molded Nylon Wheel c/w Ball Bearing 32mm OD
x 12mm ID x 10mm Wide
2.13.3 Turntable Support Wheel Axle 1 ea. M510 Turntable Support Wheel Shaft 12mm Dia.
2.13.4 Turntable Support Wheel Axle 1 ea. H960 Spring Pin Slotted 1/8" Dia. x 0.875" Long
2.4 Turntable Gear-Reducer 1 ea. Y A602 Gear-Reducer, Right Angle, 20:1 Ratio, IEC-B14
Flange with 1" Dia. Output Shaft
2.21 Turntable Gear-Reducer 4 ea. H1381 Hex Cap Screw M8 - 30mm Long Class 8.8
Hardware Plated
2.22 Turntable Gear-Reducer 4 ea. H1214 Hex Nut Metric M8x1.25
Hardware
2.23 Turntable Gear-Reducer 8 ea. H775 Flat Washer Bolt Size 5/16 or M8 Plated
Hardware
2.24 Turntable Gear-Reducer 4 ea. H776 Lock Washer Bolt Size 5/16 or M8 Plated
Hardware
2.5 Turntable Motor 1 ea. Y A619 Electric Motor, 71B14, 1/2HP 230/460 Volt 3
Phase 60 Hz, 4 Pole, 1750 RPM, TEFC - Small
Body
2.6 Turntable Drive Cover 1 ea. F4151 Turntable Drive Cover
2.7 Gear Reducer Sprocket 1 ea. K180 Sprocket 50B12 x 1" Bore, K2SS
2.9 Turntable Center Sprocket 1 ea. K510 Turntable Center Sprocket Weldment, 50A70 -
Bolt On
2.8 Turntable Center Sprocket 1 ea. Y B126 Ball Bearing Double Row 30mm ID x 62mm OD
2.10 Turntable Drive Chain 10.83 ft. K120 Roller Chain ANSI #50 Rivet Type, 208 Links
2.26 Turntable Drive Chain 1 ea. Y K121 Connecting Link ANSI #50
2.27 Turntable Drive Chain 1 ea. Y K122 Offset (Half) Link ANSI #50
2.11 Idler Sprocket 1 ea. Y K230 Idler Sprocket 50A15 c/w Ball Bearing - 5/8" ID
2.12 Chain Tensioner 1 ea. C5037 Tensioner Sprocket Slide Plate Weldment
2.14 Turntable Roller Support 12 ea. H1094 Spring Pin 1/8" dia. x 9/16" Long
Cradle
2.35 Chain Tensioner 1 ea. H942 Retaining Ring External Type for 5/8" Dia. Shaft
2.25 Chain Tensioner Hardware 2 ea. H1710 Hex Cap Screw M10 - 18mm Long
2.34 Chain Tensioner Hardware 2 ea. H778 Lock Washer Bolt Size 7/16 or M10 Plated
2.33 Chain Tensioner Hardware 2 ea. H777 Flat Washer for Bolt Size 7/16" or M10 Plated
2.18 Turntable Position Proximity 1 ea. E2166 Refer to Electrical portion of this Material List,
Sensor under "Electrical Controls on Machine Base"
1000-PILOT PILOT_LP_G1000-013-00_r1_E1000-010_r1 matlist_manual.xls Page 1 of 11

Section 11 - Page 2

ITEM #
6 OPTIONAL - HALF MOON 48" WIDE x 13.5" LONG
Half Moon Weldment (1) ea. C5169 Half Moon Weldment 48" Wide x 13.5" Long
7A OPTIONAL - PORCH 48" WIDE x 24" LONG
Porch Weldment (1) ea. C5170 Porch Weldment 48" Wide x 24" Long
7B OPTIONAL - PORCH 48" WIDE x 40" LONG
Porch Weldment (1) ea. C5236 Porch Weldment 48" Wide x 40" Long
8 OPTIONAL - RAMP 48" WIDE x 60" LONG
Ramp Weldment (1) ea. C5164 Ramp Weldment 48" Wide x 60" Long
9 OPTIONAL - SHIPPING FIXTURE
Shipping Fixture Weldment (1) ea. C5168 Shipping Fixture Weldment

Section 11 - Page 3

ITEM #
1 STD. TOWER & FILM CARRIAGE LIFT DRIVE - MECHANICAL ASSEMBLY

G2700-085-00-R1A
1.9 Tower Structure 1 ea. G2700-085-01-00 Pilot Tower Frame Weldment - Standard 80"
Wrap Height
1.24 Film Carriage Lift Gear- 1 ea. Y A617 Gear-Reducer, Right Angle Worm Gear type,
Reducer 60:1 ratio, IEC-B14 Flange with special 1"
Diameter Output Shaft
1.29 Film Carriage Lift Motor 1 ea. Y A619 Electric Motor, 71B14, 1/2HP 230/460 Volt 3
Phase 60 Hz, 4 Pole, 1750 RPM, TEFC - Small
Body
1.13 Gear-Motor Sprocket 1 ea. K174 Sprocket 40B17 x 1" Bore c/w Keyway & Set-
Screws
1.14 Top Idler Sprocket 1 ea. Y K571 Idler Sprocket 40A17 c/w 5/8” ID Ball Bearing &
Snap Ring
1.25 Idler Sprocket Hardware 1 ea. H1428 Hex Cap Screw M16x2 - 50mm long, Plated
1.28 Idler Sprocket Hardware 1 ea. H1339 Hex Nut M16x2, Plated
1.27 Idler Sprocket Hardware 1 ea. H774 Lock Washer for 5/8" Bolt, Plated
1.26 Top Idler Sprocket 1 ea. F1981-R3 Bracket For 8mm Proximity Sensor
1.5 Proximity Sensor 8mm 1 ea. Y Refer to Electrical portion of this Material List,
under "Electrical Controls on Tower"
1.15 Carriage Lift Chain 13.1 ft. K113 Chain ANSI #40 Rivet Type
(313 Pitches Long)
1.62 Carriage Lift Chain 2 ea. Y K118 Connecting Link ANSI #40
1.63 Carriage Lift Chain 1 ea. Y K119 Offset (Half) Link ANSI #40
1.52 Carriage Lift Chain Attachment 1 ea. C3325 Chain Attachment Bolt
1.43 Carriage Lift Chain Spring 1 ea. V103 Compression Spring 0.78” OD x 1.58” Long
1.44 Carriage Lift Chain Attachment 1 ea. H755 Hex Nut 1/2"-13UNC Grade 8, Plated
1.45 Carriage Lift Chain Attachment 1 ea. H754 Jam Nut 1/2"-13UNC, Plated
1.6 Film Carriage Anti-Fall Safety 1 ea. F3251 Anti-Fall Safety Latch
Latch
1.17 Film Carriage Anti-Fall Safety 2 ea. H1708 Clevis Pin 5/16" Dia. x 1-1/4" Long
Latch
1.53 Film Carriage Anti-Fall Safety 2 ea. H775 Flat Washer 5/16" Bolt Size, Plated
Latch
1.39 Film Carriage Anti-Fall Safety 2 ea. H1712 Flat Washer 11/32" ID x 9/16" OD x 1/32" TK,
Latch Plated
1.40 Film Carriage Anti-Fall Safety 2 ea. H1713 Cotter Pin 3/32" Dia. x 1/2" Long
Latch
1.54 Film Carriage Anti-Fall Safety 1 ea. V175 Extension Spring 0.5" OD x 1.75" Long, Spring
Latch Steel, Rate = 14 Lbs./In.
1.41 Film Carriage Anti-Fall Safety 1 ea. H1496 Shoulder Screw 6mm Diameter x 16mm Long,
Latch M5 Thread
1.42 Film Carriage Anti-Fall Safety 1 ea. H1649 Shoulder Screw 6mm Diameter x 12mm Long,
Latch M5 Thread
1.10 Tower Cover - Carriage Side 1 ea. F3729 Tower Middle Cover
1.11 Tower Cover - Left Side 1 ea. F4207 Left Side Cover
1.12 Tower Cover - Right Side 1 ea. F4208 Right Side Cover
1.47 Tower Cover - Control Panel 1 ea. F3523 Control Panel Side Cover
Side
1.36 Tower Cover Mounting 15 ea. H1141 Buton Head Socket Screw M5x10mm Lg.
Hardware
1.49 Control Panel Enclosure 1 ea. F3498-R4 Control Panel Enclosure Main Box
1.65 Control Panel Enclosure 4 ea. F4381 Control Panel "C" Shaped Spacer, 8GA
1.66 Control Panel Enclosure (4) ea. F4382 Control Panel "C" Shaped Spacer, 12GA
1.2 Control Panel Enclosure 2 ea. F3503 Control Panel Picture Frame Angle

Section 11 - Page 4

ITEM #
1.7 Control Panel Enclosure 1 ea. C4922 Control Panel Enclosure Door Assembly
1.50 Control Panel Enclosure Main 2 ea. F3726 Tower Side Cover Support Bracket
Box
1.21 Control Panel Enclosure 16 ea. H1497 Button Head Socket Screw M6 x 16mm Long
Mounting Hardware
1.33 Control Panel Enclosure 22 ea. H820 Hex Nut M6x1, Plated
Mounting Hardware
1.22 Control Panel Enclosure 32 ea. H767 Lock Washer for 1/4" / M6 screw, Plated
Mounting Hardware
1.32 Control Panel Enclosure 4 ea. H1615 Button Head Socket Screw M6 x 25mm Long
Mounting Hardware
1.37 Control Panel Enclosure 4 ea. H1149 Hex Cap Screw M6 x 20mm Long
Mounting Hardware
1.38 Control Panel Enclosure 4 ea. H766 Flat Washer for 1/4" / M6 screw, Plated
Mounting Hardware
1.60 Tower Cover - Control Panel 1 ea. F3887 Cable Chain Mount. Bracket-Stationary End
Side
1.3 Carriage Carrier Plate 1 ea. F3506 Cable Chain Mounting Support Bracket
1.16 Carriage Carrier Plate 1 ea. C5145 Carriage Carrier Plate Weldment
1.64 Carriage Carrier Plate 4 ea. H1369 Hex Cap Screw M10x1.5 x 25mm Long
1.18 Carriage Carrier Plate 4 ea. M1662 Uhmw Slide Bar - Short
1.48 Tower Cover - Left Side 1 ea. C3230-78 Limit Switch Striker Guide. 78.75" Long
1.30 Limit Switch Striker Guide 2 ea. F3736-R1 Limit Switch Striker
1.8 Limit Switch Striker Guide 2 ea. X234 Extrusion T-Nut Economy, M6
1.59 Control Panel Enclosure 1 ea. E2293-C Refer to Electrical portion of this Material List,
under "Electrical Controls on Tower"
1.34 Cable Chain Mounting 4 ea. H1385 Button Head Socket Screw M6 x 10mm Long
Brackets
1.61 Control Panel Enclosure 1 ea. F3753 Control Panel "E" Shaped Spacer
1.20 Film Carriage Lift Gear- 1 ea. M1667 Gearbox Adaptor Plate
Reducer
1.31 Film Carriage Lift Gear- 8 ea. H1399 Hex Cap Screw M8 - 20mm Long
Reducer
1.35 Tower Cover - Control Panel 6 ea. H1397 Hex Cap Screw M8 - 12mm Long
Side
1.55 Tower Cover - Control Panel 14 ea. H776 Lock Washer For 5/16"/M8
Side / Carriage Lift Gear
Reducer
1.1 Tower Structure 6 ea. H1379 Hex Cap Screw M12 - 30mm Long
1.23 Tower Structure 4 ea. H770 Lock Washer For 1/2"/M12
1.46 Tower Structure 2 ea. H1407 Nylon Insert Locknut M12, Plated
1.19 Uhmw Slide Bar - Short 4 ea. H987 Sholder Bolt 3/8" Dia. x 1.25" Long
1.56 Limit Switch Striker Guide 2 ea. H739 Socket Head Cap Screw #8-32UNC x 1/2" Long
1.57 Limit Switch Striker Guide 2 ea. H1697 Flat Head Socket Screw M4 x 8mm Long
1.67 Limit Switch Striker 2 ea. H1409 Button Head Socket Screw M6 x 8mm Long
1.4 Cable Chain 1 ea. E2816 Cable Chain, 30.5mm Pitch, 75mm Bending
Radius, 36mm Wide, 23mm High, 39 Pitches (3.9
ft.) Long
1.58 Tower Structure, Top Plate 1 ea. H1391 Hex Cap Screw M10 - 35mm Long

Section 11 - Page 5

ITEM #
3 PILOT 20" FILM PRESTRETCH CARRIAGE - MECHANICAL ASSEMBLY

G2900-147-00-R0
3.36 Carriage Frame 1 ea. C5146 Pilot 20" Film Prestretch Carriage Frame
Weldment
3.64 Carriage Frame 2 ea. F4362 Carriage Drive Access Panel
3.80 Carriage Drive Access Panel 4 ea. H1141 Button Head Socket Screw M5 - 10mm Long
3.11 Carriage Frame Bottom Plate 1 ea. F3644 Film Roll Support Plate
3.55 Film Roll Support Plate 1 ea. F3744 Mandrel Bottom Chuck Spacer
3.79 Film Roll Support Plate 2 ea. H1710 Hex Cap Screw M10 - 20mm Long, Plated
3.75 Film Roll Support Plate 2 ea. H771 Flat Washer for 3/8" or M10 Screw
3.78 Film Roll Support Plate 2 ea. H1449 Lock Washer for M10 Screw
3.39 Carriage Frame Back Plate 1 ea. C5115 Cable Guide Tube Weldment
3.81 Cable Guide Tube Weldment 2 ea. H1388 Button Head Socket Screw M6 - 12mm Long
3.53 Prestretch Motor 1 ea. Y A618 Electric Motor, 56C, 1/2HP 230/460 V 3 Ph 60Hz,
4 Pole, 1750 RPM, TEFC - Small Body
3.77 Prestretch Motor 4 ea. H717 Hex Cap Screw M10 - 20mm Long, Plated
3.75 Prestretch Motor 4 ea. H771 Flat Washer for 3/8"/M10 Screw
3.76 Prestretch Motor 4 ea. H772 Lock Washer for 3/8" Screw
3.37 Motor Sprocket 1 ea. Y K607 Sprocket 35B12 x 5/8” Bore K2SS
3.5 Prestretch Roller #1 1 ea. W322 Polyurethane Covered Roller c/w 20mm Shaft - 3”
OD x 22" Long, Blue Compound
3.6 Prestretch Roller #2 1 ea. W323 Polyurethane Covered Roller c/w 20mm Shaft - 4”
OD x 22" Long, Blue Compound
3.38 Roller #2 Bottom Sprocket 1 ea. K608 Sprocket 35B40 x 20mm Bore K2SS
3.48 Prestretch Drive Chain 1 ea. Y K614 Chain ANSI #35 x 53 Pitches Long + Connecting
Link + Offset Link = 55 Links
3.57 Prestretch Drive Chain 1 ea. Y K111 Chain Connecting Link ANSI #35
3.84 Prestretch Drive Chain 1 ea. Y K112 Chain Offset (Half) Link ANSI #35
3.23 Roller #2 Top Sprocket 1 ea. Y K610 Sprocket 35B14 x 20mm Bore K2SS
3.24 Roller #1 Sprocket - 214% 1 ea. K616 Sprocket 35B33 x 20mm Bore K2SS
3.24 Roller #1 Sprocket - 300% 0 ea. K618 Sprocket 35B42 x 20mm Bore K2SS
3.49 Prestretch Ratio Chain 1 ea. Y K615 Chain ANSI #35 x 51 Pitches Long + Connecting
Link + Offset Link = 53 Links
3.57 Prestretch Drive Chain 1 ea. Y K111 Chain Connecting Link ANSI #35
3.84 Prestretch Drive Chain 1 ea. Y K112 Chain Offset (Half) Link ANSI #35
3.25 Prestretch Roller Sprocket & 26 ea. H1486 Nylon Flat Washer 0.81" ID x 1.48" OD x 0.062"
Bearing Spacers Thick
3.15 Prestretch Ratio Chain Take- 1 ea. X275 Chain Tensioner For Roller Chain #35
up Idler Sprocket Mount
3.66 Prestretch Ratio Chain Take- 1 ea. H1404 Socket Head Cap Screw M6x1 - 12mm Long
3.65 Prestretch Ratio Chain Take- 1 ea. H1390 Hex Cap Screw M8 - 35mm Long, Plated
3.16 Prestretch Ratio Chain Take- 1 ea. Y K606 Idler Sprocket 35A18H c/w 1/2” Id, Ball Bearing
up Idler Sprocket
3.19 Prestretch Ratio Chain Take- 1 ea. H1214 Hex Nut Metric M8x1.25
up Idler Sprocket
3.22 Prestretch Ratio Chain Take- 1 ea. H776 Lock Washer for 5/16"/M8 Screw
up Idler Sprocket
3.21 Prestretch Ratio Chain Take- 1 ea. H775 Flat Washer for 5/16"/M8 Screw
up Idler Sprocket
3.4 Prestretch Roller Bearings 4 ea. B301 Bearing 2-Bolt Flange c/w Pressed-Steel Housing
20mm ID
3.67 Prestretch Roller Bearings 8 ea. H1397 Hex Cap Screw M8- 12mm Long, Plated
3.3 Nip & Diverter Rollers 3 ea. Y W223 Roller Aluminum 1.9” OD x 22.75” Long c/w 7/16”
Hex Bore
3.8 Nip & Diverter Roller Axles 1 ea. W412 Shaft 7/16” Hex x 25.50” Long c/w M8-1.25
Tapped Ends

Section 11 - Page 6

ITEM #
3.72 Prestretch Roller Bearings 2 ea. H1400 Hex Cap Screw M8- 16mm Long, Plated
3.21 Nip & Diverter Roller Axles 1 ea. H775 Flat Washer for 5/16"/M8 Screw
Tapped Ends
3.58 Nip & Diverter Roller Axles 1 ea. H1506 Flat Head Socket Screw M6 x 14mm Long
3.59 Nip & Diverter Roller Axles 1 ea. H1383 Hex Cap Screw M6 - 16mm Long, Plated
Tapped Ends
3.69 Nip & Diverter Roller Axles 2 ea. H1399 Hex Cap Screw M8 - 20mm Long, Plated
3.22 Nip & Diverter Roller Axles 2 ea. H776 Lock Washer for 5/16"/M8 Screw
3.21 Nip & Diverter Roller Axles 2 ea. H775 Flat Washer for 5/16"/M8 Screw
3.7 Dancer Roller Frame 1 ea. C3742 Dancer Roller Frame Weldment 3.25" Radius
3.32 Dancer Pivot Bushing - Upper 1 ea. Y B299 Bronze Flange Bearing 12mm ID x 16mm OD x
8mm Long c/w 23mm OD x 3mm TK Flange
3.83 Dancer Upper Pivot Bushing 1 ea. Q183 Shaft Collar Steel 12mm ID c/w Set-Screw
Retainer
3.33 Dancer Bar Pivot - Lower 1 ea. H1373 Shoulder Screw 10mm Dia. x 20mm long,
M8x1.25 Thread
3.34 Dancer Bar Pivot - Lower 1 ea. H1330 Nylon Round Spacer 0.515" ID x 0.775" OD x
Spacer 0.250" Long
3.31 Dancer Pivot Bushing - Lower 1 ea. Y B297 Sintered Bronze Flange Bearing 10mm ID x
13mm OD x 10mm Long c/w 16mm OD x 1.5mm
TK Flange
3.9 Dancer Roller 1 ea. Y W324 Roller Aluminum 1.9” OD x 24.44” Long c/w 7/16”
Hex Bore
3.8 Dancer Roller Axle 1 ea. Y W412 Shaft 7/16” Hex x 25.50” Long c/w M8-1.25
Tapped Ends
3.69 Dancer Roller Axle 2 ea. H1399 Hex Cap Screw M8 - 20mm Long, Plated
3.35 Dancer Roller 4 ea. Q114 Shaft Collar Steel 1/2" ID c/w Set-Screw
3.27 Dancer Spring Mount - 1 ea. H1491 Shoulder Screw 6mm Dia. x 30mm long, M5x0.8
Stationary End Thread
3.28 Dancer Spring Mount - Moving 1 ea. H1496 Shoulder Screw 6mm Dia. x 16mm long, M5x0.8
End Thread
3.26 Dancer Bar Spring 2 ea. Y V203 Extension Spring 0.5” OD x 0.055 Wire x 2.5”
Long
3.17 Dancer Bar Proximity Sensor 1 ea. M1074 Dancer Bar Proximity Sensor Target Cam
Target Cam
3.70 Dancer Bar Proximity Sensor 1 ea. H1168 Socket Set Screw M6x1 x 6mm"Long - Cup Point
Target Cam
3.10 Dancer Bar Proximity Sensor 1 ea. F3421 Dancer Bar Proximity Sensor Mounting Bracket
Mounting Bracket
3.59 Dancer Bar Proximity Sensor 2 ea. H1383 Hex Cap Screw M6 - 16mm Long, Plated
Mounting Bracket
3.18 Dancer Bar Stops - Lower and 10 ea. H1353 Spacer-Nylon RoundD 0.257" Id x 0.50"Od x
Upper 0.50" Lg.
3.20 Dancer Bar Stops - Lower and 4 ea. H1381 Hex Cap Screw M8 - 30mm Long, Plated
Upper
3.14 Dancer Proximity Sensor 1 ea. E488 Refer to Electrical portion of this Material List,
under "Electrical Controls on Film Carriage"

Section 11 - Page 7

ITEM #
3.1 Film Roll Mandrel Ass'y - 20" 1 ea. G1700-007-00-R2

- consisting of:
3.1.1 Film Roll Spindle Bottom 1 ea. M9-CM4 Film Roll Spindle Bottom Chuck Bushing
Chuck Bushing
3.1.2 Film Roll Spindle Bottom 1 ea. M9-CM3 Film Roll Spindle Bottom Chuck
Chuck
3.1.3 Film Roll Spindle Top Chuck 1 ea. M79 Film Roll Spindle Top Chuck
3.1.4 Film Roll Spindle Shaft 4 ea. H764 Jam Nut 1” - 8NC
3.1.5A Film Roll Spindle Shaft 1 ea. H1463 Threaded Rod 1”-8UNC x 19.875” Long Plated
******************************
3.41 Prestretch Carriage Door 1 ea. C5147 Carriage Door Weldment
3.42 Prestretch Safety Door Hinge 2 ea. C3234 Prestretch Safety Door Hinge Pin
3.70 Prestretch Safety Door Hinge 2 ea. H1168 Socket Set Screw M6x1 x 6mm"Long - Cup Point
3.43 Prestretch Safety Door 2 ea. H1709 Shoulder Screw 10mm Dia. x 30mm Long
Stopper
3.19 Prestretch Safety Door 2 ea. H1214 Hex Nut Metric M8x1.25
Stopper
3.47 Prestretch Safety Door Slam 1 ea. Y X101 Rotary Slam Latch – Left-Hand
Latch
3.74 Prestretch Safety Door Slam 2 ea. H1255 Button Head Socket Screw 1/4"-20 X 3/4" Long
Latch
3.45 Prestretch Safety Door Latch 1 ea. H842 Shoulder Screw 3/8" Dia. x 5/8" Long
Pin
3.44 Prestretch Safety Door Latch 1 ea. H922 Top Lock Flange Nut 5/16"-18UNC
Pin
3.46 Prestretch Safety Door 1 ea. X103 Plastic Cabinet U-Handle
3.66 Prestretch Safety Door Handle 2 ea. H1404 Socket Head Cap Screw M6x1 - 12mm Long
3.56 Carriage Cover 1 ea. F3745 Carriage Cover - Steel Sheet

3.80 Carriage Cover 4 ea. H1141 Button Head Socket Screw M5 x 10mm Long
3.50 Descent Obstruction Plate 1 ea. F3734 Film Carriage Safety Tray
Safety Tray
3.68 Descent Obstruction Plate 4 ea. H1394 Button Head Socket Screw M5 - 20mm Long
Safety Tray
3.51 Carriage Safety Limit Switch 1 ea. M1073 Carriage Safety Limit Switch Mounting Plate
Mounting Plate
3.82 Carriage Safety Limit Switch 2 ea. H1401 Button Head Socket Screw M5 - 12mm Long
Mounting Plate
3.52 Carriage Safety Limit Switch 1 ea. E1663 Refer to Electrical portion of this Material List,
3.12 Auto Load Height Sensing 1 ea. F2205 Photo-Eye Angled Mounting Plate
Photo-Eye Mounting Plate
3.80 Auto Load Height Sensing 2 ea. H1141 Button Head Socket Screw M5 - 10mm Long
Photo-Eye Mounting Plate
3.-- Auto Load Height Sensing 1 ea. Refer to Electrical portion of this Material List,
Photo-Eye under "Electrical Controls on Film Carriage"
3.13 Film Carriage Limit Switches 2 ea. E1873 Refer to Electrical portion of this Material List,

Section 11 - Page 8

ITEM #
4 PILOT ELECTRICAL CONTROLS

Electrical Drawing: E1000-010 Rev. 1
- Control Panel Enclosure & Exterior
- Control Panel Enclosure Shell 1 ea. F3498 Main Control Panel Enclosure
- Microprocessor control 1 ea. E2881 Microprocessor Control Board c/w Keypad Pilot
assembly - consisting of: Label
- Control Panel Enclosure Door 1 ea. C4922 Main Control Panel Door Assembly
- Control Panel Door Keypad 1 ea. D316 Keypad Label for Pilot Series Machines
Label
******************************
- Microprocessor Control Board 1 ea. Y E2266 Fuse 3 Amp 250V Time-Delay Type 5mm x
Fuse #F2 20mm RoHS Compliant
- Microprocessor Control Board 1 ea. Y E1806 Fuse 1 Amp 250V Fast-Blow Type 5mm x 20mm
Fuse #F6 RoHS Compliant
- Power Off - On - Reset 1 ea. Y E1965 Selector Switch Operator 3-Position Spring-
Selector Switch Return Right to Center – Standard Knob
- Power Off - On - Reset 1 ea. E1939 Contact Block c/w Mounting Base 1 x N.O. & 1 x
Selector Switch N.C.
- Emergency Stop Push-Button 1 ea. Y E1812 Push-Pull Mushroom Head Button Red 40mm
Diameter 2-Position Maintained
- Emergency Stop Push-Button 1 ea. E1813 Contact Block c/w Mounting Base 1 x N.C.
- Manual Film Feed Push-Button 1 ea. Y E1960 Push-Button Head Blue Flush Momentary
- Manual Film Feed Push-Button 1 ea. E1937 Contact Block c/w Mounting Base 1 x N.O.
- 1CS - Connector Jumper 1 ea. Y S387 SWCB 1CS Jumper Plug - for Machine Without
Plug Ass'y - consisting of: Remote Start
- SWCB 1CS Connector 1 ea. Connector Receptacle Female 8-Position 4.2mm
Vertical Dual Row Mini-Fit Jr.
- SWCB 1CS Connector 2 ea. E2178-2 Connector Crimp Terminal Female 18-24AWG
Tin-Plated Phosphor Bronze Mini-Fit Jr.
- SWCB 1CS Connector 0.25 ft. E174 Wire Type TR-64 #18 AWG/16 Strand Black (ft.)
******************************
- Control Panel Cable Entry 6 ea. E1877 Knock-Out Bushing SB875-11 Black - for 7/8"
Dia. Hole c/w 0.687" ID, Suitable for Maximum
0.125" Panel thickness
- Control Panel Cable Entry 0.4 ft. E2215 Grommet Strip for 0.085" Max. Chassis
Thickness - Extruded Serrated Polyethylene
Type, Natural (100 ft. Roll)
- Power Cord 1 ea. E168 Strain Relief Connector 1/2" NPT 0.236"-0.472"
Dia. - Black
- Power Cord 1 ea. E146 Lock Nut 1/2" Conduit
Power Cord 1 ea. E2243 Power Cord Assembly 14-3 SJT x 15.5 ft. Long
c/w 3-Pin Straight Male Plug on one end and
other end blunt cut

Section 11 - Page 9

ITEM #
- Control Panel - Inner Panel
- Inner Panel 1 ea. E2293-C Control Panel Inner Panel c/w Special Piercing -
12 GA HRS 16.75" x 11.875" c/w Gloss White
Paint
- Wiring Harness 1 ea. E2343 Control Panel Wiring Harness for 2100-SRT to
Schematic E2100-188
- 1PS 1 ea. Y E2333 Power Supply 24VDC 0.6 amp Output, 90-264
VAC Input, Phaseo
- MCR 1 ea. Y E1156-4 Relay 4PDT 15A c/w 24VDC Coil
- MCR 1 ea. E103-4 Relay Base 4-Pole for RPM41 Relay
- MCR 1 ea. E416 Diode General Purpose 400 PRV 1A DO-41
- Relay Mounting Rail 0.113 2 m. E474 DIN Rail 35mm x 7.5mm Symmetrical
- 1FU 1 ea. E447 Fuse Holder 1-Pole, Dead Front, DIN-Rail
Mounted, for Midget & Class 'CC' Fuses 600V
30A
- 1FU 1 ea. Y E448 Fuse 600 Volt 15 Amp Class HRCI-CC Dual-
Element Time-Delay Type
- 5FU 1 ea. E2239-2 Fuse-Holder Terminal Block for 5mm x 20mm
Fuse, 2002 Series, Grey
- 5FU 1 ea. Y E1810 Fuse 2 Amp 250V Fast-Blow Low Breaking Type,
IEC/SEMKO/CEE Certified for Europe 5mm x
20mm
- 1VFD 1 ea. Y E1569-2 Altivar 12 AC Variable Speed Drive 115 Volt 1
Phase 50/60 Hz Input - 1/2 HP 2.4A 230 Volt 3
Phase Output
Phase Output
Phase Output
- Terminal Strip 2 ea. E2232-2 Terminal Block 3-Position Cage Clamp Through
Type, 2002 Series, Grey
- Terminal Strip 2 ea. E2233-2 Terminal Block 3-Position Cage Clamp Through
Type, 2002 Series, Blue
- Terminal Strip 1 ea. E2234-2 Terminal Block End & Intermediate Plate for 3-
Position Terminal Block, Type 2002 Series, Grey
- Terminal Strip 2 ea. E2235-2 Terminal Push-In Jumper Bar 2 Pole Type, 2002
Series, Light Grey
- Terminal Strip 0.5 ea. E2236-2 Terminal Markers 5mm, Blank - Card with 10
Strips of 10 Markers
- Terminal Strip & Other DIN- 4 ea. E2270 Terminal End Stop Screwless 6mm Wide, for
Rail Devices 35mm Symmetrical DIN Rail

Section 11 - Page 10

ITEM #
- Electrical Controls on Machine Base
1PX - Turntable Home Position 1 ea. Y E2166-3 Inductive Proximity Sensor QD Type 18mm Dia.
Sensor Nickel-Plated Brass 24VDC PNP N.O. Flush 5mm
Range c/w 4-Pin M12 Micro Connector
1PX - Turntable Home 1 ea. Y S333

Position Sensor Cable
1PX Assembly - consisting of:
Sensor Cable 1 ea. E2106-3 QD Connector Cable DC 4-Wire M12 Micro Style
Black PUR Insulated 90° - 5m Long
SWCB 1PX Connector 1 ea. E2168 Connector Receptacle Female 4-Position 4.2mm
SWCB 1PX Connector 3 ea. E2178-2 Connector Crimp Terminal Female 18-24AWG
- Electrical Controls on Machine Tower
- Turntable Motor 2.286 mtr. E2230-1 Flexible Motor Supply Cable #18 AWG 4
Conductor (3 + Ground) Shelded c/w PVC Jacket
(mtr.)
- Film Carriage Elevator Motor 1.677 mtr. E2230-1 Flexible Motor Supply Cable #18 AWG 4
Conductor (3 + Ground) Shelded c/w PVC Jacket
(mtr.)
- Turntable Motor - 1MTR 1 ea. E168 Strain Relief Connector 1/2" NPT 0.236"-0.472"
Dia. - Black
- Film Carriage Elevator Motor - 1 ea. E168 Strain Relief Connector 1/2" NPT 0.236"-0.472"
2MTR Dia. - Black
5PX - Carriage Height Pulse 1 ea. Y E1583-1 Inductive Proximity Sensor QD Type 8mm Dia.
Sensor Nickel-Plated Brass 24VDC PNP N.O. Shielded
1.5mm Range c/w 4-Pin M12 Micro Connector
5PX - Carriage Height Pulse 1 ea. F1981-R2 Bracket for 8mm Prox Sensor on Tower
Sensor
5PX - Carriage Height Pulse 1 ea. Y S381
5PX Sensor Cable Assembly -
consisting of:
5PX - Carriage Height Pulse 1 ea. E2106-3 QD Connector Cable DC 4-Wire M12 Micro Style
Sensor Black PUR Insulated 90° - 5m Long
SWCB 5PX Connector 1 ea. E2171 Connector Receptacle Female 3-Position 4.2mm
Vertical Single Row Mini-Fit Jr.
SWCB 5PX Connector 3 ea. E2178-2 Connector Crimp Terminal Female 18-24AWG

Section 11 - Page 11

ITEM #
- Electrical Controls on Film Carriage
- Carriage Cable - Control 3.353 mtr. E1615-1 Flexible Control Cable Type 190 #18 AWG 12
Conductor c/w Grey PVC Cover (mtr.)
- Carriage Cable - 3MTR 3.05 mtr. E1710-1 Flexible Control Cable Type 190 #18 AWG 4
Conductor Shielded c/w Grey PVC Cover (mtr.)
- Carriage Cable - 3MTR 1 ea. E168 Strain Relief Connector 1/2" NPT 0.236"-0.472"
Dia. - Black
- Cable Chain 1 e E2816 Refer to Tower & Film Carriage Lift Drive -
Mechanical Assembly
- Carriage Cable 1 ea. E469 Pipe Strap 3/8" EMT One-Hole
- Carriage Cable 2 ea. E234-1 Fixed Diameter Clamp 0.437" Dia. (P-CLIP)
- ******************************
1PE - Auto Load Height 1 ea. Y E1661 Photo-Eye Adjustable Range Reflective Type
Sensing Photo-Eye 2.5m Range, 24 -240VAC/12-240VDC Supply, E-
M Form-A Relay Output
1PE - Auto Load Height 2.5 ft. E2127 Cable 4-Conductor 20 Gauge PVC or PUR
1PE
Sensing Photo-Eye Insulated
1PE - Auto Load Height 1 ea. Refer to Mechanical portion of this Material List,
Sensing Photo-Eye Mounting under "Super Rapid Thread II 20" Prestretch
Bracket Mechanical Assembly"
2LS 2LS - Film Carriage Elevator 1 ea. Y E1873 Limit Switch Side-Rotary c/w 30mm Radius Arm
Top Limit Switch
3LS 3LS - Film Carriage Elevator 1 ea. Y E1873 Limit Switch Side-Rotary c/w 30mm Radius Arm
Bottom Limit Switch
3PX - Dancer Proximity Sensor 1 ea. Y E488 Inductive Proximity Sensor 18mm Dia. 12-48VDC
0 - 10mA Analogue Output 0.8 - 8.0mm Sensing
Distance
3PX
3PX - Dancer Proximity Sensor 1 ea. Refer to Mechanical portion of this Material List,
Mounting Bracket under "Super Rapid Thread II 20" Prestretch
Mechanical Assembly"
Hall Effect Cable Connector 0 ea. E2168 Connector Receptacle Female 4-Position 4.2mm
Vertical Dual Row Mini-Fit JR
4LS - Film Carriage Safety 1 ea. Y E1663 Safety Switch c/w Straight Centered Rotary Lever
Switch - Plastic 2-Pole N/C + N/C Slow Break Contacts -
PG11 Conduit Opening
4LS - Film Carriage Safety 1 ea. E899 Strain Relief Connector w/o Locknut PG11 .200"-
4LS
Switch .394" DIA. - Black
4LS - Film Carriage Safety 1 ea. Refer to Mechanical portion of this Material List,
Switch Mounting Plate under "Super Rapid Thread II 20" Prestretch
Mechanical Assembly"
- SWCB CARR Connector 1 ea. E2227 Connector Receptacle Female 18-Position 4.2mm
- SWCB CARR Connector 11 ea. E2178-2 Connector Crimp Terminal Female 18-24AWG

12:0
C
O
M
P
O
N
E
N
T
M
A
N
U
A
L
S
Thank you very much for using SUNX products. Please
read this Instruction Manual carefully and thoroughly for 4 MOUNTING
the correct and optimum use of this product. Kindly keep ٨ The tightening torque should be 0.8N㨯m or less.
this manual in a convenient place for quick reference. M5 PWV
INSTRUCTION MANUAL ٨ Never use this product as a sensing M5 (length 32mm)
device for personnel protection. screw with washers
Photoelectric Sensor ٨ In case of using sensing devices for personnel
protection, use products which meet standards,
Adjustable Range Reflective WARNING such as OSHA, ANSI or IEC etc., for personnel Sensor
protection applicable in each region or country.
EQ-500 Series mounting
bracket
MS-EQ5-01
1 SPECIFICATIONS (Optional)
Multi-voltage DC-voltage
Type
Short sensing range Short sensing range ٨ Care must be taken regarding the sensor mounting direc-
Model No. EQ-501 EQ-502 EQ-511 EQ-512 tion with respect to the object's direction of movement.
Item With timer EQ-501T EQ-502T EQ-511T EQ-512T
Adjustable range (Note 1) (Note 2) 0.2 to 2.5m 0.2 to 1.0m 0.2 to 2.5m 0.2 to 1.0m
Sensing range (Setting dis-
tance maximum) (Note 2) 0.1 to 2.5m 0.1 to 1.0m 0.1 to 2.5m 0.1 to 1.0m
Hysteresis (Note 2) 10% or less of operation distance
24 to 240V AC r 10% or 12 to 240V DC r 10%
Supply voltage 12 to 24V DCr10%˴Ripple P-P 10% or less
Ripple P-P 10% or less
Power / Current AC: 4VA or less (With timer: 5VA or less)
45mA or less
consumption DC: 3W or less (With timer: 4W or less) Sensing object Sensing object Sensing object
NPN open-collector transistor
࡮Maximum sink current: 100mA Do not make the sen-
Relay contact 1a sor detect an object
࡮Applied voltage: 30V DC or less (between output and 0V)
࡮Switching capacity: 250V AC 3A (resistive load) in this direction be-
࡮Residual voltage: 1V or less (at 100mA sink current)
30V DC 3A (resistive load) cause it may cause
0.4V or less (at 16mA sink current)
Output ࡮Electrical life: 100,000 or more operations unstable operation.
PNP open-collector transistor
(switching frequency 1,200 times/hour)
࡮Maximum source current: 100mA ٨ When detecting a specular object (aluminum or copper
࡮Mechanical life: 50,000,000 or more operations
࡮Applied voltage: 30V DC or less (between output and +V)
(switching frequency 18,000 times/hour) foil, etc.) or an object having a glossy surface or coat-
࡮Residual voltage: 1V or less (at 100mA source current)
0.4V or less (at 16mA source current) ing, please take care that there are cases when the
object may not be detected due to a small change in
Output operation Switchable either Detection-ON or Detection-OFF
angle, wrinkles on the object surface, etc.
Short-circuit protection 㧙 Incorporated
٨ When a specular body is present below the sensor,
Response time 20ms or less (Depends on the timer setting period for EQ-50‫غ‬T) 2ms or less (Depends on the timer setting period for EQ-51‫غ‬T) use the sensor by tiling it slightly upwards to avoid
Operation indicator Orange LED (lights up when the output is ON) wrong operation.
Stability indicator Green LED (lights up under stable operating condition)
Specular Specular
Distance adjuster 2-turn mechanical adjuster with pointer
face face
Sensing mode 㧙 Switch either BGS or FGS function
Timer function EQ-5‫غ‬T: Selectable from ON-delay and OFF-delay (0.1 to 5 sec. variable)
Automatic interference Tilt
Incorporated (Note 3)
prevention function
Protection IP67 (IEC) ٨ If a specular body is present in the background, wrong
Ambient temperature -25 to +55͠ (No dew condensation or icing allowed), Storage: -30 to +70͠ operation may be caused due to a small change in the
Ambient humidity 35 to 85% RH, Storage: 35 to 85% RH
angle of the background body. In that case, install the
sensor at an inclination and confirm the operation with
Emitting element Infrared LED (modulated)
the actual sensing object.
Receiving element 2-segment photodiode
٨ This product is not easily affected by the reflected light in-
Material Enclosure: ABS, Front cover: Polycarbonate, Display cover: Polycarbonate
tensity since this sensor is the adjustable range reflective
Connection method Screw-on terminal connection type. When the reflected light intensity is remarkably low, the
Cable Suitable for round cable Ǿ9 toǾ11mm sensing range may be affected. In that case, mount the sen-
Cable length Extension up to total 100m is possible with 0.3mm2, or more, cabtyre cable sor, while checking light-up of the stable indicator (green).
Weight 100g approx. 85g approx. ٨ Mounting screws of the terminal cover and display cov-
Accessory Adjusting screwdriver: 1 pc. er should certainly be tightened to maintain the water
Notes: 1) The adjustable range stands for the maximum sensing range which can be set with the adjuster. tight rating, however, the tightening torque of the
2) The adjustable range, the sensing range and the hysteresis are specified for white non-glossy paper (200200mm) as the object. screws should be of 0.3 to 0.5N㨯m.
3) When the sensors are mounted closely, use them in the interference prevented area, as shown below.
3 3 5 WIRING CONNECTIONS
Setting range (m)
Setting range (m)
٨ Check all wiring before applying power since incorrect

2 2 wiring may damage the internal circuit.
Also, carefully tighten the terminal screws so that the
1 1 wires of adjacent terminals do not touch.
L mm Interference Interference ٨ The mounting hole for screw the terminal cover fixing
or more prevented area L mm L mm L mm prevented area inclines 70 degrees to the Screw for terminal
or more or more or more terminal cover, as shown cover fixing
20 40 60 80 0 0 50 100 150 200 250 in the figure below.
Mounting interval L (mm) Mounting interval L (mm) To avoid damaging this
Note that the detection may be unstable depending on the mounting conditions or the sensing object. In the state where this prod- product or a screw, take 70q
uct is mounted, be sure to check the operation with the actual sensing object to be used.
care when tightening or Screwdriver
٨ Do not run the wires together with high-voltage lines or loosening a screw.
2 INFORMATION RELATING TO power lines or put them in the same raceway. This can ٨ To maintain a watertight performance, the cable should
LOW VOLTAGE DIRECTIVE cause malfunction due to induction. have an outer diameter between Ǿ9 to Ǿ11mm with a
٨ In case noise generating equipment (switching regula- smooth covering material that allows the accessory con-
(Multi-voltage type only) tor, inverter motor, etc.) is used in the vicinity of this duit connector to be securely tightened, however, the tight-
Item Description product, connect the frame ground (F.G.) terminal of ening torque of the screw should be of 1.5 to 2.0N㨯m.
Refering standard IEC 60947-5-2: 1998
the equipment to an actual ground. ࡮ Composition of a conduit connector, and process-
٨ Take care that the sensor is not directly exposed to fluo- ing of a cable
Utilaization category AC-12/DC-12
rescent light from a rapid-starter lamp or a high frequency
Impulse withstanding voltage 2.5kV
lighting device, as it may affect the sensing performance.
Pollution degree 3
٨ If an external surge voltage exceeding 4kV (DC-voltage:
Frequency of operation cycle 25Hz 1kV) is impressed, the internal circuit will be damaged, Conduit connector
Turn off time 20ms and a surge suppressing element should be used.
Excess gain 12% ٨ Do not use during the initial transient time (50ms) after
Rated conditional protective device 100A the power supply is switched on. Gland packing (Note) Gland
Short-circuit protective device FUSE 5A FAST BLOW ٨ This sensor is suitable for indoor use only. 37mm
Note: Each condition for use that the standards require is under ٨ A mechanical structure is employed for the distance ad-
less than 2,000m above sea level. juster of this product. Take care not to drop the product. Power supply
٨ Do not use this sensor in places having excessive va-
3 CAUTIONS por, dust, etc., or where it may come in direct contact
with water, or corrosive gas.
Output
٨ Make sure that the power supply is off while wiring and adjusting. ٨ Take care that the sensor does not come in direct con- 25mm
٨ Take care that wrong wiring will damage the sensor. tact with water, oil, grease, or organic solvents, such Note: When assembling the conduit connector, take care of the
٨ Verify that the supply voltage variation is within the rating. as, thinner, etc. direction of the gland packing.
٨ If power is supplied from a commercial switching reg- ٨ This sensor cannot be used in an environment con- Furthermore, in order to maintain a watertight performance, fit
ulator, ensure that the frame ground (F.G.) terminal of taining inflammable or explosive gases. the gland packing such that the seating surface of the gland
the power supply is connected to an actual ground. ٨ Never disassemble or modify the sensor. packing contacts the packing holder part of the terminal cover
٨ If pressure terminals are to be used, affix the connect-
ed pressure terminals to a terminal (M3.5 screw). 9 BGS/FGS FUNCTION 11 STABILITY INDICATOR
࡮ Dimensions of the suitable crimp terminals (DC-voltage type only) ٨ Since the EQ-500 series use a 2-segment photo-
(Unit: mm) diode as its receiving element, and sensing is done
٨ This sensor incorporates BGS/FGS function. Select based on the difference in the incident beam angle
Round type Y-shaped type either BGS or FGS function depending on the posi- of the reflected beam from the sensing object, the
22 or less 22 or less tions of the background and sensing object. output and the operation indicator (orange) operate
Ǿ3.6 Ǿ3.6
or more 10 or more 10 BGS/FGS function is set with the operation mode according to the object distance.
or less or less switch. Further, the stability indicator (green) shows the
٨ Depends on a selection of either BGS or FGS func- margin to the setting distance.
tion, the output operation changes as follows.
Setting distance
17 7 17 7 Sensing range
7.5 or less or less 7.5 or less or less
or less or less
(After crimping) (After crimping) Adjusted distance
࡮ The tightening torque of the terminal screws should be Non-detectable area
0.3 to 0.5N㨯m. ON
L-ON Sensing object
OFF
BGS
6 I/O CIRCUIT DIAGRAMS D-ON
ON
OFF
Output ON (lights up)
(operation indicator)
٨ Multi-voltage type ON (In case of Detection-ON) OFF (lights off)
Terminal No. L-ON
OFF
FGS Lights up
Power supply ON Stability indicator Stable Stable operating
D-ON Lights off
Multi-voltage 24 to 240V ACr10% OFF operating condition
circuit or condition Unstable operating
Sensor circuit
12 to 240V DCr10% <BGS function> condition
Background
٨ This function is used when
Output relay the sensing object is apart 12 TIMER FUNCTION (EQ-5‫غ‬T only)
Relay contact
from the background. Sensing object ٨ An OFF-delay timer, which is useful when the re-
(1a) <FGS function> sponse of the connected device is slow, etc., an
ON-delay timer, which is useful when the input
٨ This function is used when the sensing
Internal circuit specifications of the connected device require a sig-
object contacts the background or the
٨ DC-voltage type nal of a fixed width, are possible with EQ-5‫غ‬T.
sensing object is glossy, etc.
Terminal No. ٨ The OFF-delay timer and the ON-delay timer can be
used at the same time.
D +V Sensing
٨ For DC-voltage type, set the DIP switch for the timer
object
Sensor circuit
Tr2 ZD2 100mA max. selecting to 'Timer ON' side.

Background
Load +
Output (PNP) 12 to 24V DC <Time chart>
Load r10%
Output (NPN)
100mA max.
-
10 DISTANCE ADJUSTMENT Sensing
condition
Beam-
received
Tr1 ZD1
For DC-voltage type, be sure to set the BGS/FGS func- Beam-
0V Operation interrupted
Internal circuit Users' circuit tion before distance adjustment. If the setting is done af- ON
Light-received
ter the distance adjustment, the sensing area is changed. normal operation
Symbols...D: Reverse supply polarity protection diode OFF
ZD1, ZD2: Surge absorption zener diode ٨ Turn the distance adjuster gradually and lightly with a ON
Light-received
Tr1: NPN output transistor screwdriver (please arrange separately). In order to ON-delay
Tr2: PNP output transistor protect itself, the distance adjuster idles if turned fully. OFF
ON
Light-received
٨ Terminal position ٨ Multi-voltage type, DC-voltage type࡮BGS select OFF-delay OFF
Distance ON
Step Description Light-received
adjuster
Ԙ ԙ ON/OFF-delay OFF
Ԛ ԛ ON
Turn the distance adjuster fully counterclock- Light-interrupted
Ԙ wise to the minimum sensing range position. normal operation OFF
(0.2m approx.) ON
Light-interrupted
Turn fully
ON-delay
OFF
Please an object at the required distance ON
7 PART DESCRIPTION from the sensor, turn the distance adjuster Light-interrupted
OFF-delay
ԙ gradually clockwise, and find out point OFF
Stability indicator (Green)
where the sensor changes to the light re- ON
Distance adjuster OFF-delay timer switch Light-interrupted
ceived condition.
(2-turn) (Note 2) ON/OFF-delay OFF
Remove the object, turn the distance adjuster
further clockwise, and find out point where Timer period: T = 0.1 to 5s (variable)
the sensor changes to the light received con- Note: Turn the timer switch gradually and lightly with the attach-
Ԛ dition again with only the background. ed screwdriver. If the distance adjuster is over turned or
ON-delay timer switch When the sensor does not go to the light re- pressed heavily, it may be damaged.
Adjuster indicator ceived condition even if the adjuster is fully
(Note 2)
Operation indicator (Orange) turned clockwise, point is this extreme point.
Operation mode switch (Note 1) 13 DIMENSIONS (Unit: mm)
Notes: 1) The operation mode switch of the DC-voltage type is the Optimum
DIP switch. Refer to ' 8 OPERATION MODE SWITCH' for The optimum position to stably detect objects position
ԛ
details. is the center point between and .
2) Incorporated on EQ-5‫غ‬T only.
3-Ǿ5.1 mounting hole

٨ DC-voltage type࡮FGS select
8 OPERATION MODE SWITCH Distance
Beam-
receiving 26
2
68
Step Description part
٨ Multi-voltage type (L-ON / D-ON mode only) adjuster
Operation mode switch Description Beam-
emitting
Turn the distance adjuster fully clockwise to part
Detection-ON mode is obtained when the Ԙ the maximum sensing range position. (2.5m Center of
switch is turned fully clockwise. approx., 1.0m approx. for EQ-512‫غ‬ sensing 68 58
Turn fully
Detection-OFF mode is obtained when the 22
switch is turned fully counterclockwise. In the state where the sensor detects the
background, turn the distance adjuster gradu-
ԙ ally counterclockwise, and find out point 5 5 30
Note: Turn the operation mode switch gradually and lightly with the 58
where the sensor changes to the undetecting
attached screwdriver. If the distance adjuster is over turned or 3-M5 nut seats
condition.
pressed heavily, it may be damaged. (on both sides)
Place an object at the required distance from the sensor, turn
٨ DC-voltage type the adjuster counterclockwise further until the sensor goes in-
to the undetecting condition again. Once it has entered, turn
L-ON / D-ON mode L D Ԛ the adjuster backward a little until the sensor returns to the
BGS/FGS mode BGS FGS detecting condition. That position is designated as point .
Timer mode OFF Timer ON When the sensor does not go into the undetect- SUNX Limited http://www.sunx.co.jp/
Not used N.C. N.C. ing condition even if the adjuster is fully turned
counterclockwise, the position where the adjust- Head Office
er was fully turned is regarded as the point . 2431-1 Ushiyama-cho, Kasugai-shi, Aichi, 486-0901,
Japan
Optimum Phone: +81-(0)568-33-7211 FAX: +81-(0)568-33-2631
The optimum position to stably detect objects position
ԛ Overseas Sales Dept.
is the center point between and .
Phone: +81-(0)568-33-7861 FAX: +81-(0)568-33-8591
PRINTED IN JAPAN
Product data sheet XS118BLPAM12
Characteristics inductive sensor XS1 M18 - L64mm - brass -
Sn5mm - 12..24VDC - M12
Disclaimer: This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications
Main
Range of product OsiSense XS
Series name General purpose
Sensor type Inductive proximity sensor
Sensor name XS1
Sensor design Cylindrical M18
Size 64 mm
Body type Fixed
Enclosure material Nickel plated brass
Type of output signal Discrete
Wiring technique 3-wire
[Sn] nominal sensing distance 5 mm
Discrete output function 1 NO
Discrete output type PNP
Electrical connection 4 pins M12 male connector
[Us] rated supply voltage 12...24 V DC with reverse polarity protection
Switching capacity in mA <= 200 mA with overload and short-circuit protection
IP degree of protection IP67 conforming to IEC 60529
Complementary
ISO thread M18 x 1
Detection face Frontal
Detector flush mounting acceptance Flush mountable
Material Metal
Front material PBT
Operating zone 0...4 mm
Differential travel 1...15% of Sr
Output circuit type DC
Nov 24, 2017

1
Status LED 1 LED yellow for output state
Supply voltage limits 10...36 V DC
Switching frequency <= 1200 Hz
Voltage drop <= 2 V at closed state
Current consumption <= 10 mA at no-load
Delay first up <= 15 ms
Delay response <= 0.1 ms
Delay recovery <= 0.3 ms
Marking CE
Threaded length 43 mm
Height 18 mm
Length 64 mm
Product weight 0.035 kg
Environment
Product certifications UL
CSA
Ambient air temperature for operation -25...70 °C
Ambient air temperature for storage -40...85 °C
Vibration resistance 25 gn amplitude = +/- 2 mm (f = 10...55 Hz) conforming to IEC 60068-2-6
Shock resistance 50 gn for 11 ms conforming to IEC 60068-2-27
Offer Sustainability
Sustainable offer status Green Premium product
RoHS (date code: YYWW) Compliant - since 0903 - Schneider Electric declaration of conformity
Schneider Electric declaration of conformity
REACh Reference not containing SVHC above the threshold
Reference not containing SVHC above the threshold
Product environmental profile Available
Product environmental
Product end of life instructions Available
End of life manual
Contractual warranty
Warranty period 18 months
2
Dimensions Drawings
Dimensions
(1) LED
3
Mounting and Clearance
Minimum Mounting Distances
Side by side
e (1) ≥ 10 mm/0.39 in.
Face to face
e (2) ≥ 60 mm/2.36 in.
Facing a metal object
e (3) ≥ 15 mm/0.60 in
4
Connections and Schema
Wiring Schemes
M12 connector
PNP
1: (+)
2: Not connected
3: (-)
4: NO Output
5
Performance Curves
Performance Curves
Standard Steel Target : 18x18x1 mm
(1) Pick-up points

(2) Drop-out points (object approaching from the side)
(y) Sensing distance in mm
6
+++++++++++++++++++++++++++tm
M I T - detection / Tome 1
XS1-M / XS2-M / XS4-P Détecteurs de proximité analogiques / Analogue proximity sensors

e4
Références / References e1 PROTECTIONS
E e2 e3
H
XS1-M12AB110/120 C (Nm)
XS1-M18AB110/120
Produit E (mm) C (Nm) e1 (mm) e2 (mm)
e3 (mm) e4 (mm) H (mm)
XS1-M30AB110/120 XS1-M12 17 6 4 24 6 12 0
XS2-M12 17 6 16 48 12 36 8
XS4-P12 17 2 16 48 12 36 8
XS2-M12AB110/120 XS1-M18 24 15 10 60 15 18 0
XS2-M18AB110/120 XS2-M18 24 15 32 96 24 54 16
XS2-M30AB110/120 XS4-P18 24 5 32 96 24 54 16
XS4-P12AB110/120 XS1-M30 36 40 20 120 30 30 0
XS4-P18AB110/120 XS2-M30 36 40 60 180 45 90 30
XS4-P30AB110/120 XS4-P30 36 20 60 180 45 90 30
Courbes de sortie / Output curves Is = courant de sortie du détecteur / Output current
Caractéristiques électriques / XS1-M12AB120 Sn = 0,2…2 mm XS2-M/XS4-P12AB120 Sn = 0,4…4 mm XS2-M/XS4-P12AB110 Sn = 0,4…4 mm
22 22 11
Electrical characteristics 20 20 10
18 18 9
Type de détecteurs / XS1-M Métalique noyable / 16 16 8
Is (mA)
Is (mA)
14 14 7
Us (V)
Detector type Metal Flush Mountable 12 12 6
10 10 5
XS2-M Métalique non noyable / 8 8 4
6 6 3
Metal Non Flush Mountable 4 4 2
XS4-P Plastique non noyable / 2
0
2
0
1
0 F ≤ 2 Kg
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2 2,2 2,4 2,6 0 0,4 0,8 1,2 1,6 2 2,4 2,8 3,2 3,6 4 4,4 4,8 5,2 0 0,4 0,8 1,2 1,6 2 2,4 2,8 3,2 3,6 4 4,4 4,8 5,2
Plastic Non Flush Mountable 10 cm
Distance détecteur/écran (mm) Distance détecteur/écran (mm) (1) Distance détecteur/écran (mm) (1)
Limites de tension / XS…120 --> 10…38 V a Sensing distance (mm) (1)
Supply voltage limits XS…110 --> 10…58 V a XS1-M18AB120 Sn = 0,5…5 mm XS2-M/XS4-P18AB120 Sn = 0,8…8 mm XS2-M/XS4-P18AB110 Sn = 0,8…8 mm
22 22 11
Type de sortie XS…110 --> 0…10 V 20 20 10
18 18 9
analogique / branchement 3 fils avec R = 1 kΩ 16 16 8
14
Is (mA)
Is (mA)
14 7 fixe / fixed
Us (V)
Analog. output type XS…120 --> 4…20 mA 2 12 6
10 10 5
branchement 2 fils 8 8 4
6 6 3
Courant consommé ≤ 4 mA 4
2
4
2
2
1
sans charge / No load 0
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5
0
0 0,8 1,6 2,4 3,2 4 4,8 5,6 6,4 7,2 8 8,2 8,4 9,2
0
0 0,8 1,6 2,4 3,2 4 4,8 5,6 6,4 7,2 8 8,8 9,610,4
current consumption Distance détecteur/écran (mm) (1) Distance détecteur/écran (mm) (1) Distance détecteur/écran (mm) (1)
XS1-M30AB120 Sn = 1…10 mm XS2-M/XS4-P30AB120 Sn = 1,5…15 mm XS2-M/XS4-P30AB110 Sn = 1,5…15 mm
22 22 11
20 20 10
Mise en œuvre / Setting up procedure 18 18 9
16 16 8
Is (mA)
Is (mA)
Us (V)
14 14 7
Domaine de fonctionnement / Operating range 2 2 6
10 10 5
8 8 4
XS1-M12… --> 0,2…2 mm 6 6 3
XS2-M12… --> 0,4…4 mm
4
2
4
2
2
1
≥ 10 cm.
0 0 0
XS4-P12… --> 0,4…4 mm 0 1 2 3 4 5 6 7 8 9 10 11 12 13 0 1,5 3 4,5 6 7,5 9 10,5 12 13,5 15 16,5 18 19,5 0 1,5 3 4,5 6 7,5 9 10,5 12 13,5 15 16,5 18 19,5
Distance détecteur/écran (mm) (1) Distance détecteur/écran (mm) (1) Distance détecteur/écran (mm) (1)
XS1-M18… --> 0,5…5 mm
chap.
Branchement 2 fils / 2-wire type Branchement 3 fils / 3-wire type

10
XS2-M18… --> 0,8…8 mm BN/1

+ BN/1
+ Sortie tension /
mA mA BK/4
Sortie courant / Is
XS4-P18… --> 0,8…8 mm
BK/4 Voltage type output
R Current type output BU/3
R BU : bleu, blue, blau, blu, azul, bla, blauw, Ì_ÏÂ
XS1-M30… --> 1…10 mm
BU/3
– – Us=R.Is BN : brun, brown, marrón, castanho, brun, bruin, Î·Ê¤
Is
Courant de sortie / Valeur de charge / Courant de sortie / Valeur de charge / Tension de sortie Valeur de charge BK : noir, black, schwarz, nero, negro, preto, svart, Ì·‡ÚÔ
XS2-M30… --> 1,5…15 mm
page
Output current (2) Load value Output current (2) Load value (3) Output voltage Load value
R ≤ 82 Ω ≤ 560 Ω
2
XS4-P30… --> 1,5…15 mm XS...120 12 V 4…20 mA XS...110 12 V 0…10 mA 0…10 V (impossible)

24 V 4…20 mA R ≤ 450 Ω 24 V 0…10 mA ≤ 1500 Ω 0…10 V R = 1000 Ω
48 V 0…10 mA ≤ 3300 Ω 0…10 V R = 1000Ω
Respecter une tension mini de 10 V entre le + (borne 1) et le - (borne 3)
du détecteur / the supply voltage between terminals 1 (+) and 3 (-) Respecter une tension mini de 5V entre le + (borne 1) et la sortie du détecteur (borne 4) / The supply voltage
must be ≥ 10 V between terminals 1 (+) and the output terminal 4 must be ≥ 5V
W914581670111 A03 04-2002

Inductive Sensors
BES M08MH1-PSC20B-S04G
Ordercode: BES0028
EN 60068-2-6, Vibration 55 Hz, amplitude 1 mm, 3x30

min
Display/Operation Protection degree IP67
Function indicator yes
Power indicator no
Functional safety
MTTF (40 °C) 880 a
Electrical connection
Connection M12x1-Male, 4-pole, A-coded
Polarity reversal protected yes General data
Protection against device mix-ups yes Approval/Conformity CE
Short-circuit protection yes cULus
EAC
Basic standard IEC 60947-5-2
Electrical data Trademark Global
Load capacitance max. at Ue 1 µF

Min. operating current Im 0 mA Material
No-load current Io max., damped 10 mA
Housing material Brass
No-load current Io max., undamped 5 mA
Material sensing surface PA 12
Operating voltage Ub 12…30 VDC
Surface protection nickel plated
Output resistance Ra 33.0 kOhm + D
Rated insulation voltage Ui 75 V DC
Rated operating current Ie 200 mA Mechanical data
Rated operating voltage Ue DC 24 V
Rated short circuit current 100 A Dimension Ø 8 x 65 mm
Ready delay tv max. 30 ms Installation for flush mounting
Residual current Ir max. 20 µA Size M8x1
Ripple max. (% of Ue) 15 % Tightening torque 3 Nm
Switching frequency 700 Hz
Utilization category DC -13
Output/Interface
Voltage drop static max. 2.5 V
Switching output PNP normally open (NO)
Environmental conditions
Range/Distance
Ambient temperature -25…70 °C
Contamination scale 3 Assured operating distance Sa 1.6 mm
EN 60068-2-27, Shock Half-sinus, 30 gn, 11 ms Hysteresis H max. (% of Sr) 15.0 %
Internet www.balluff.com For definitions of terms, see main catalog eCl@ss 9.1: 27-27-01-01 1(2)
Balluff Germany +49 (0) 7158 173-0, 173-370 Subject to change without notice [141933] ETIM 6.0: EC002714
Balluff USA 1-800-543-8390 BES0028_0.19_2018-07-27
Balluff China +86 (0) 21-50 644131
Inductive Sensors
BES M08MH1-PSC20B-S04G
Ordercode: BES0028
Rated operating distance Sn 2 mm

Real switching distance sr 2 mm Remarks
Repeat accuracy max. (% of Sr) 5.0 %
Shielded: See installation instructions for inductive sensors with extended
Switching distance marking ∎∎ range 825357.
Temperature drift max. (% of Sr) 10 % The sensor is functional again after the overload has been eliminated.
Tolerance Sr ±10 % For more information about MTTF and B10d see MTTF / B10d Certificate
Indication of the MTTF- / B10d value does not represent a binding composition
and/or life expectancy assurance; these are simply experiential values with no
warranty implications. These declared values also do not extend the expiration
period for defect claims or affect it in any way.
Connector view

Wiring Diagram
Internet www.balluff.com For definitions of terms, see main catalog eCl@ss 9.1: 27-27-01-01 2(2)
Balluff Germany +49 (0) 7158 173-0, 173-370 Subject to change without notice [141933] ETIM 6.0: EC002714
Balluff USA 1-800-543-8390 BES0028_0.19_2018-07-27
Balluff China +86 (0) 21-50 644131
COMPACT SIZE VL (AZ8)
LIMIT SWITCHES
Limit Switches
A compact and accurate vertical limit switch. Switches with indicator lamp available for
convenient maintenance; either a neon AC powered lamp or an LED DC powered lamp.
Inner construction of the lamp holder attachment, it is
Cover possible to display both lights during
attachment screw
inoperability and during operation
(however, if both NO and NC loads are
Cable connected, only the inoperability lamp
Cover
can be displayed.)
Terminal screw Cord vent
Construction permits lamp attach-
ment method to be changed.
Body
Operating lamp Inoperability lamp
Head block (with output)
4. Mounting is possible from both

front and back
<Front>
Standard type With lamp
(Roller arm)
M4 attachment nut
• Lead wiring type <Current leakage
M4 attachment bolt
Characteristics 0>
(LED lamp type only)
1. Compact design approximately
Because the wiring can be made par-
1/3 of the AZ5 limit switches
Spring washer allel to the load, current leakage from
the lamp can be reduced to 0. Even
Approx. 1/3 <Rear> with a slight leak, the electronic circuit
incurring the leak can be used safely.
r M5 attachment bolt
7. Dust-proof, waterproof, oil resis-
tant construction
The main unit and the cover are
AZ5 type VL sealed with rubber packing, and the
cord runner is doubly sealed by the
2. Gold-clad contacts provide reli-
cord vent. The actuator is sealed by
able operation in low voltage cir- Spring washer
both a rubber cap and an O ring in all
cuits. Design minimizes contact
models. Also, the lens and cover are
chatter and bounce 5. Lamp type switches can be used
formed simultaneously with the lamp
The built-in switch has gold-clad con- with a wide range of voltages
type, and moreover, a nameplate is
tacts and uses a crossbar contact • With neon lamp
affixed to the upper surface, thereby
method for excellent reliability. It also Compatible with: AC100 and 200V ;
improving the already excellent water-
has a dual cutoff circuit (1a1b contact) Even at AC 100V, sufficient luminosity
proof capabilities.
with little chattering and bouncing due is achieved through the diamond-cut
(Note: Applications directly involving
to computer-operated analysis. lens. The lamp has a long lifespan of
the cord entrance and the locations
3. Easy wiring with full-open terminals more than 20 thousand hours.
which are always wet and oily, or sub-
When the cover is removed, the termi- • With LED lamp
mersion in water or oil, cannot be
nals are fully accessible. Moreover, the Covers 6 to 48V DC and comes in
used.)
wiring space is large despite the com- three types, 6V DC , 12V DC ,
pact size, and the terminals are spread 24 to 48V DC Uses two highly lumi-
in a tiered array, so that wiring work nescent LEDs and a diamond-cut lens. TYPICAL
can be completed very easily. 6. Lamp connection can be either APPLICATIONS
The cable can either be screwed in spring type or lead wire type Ideal for general plant facilities such as
directly, or can use U-shaped and cir- • Spring type (wiring unnecessary) engineering machinery, conveyer
cular pressure terminals. (With neon or LED lamp type) machinery, and assembly lines
Wiring is unnecessary because the LED lamp type is also compatible with
UL lamp is directly connected to the termi-
®
low-voltage DC control circuits such as
nals. By simply changing the direction in PCs and computers.
431
VL (AZ8)
PRODUCT TYPE
1. Standard type
Actuator Part No.
Push plunger AZ8111
Roller plunger AZ8112
Cross roller plunger AZ8122
Roller arm AZ8104
Adjustable roller arm AZ8108
Adjustable rod AZ8107
Flexible rod AZ8166
Spring wire AZ8169
Remote wire control plunger AZ8181
Note) When ordering an overseas-specified product,refer to the Overseas Standards given below.
2. With Neon lamp

Lamp connection Actuator Lamp rating Part No.
Push plunger AZ811106
Roller plunger AZ811206
Cross roller plunger AZ812206
Roller arm AZ810406
Spring type Adjustable roller arm 100 to 200V AC AZ810806
Adjustable rod AZ810706
Flexible rod AZ816606
Spring wire AZ816906
Remote wire control plunger AZ818106
Note) When ordering an overseas-specified product,refer to the Overseas Standards given below.
3. With LED
Lamp rating
Lamp connection Actuator 12V DC 24 to 48V DC
Part No.
Push plunger AZ8111161 AZ811116
Roller plunger AZ8112161 AZ811216
Cross roller plunger AZ8122161 AZ812216
Roller arm AZ8104161 AZ810416
Spring type Adjustable roller arm AZ8108161 AZ810816
Adjustable rod AZ8107161 AZ810716
Flexible rod AZ8166161 AZ816616
Spring wire AZ8169161 AZ816916
Remote wire control plunger AZ8181161 AZ818116
Push plunger AZ8111661 AZ811166
Roller plunger AZ81122661 AZ811266
Cross roller plunger AZ8122661 AZ812266
Roller arm AZ8104661 AZ810466
Lead wire type Adjustable roller arm AZ8108661 AZ810866
Adjustable rod AZ8107661 AZ810766
Flexible rod AZ8166661 AZ816666
Spring wire AZ8169661 AZ816966
Remote wire control plunger AZ8181661 AZ818166
Notes) 1. LED rating 6V DC type is available. When ordering, add suffix 162(spring type) or 662(lead wire type) to the standard part No.
2.The DC24-48V rated lamp is recommended for PC input use.
4. Option
Application Part No.
VL limit conduit adapter VL, VL with lamp, VL-T AZ8801
STANDARDS
Standard Applicable product Part No.
File No. : E122222
Ratings : 5A 250V AC
UL
Pilot duty B300 Order by standard part No. However,
Product type : Standard model, with neon lamp add “9” to the end of the part No. for the
File No. : LR55880 model with neon lamp.
Ratings : 5A 250V AC
CSA
Pilot duty B300
Product type : Standard model, with neon lamp
File No. : J9551203
TÜV Ratings : AC-15 2A/250V upwards Order by standard part No.
Product type : Standard model only
432
VL (AZ8)
SPECIFICATIONS
1. Contact Rating
1) Standard type 2) Type with indicator
Load Resistive load Inductive load Rated control Resistive load Inductive load
(cos φ]1) (cos φ]0.4) Types (cos φ]1) (cos φ]0.4)
Rated control voltage voltage
125V AC 5A 3A 125V AC 5A 3A
With Neon lamp
250V AC 5A 2A 240V AC 5A 2A
125V DC 0.4A 0.1A With LED 24V DC 3A –
2. Contact Characteristics
Contact arrangement 1 Form Z
Initial contact resistance, max. 15mΩ (By voltage drop 6 to 8V DC at rated current)
Contact material Gold clad over silver
Initial insulation resistance (At 500V DC) Min. 100MΩ
1,000Vrms for 1 min Between non-consective terminals 2,000Vrms for 1 min Between
Initial breakdown voltage
dead metal parts and each terminal 2,000Vrms for 1 min Between ground and each terminal
In the free position Max. 98m/s2 {10G}
Shock resistance max.
In the full operating position Max. 294m/s2{30G}
Vibration resistance Standard type: Max. 55Hz Type with indicator: 10 to 50Hz, double amplitude of 1.5mm
Mechanical 107 (at 120 cpm)
Expected life (Min. operations) Electrical 3u105 (at rated resistive load) 5u106 (Magnetic contactor FC-100 200V AC load)
Life of lamp Min. 2u104 hours (Neon lamp type)
Ambient temperature/Ambient humidity –20 to +60°C –4 to +140°F/Max. 95%
Max. operating speed 120 cpm
3. EN60947-5-1 performance
Item Rating
Rated insulation voltage (Ui) 250VAC
Rated impulse withstand voltage (Uimp) 2.5kV
Switching overvoltage 2.5kV
Rated enclosed thermal current (Ithe) 5A
Conditional short-circuit current 100A
Short-circuit protection device 10A fuse
Protective construction IP64
Pollution degree 3
4. Operating characteristics
Characteristics Pretravel (P.T.), max. Movement Differential Overtravel (O.T.), min. Totaltravel (T.T.),
O.F. (N {gf}) max. R.F. (N {gf}) min.
Actuator mm inch (M.D.), max. mm inch mm inch min. mm inch
Push plunger
Roller plunger 8.83 {900} 1.47 {150} 1.5 .059 0.7 .028 4 .028 5.5 .217
Cross roller plunger
Roller arm 5.88 {600} 0.49 {50} 20° 10° 75° 95°
Adjustable roller arm 7.84 {800}~3.35 {342} 0.49 {50}~0.21 {21} 20° 10° 75° 95°
Adjustable rod 7.84 {800}~1.99 {203} 0.49 {50}~0.12 {12} 20° 10° 75° 95°
Flexible spring wire 0.88 {90} – 30 (1.181) – 20 (.787) 50 (1.969)
Remote wire control 19.61 {2,000}~ 1.96 {200}~
1.5 .059 4 .157* 0.7 .028 2.0 .079* 4.5 .177 2.0 .079* 6 .236 6 .236*
plunger 24.52 {2,500}* 1.96 {200}*
*Characteristics measured at bent condition: min. radius 100mm 3.937inch.
Notes) 1. Keep the total travel values in the specified range. Otherwise the actuator force may rise to several times the operating force, resulting in a mechanical failure or much shorter service life.
2. For the operating characteristics, refer to the TECHNICAL INFORMATION.
5. Protective construction 6.Lamp rating
Protective construction VL mini limit SW Types Rated operating voltage Operating voltage range Internal resister
VL mini limit SW
IEC (with indicator) Neon lamp 100 to 200V AC 80 to 240V AC 120kΩ
IP60 p p 6V DC 5 to 15V DC 2.4kΩ
IP64 p p LED 12V DC 9 to 28V DC 4.7kΩ
24 to 48V DC 20 to 55V DC 15kΩ
DATA WIRING DIAGRAM

1. Life curve 2. Actual load life curve (relay coil load) Output 13
VL
14
Life curve, resistive load 1000 circuit NO NO
No. of operating, million times
(AC 240VC cos φ =1) 11 12

1000 NC NC
No. of operating, million times
500 500
400 Terminal
300 13 14
0 0.5 1.0 3 5 50 260 700
200
NK HC HP HG VC-20 FC-10 FC-35 FC-100
100 Various relay loads (VA)
30
Note: The FC magnetic contactor series is 200V AC. The K is
0 5 10 2 Form C 24V DC type. 11 12
Load current, A
433
VL (AZ8)
DIMENSIONS 7 .276 dia.
stainless steel plunger 3
10.2
.402
10.2
.402
mm inch
• Push plunger type PT 1.5max .118 General

+0.2
2-4.1 0 dia.
tolerance:
4 4
Standard type mounting holes 26.5
1.043 .157 .157 ±0.4
M326
20.4±0.3 2-M5 (P=0.8) tapped 2-M5 (P=0.8)
cover screw 7 .276 in depth 7 .276 in depth
.803±.012
mounting holes mounting holes
56±0.3 64 64
2.205±.012 2.520 2.520
Operation indicator
2-M5 (P=0.8) tapped 2-M5 (P=0.8)

2-M3223
cover screw 14 14
.551 .551
7.5±0.2 7.5±0.2
21±0.2 .295±.008 .295±.008
.827±.008 15.1 15.1
28 .594 .594 20.4±0.3
1.102 25 .803±.012
.984 30.3
1.193
(Standard type) (With Neon lamp)
• Roller plunger type 12.5 dia.23.8 10.2 10.2

stainless steel roller
PT 1.5max
.402 .402 General
Standard type tolerance:
14.8
.583 ±0.4
+0.2
2-4.1 0 dia. 38
1.496 4 4
mounting holes .157 .157
M326 2-M5 (P=0.8) tapped 2-M5 (P=0.8)

cover screw 20.4±0.3
.803±.012 7 .276 in depth 7 .276 in depth
56±0.3 64 64
2.205±.012 2.520 2.520
Operation indicator
2-M5 (P=0.8) tapped 2-M5 (P=0.8)

2-M3223
cover screw 14 14
.551 .551
7.5±0.2 7.5±0.2
21±0.2 .295±.008 .295±.008
.827±.008 15.1 15.1
28 .594 .594 20.4±0.3
1.102 25 .803±.012
.984 30.3
1.193
• Cross roller plunger type 12.5 dia.23.8

stainless steel roller
10.2
.402
10.2
.402 General
Standard type
PT 1.5max
tolerance:
14.8
.583
±0.4
+0.2
2-4.1 0 dia. 38
1.496 4 4
mounting holes .157 .157
M326 2-M5 (P=0.8) tapped 2-M5 (P=0.8)

cover screw 20.4±0.3
.803±.012 7 .276 in depth 7 .276 in depth
56±0.3 64 64
2.205±.012 2.520 2.520
Operation indicator
2-M5 (P=0.8) tapped 2-M5 (P=0.8)

2-M3223
cover screw 14 14
.551 .551
7.5±0.2 7.5±0.2
21±0.2 .295±.008 .295±.008
.827±.008 15.1 15.1
28 .594 .594 20.4±0.3
1.102 25 .803±.012
.984 30.3
1.193
18 dia.27
• Roller arm type nylon roller
(Roller can be rotated
41.2±0.8
1.622±.031
45.2±0.8
1.780±.031 General
36.2±0.8 40.2±0.8
20° m
ax
Standard type PT
and locked in any
position through 360°)
1.425±.031 1.583±.031
tolerance:
10.2 10.2
±0.4
.402 .402
0
M4 arm
R3
M4 arm fixing nut

fixing screw
+0.2
2-4.1 0 dia. (with hexagonal
mounting holes holes) 18.5 2-M5 (P=0.8) tapped 18.5 2-M5 (P=0.8)
.728 7 .276 in depth .728 7 .276 in depth
12.5 mounting holes mounting holes
.492
M326 20.4±0.3
cover screw .803±.012
56±0.3 64 64
2.205±.012 2.520 2.520
Operation indicator 2-M5 (P=0.8) tapped 2-M5 (P=0.8)
2-M3223
cover screw 14 14
.551 .551
7.5±0.2 7.5±0.2
21±0.2
15.1 .295±.008 15.1 .295±.008
.827±.008
28 .594 25 .594 20.4±0.3
1.102 38.1 .984 Standard type 30.3 .803±.012 With lamp
1.5 1.193
( ) ( )
434
VL (AZ8)
OPTION (A set of mounting hex.
mm inch
VL Conduit Adapter socket screws is supplied.) t=7 max.

.276
AZ8801
56
• Applicable wire 13/64
(Same as with the
VL limit switch)
Electric wire name Finished outside diameter
Vinyl cabtire cord (VCTF) 8.7 to 11 dia. 23
.906 18
Vinyl cabtire cable (VCT) .343 to .433 dia. .709 Part A
(Tighten up
with no gap)
21 14.8
.827 .583
28 27.8
1.102 1.094
(Same as with the
VL limit switch)
(Front) (Side)
INDICATOR LIGHTING CIRCUIT

1. Spring type
1) When connecting a load to the N.O. 2) When connecting a load to the N.C. 3) When connecting loads to both N.O.
side: side: and N.C. sides:
When the switch is in the free position, When the switch is in the free position, Same as in 1).
the indicator is lit. When the switch the indicator is off. When the switch (With the lamp holder in the same
operates, the indicator turns off. (With operates, the indicator turns on. position as shipped from the factory. In
the indicator holder in the same posi- (With the lamp holder position this case, the holder position cannot
tion as shipped from the factory.) changed by 180° from the factory set be changed.)
position.)
(With Neon lamp) (With LED) (With Neon lamp) (With LED) (With Neon lamp) (With LED)
(With Neon lamp) LED Resistor
(With Neon lamp) LED Resistor Neon lamp Resistor
Built-in switch Built-in switch
Neon lamp Resistor 13 14
N.O. Load
13 14
13 14 N.O. N.O.
N.O. Load 3 4 N.C. N.O.
N.C. 13 14
N.O. Load Load
13 14 Load 11 12
N.C. 11 12 N.C. Built-in switch N.C.
11 12 Load
Resistor Load
~
1 2
Built-in switch N.C. 11 12
AC power source
~
11 12 Neon lamp
~
AC power source
AC power source Built-in switch
Built-in switch
LED Resistor
– + – + – +
DC power source DC power source DC power source
2. Lead wire type (only for switches with 2) When the indication circuit is con- LED
LED) nected with load in parallel:

1) When giving indication on N.O. side Load performs the same operation as
or N.C. side, operation is the same as the indication circuit does. N.O.
for the spring type. However, when the (When load operates, the lamp is lit, 13 14
Resistor
Load
load is connected to both the N.O. side and when load is turned off, the lamp N.C.
and N.C. side, indication can be given goes out.) 11 12
on both N.C. side and N.O. side. • More loads than for one circuit can- Built-in switch
not be controlled.
• There is no leakage current. – +
DC power source
MOUNTING DIMENSIONS mm inch

Surface mounting Through hole mounting Rear mounting
t
4 .157 tap 5 .197 mounting screw

(P=0.7) mounting nut
4 .157 4 .157 dia. 4-5.5 .217 dia.
mouting screw 4 .157
mounting screw
56±0.2 56±0.3
2.205±.008 56±0.3
2.205±.012 2.205±.012
washer 21±0.2
.827±.008 washer 21±0.3 washer 21±0.3
.827±.012 .827±.012
Depth of screw holes > 15mm .591inch Thickness of panel < 5mm .197inch Length of bolt < panel thickness t+7mm
437
VL (AZ8)
WIRING mm inch Applicable fasten terminal
Cable treatment
Ordinary termi-
-Insulation distance more than Max. 6.4 .252 Max. 6.4 .252 Max. 6.4 .252
3.0 to 3.7 dia. N.C. use N.O. use
6.4mm .252inch for wiring and live .118 to .146
9 .354
parts 9 .354
3.0 to 3.7 dia. 3.0 to 3.7 dia. 27 1.063
11 .433
-Special assembly screws Max. 10
.394
Max. 10
.394 .118 to .146 .118 to .146
With insulated grip Fasten terminal

N.C. use N.O. use
Terminal Max. 6.4 .252 Max. 6.4 .252 Max. 6.4 .252
Projection (8 locations) screw 3.0 to 3.7 dia.
.118 to .146 32 1.260
Groove (8 points) 16 .630
3.0 to 3.7 dia. 3.0 to 3.7 dia.
Spring (4 locations) .118 to .146 .118 to .146
Max. 14 Max. 14 Max. 10
Terminal .551 .551 .394
washer
Grounding terminal
Applicable wire Head direction change

(Roller arm, adjustable roller arm, adjustable rod types)
Applicable wire
Wire name
Wire-strand Conductor Finished outside diameter Actuator heads
Lock screw (Black)
2-wire 0.75mm2•1.25mm2 may be moved in
Vinyl cabtire cord (VCTF) 3-wire 2.0mm2 90° increments to
4-wire 0.75mm2•1.25mm2 Round shape
6 dia. to 9 dia. any of four direc-
Vinyl cabtire cable (VCT) 2-wire 0.75mm2
Flat shape Max. 9.4 tions, by removing
600V vinyl insulation sealed 1.0 dia. to 1.2 dia.
cable (VVF)
2-wire one screw.
1.6 dia.
CAUTIONS 5. Remote wire control types (fig. 1):

Because the main unit is not of water
1. When overtravel is too large, life is
resistant or immersion-proof construc-
shortened due to possible damage to the
tion, their use in water or oil should be
mechanism. Please use in the following
avoided. Also, locations where water or
appropriate range.
oil can normally impinge upon the switch Driver
Types Overtravel or where there is an excessive accumu- Spring

Lamp
Plunger 1.5 to 2.0mm lation of dust should be avoided. The holder
(AZ8111, 8112, 8122) .059 to .079inch main unit should be installed above the Cover
Roller Arm detection part in such case. (An actuator
20 to 30°
(AZ8104, 8107, 8108)
Flexible Rod 15 to 20mm .591 to is immersion-protected construction.)
(AZ8166, 8169) .787inch (at the top) 6. Mounting fig. 2
Three cover screws should be fastened
2. Because these switches are not of
uniformly. The rubber for opening cord
immersion protected construction, their 8. Matters to be attended to in using
should be corrected as normal condition
use in water or oil should be avoided. spring type VL Limit Switch with indica-
after connecting the wire.
Also, locations where water or oil can tor.
7. How to change the indicator holder.
normally impinge upon the switch or 1) When loads are connected to both
1) As shown in the photograph (fig. 2),
where there is an excessive accumula- N.O. and N.C. only the indicatin at non-
insert a flatblade screw driver in the gap
tion of dust should be avoided. operation time can be used.
between the cover and the part of the
3. The use of these switches under the 2) Take special care not to damage or
indicator holder indicated by the arrow in
following conditions should be avoided. If deform the contact spring during change
the direction of insertion, and raise the
the following conditions should become of indicator holder direction or during
lamp a little.
necessary, we recommend consulting us connection work.
2) After removing the indicator holder,
first. 3) In the case of VL Limit Switch with
insert it in the reverse direction, and
• Use where there will be direct contact Neon lamp, if the indicator is connected
push it in until a snap is heard.
with organic solvents, strong acids or in series in a 100V circuit, the indicator
3) After changing the direction of the
alkalis, or direct exposure to their vapors. ceases to be lighted.
indicator holder, put the cover on it in
• Use where inflammable or corrosive However, for a 200V circuit, up to 2
such a way that the spring touches the
gases exist. lamps can be connected in series.
top of the terminal screw.
4. In order to maintain the reliability at a 9. Matters to be attended to in using lead
(Unless the spring rests completely on
high level under practical conditions of wire type VL with lamp.
the terminal screw, distortion of the
use, the actual operating conditions 1) When loads are connected to both
spring, failure in lighting of the lamp or
should be checked for the benefit of the N.O. and N.C. indication can be given on
short circuit may result.)
quality of the product. both N.O. and N.C. sides, but it is impos-
sible to connect the indication circuit to
the load in series.
Detected object
fig. 1
438
ENGLISH Quick Start Guide - ATV12
S1A5614601
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Read and understand this quick start guide before performing any procedure with this drive.
• The user is responsible for compliance with all international and national electrical code requirements with respect to grounding of all
equipment.
• Many parts of this drive, including the printed circuit boards, operate at the line voltage. DO NOT TOUCH. Use only electrically insulated tools.
• DO NOT touch unshielded components or terminal strip screw connections with voltage present.
• DO NOT short across terminals PA/+ and PC/- or across the DC bus capacitors.
• Before servicing the drive:
- Disconnect all power, including external control power that may be present.
- Place a "DO NOT TURN ON" label on all power disconnects.
- Lock all power disconnects in the open position.
- WAIT 15 MINUTES to allow the DC bus capacitors to discharge.
- Measure the voltage of the DC bus between the PA/+ and PC/- terminals to ensure that the voltage is less than 42 Vdc.
- If the DC bus capacitors do not discharge completely, contact your local Schneider Electric representative. Do not repair or operate
the drive
• Install and close all covers before applying power or starting and stopping the drive.
Failure to follow these instructions will result in death or serious injury.
Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider
Electric for any consequences arising out of the use of this product.
Information below is designed to use single drive connected to single motor with a motor cable length less than 50 meters (164 ft).
In any other case, consult the ATV12 user manual on www.schneider-electric.com.
Check your cables before connecting the drive with motor (length, power, shielded or unshielded). Motor cable length is _______(< 50 meters, 164 ft)
1 Check the delivery of the drive

• Remove ATV12 from the packaging and check that it has not been damaged.
WARNING
DAMAGED DRIVE EQUIPMENT
Do not operate or install any drive or drive accessory that appears damaged.
Failure to follow these instructions can result in death, serious injury, or equipment damage.
• Check that the drive reference printed on the label is the same as that on the delivery note corresponding to the
purchase order. ATV12HU15M2
1.5KW - 2HP - 200 / 240V
Write the drive Model Reference: _____________ ___________and Serial Number: ____________________________
2 Check the line voltage compatibility

8B0915316127
• Check that the line voltage is compatible with the supply range of the drive.
Line voltage _______ Volts Drive voltage range _______ Volts
Drive range: ATV12 F1 = 100 ... 120 V single phase / ATV12 M2=200 ... 240 V single phase / ATV12 M3 = 200 ... 240 V three-phase.
3 Mount the drive vertically

For a surrounding air temperature up to 50 °C (122 °F)
(a)
(a) (a)
(b)
(a)
(a) 50 mm (2 in.) (b) 10 mm (0.4 in.)
See user manual on www.schneider-electric.com for other thermal conditions.
www.schneider-electric.com 1/4 S1A56146 - 05/2010

4 Connect the drive: Power Connect the drive:
5
• Wire the drive to the ground.
• Check circuit breaker rating or fuse rating. Control choice
• Check that the motor voltage is compatible with the drive voltage.
Motor voltage ______Volts. [REMOTE configuration]
• Wire the drive to the motor. 5.1 (Control by external reference)
• Wire the drive to the line supply.
• Wire the speed reference:
AI 1
COM
+5v
Do: 6 + 7 + 8 + 9.1
or
ATV12F1 2.2 KΩ
• Wire the command:

Control command 2-wire:
ATV12M2 Parameter tCC = 2C
LI1: forward ATV 12

LIx: reverse
+24 V LI1 LIx Do: 6 + 7 + 8 + 9.1
ATV12M3
Control command 3-wire:

Parameter tCC = 3C
LI1: stop ATV 12
0,8...1,2 N.m 6 + 7 + 8 + 9.1
LI2: forward Do:
7.1...10.6 lb.in +24 V LI1 LI2 LIx
LIx: reverse
200...240V
[LOCAL configuration]
5.2 (control by internal reference).
.
Do: 6 + 7 + 8 + 9.2
6 Apply power to the drive

• Check that used Logic Inputs are not active (see Li1, Li2, Lix ).
• Apply power to the drive.
• Drive displays bFr at first power up.
• On next start-ups, drive displays rdY .
7 Set motor parameters

• See on the motor Nameplate to set the following parameters.
Customer
Menu Code Description Factory setting
setting
[Standard motor frequency]:
bFr 50.0
COnF > FULL > Standard motor frequency (Hz)
drC- [Rated motor power]:
nPr drive rating
[Motor control menu] Nominal motor power on motor nameplate
[Rated motor current]:
nCr drive rating
Nominal motor current on motor nameplate (A)
8 Set basic parameters

Customer
Menu Code Description Factory setting
setting
[Acceleration]:
ACC 3.0
Acceleration time (s)
[Deceleration]:
dEC 3.0
COnF Deceleration time (s)
[CONFIGURATION] [Low speed]:
LSP 0.0
Motor frequency at minimum reference (Hz)
[High speed]:
HSP 50.0
Motor frequency at maximum reference (Hz)

9 Set control choice
Menu Code Description 5.1 [REMOTE configuration] 5.2 [LOCAL configuration] Customer Setting
COnF > FULL >
[Reference channel1]:
Ctl- Fr1 Al1 AlU1
Reference control
[Control menu]
COnF > FULL >
[Type of control]: 2C: 2-wire control
I_0- tCC _
Command control 3C: 3-wire control
[Input Output menu]
9.1 [REMOTE configuration] 9.2 [LOCAL configuration]

(configuration factory setting)
Parameters factory settings: Parameters factory settings:

Fr1 = AI1 Fr1 = AIU1
tCC = 2C
MODE
3s
LOC rdY
35.
1
[Analog input virtual] (Hz)
10 Start the motor

Menus structure
[REMOTE configuration] [LOCAL configuration]

MODE
ESC
3s LOC
rdY 2s rdY
rEN
MODE ESC ENT
3s
35. [Analog input virtual] (Hz)
ESC ESC
ESC
rEF MODE MOn MODE COnF MODE
[SPEED REFERENCE] [MONITORING] [CONFIGURATION]
rEF MOn COnF
ESC
(2) 0 HErt
2s / ESC
(1) ENT bFr 50
Fr1 AI1
ESC (2) 0.
0
2s / ESC
ACC 3 SEC
2s / ESC
ENT Frh 0 HErt
51.
3 HErt 2s / ESC dEC 3 SEC
2s / ESC
2s / ESC
rFr 0.
0 HErt
LSP 0 HErt
(1) LFr 2s / ESC
2s / ESC
AIU1
LCr 0.
0 AMP HSp 50 HErt
FrH 2s / ESC 2s / ESC
rPI nPr
rPE At
rPC 2s / ESC
2s / ESC
nCr AMP
2s / ESC
rPF
2s / ESC
AI1t 5U
rPC
2s / ESC SCS
2s / ESC
FCS
CFG
2s / ESC
I_0-
2s / ESC
drC-
2s / ESC
CtL-
rdY
FUn-
(2) LFr FLt-

AIU1
COd (2) LFr CON-
AIU1
Refer to the user manual for comprehensive menu description.
A dash appears after menu codes to differentiate them from parameter codes.
Example: [Motor control menu] (drC-), bFr parameter.

Diagnostics and Troubleshooting
Drive does not start, no error code displayed

• If the display does not light up, check the power supply to the drive (ground and input phases connection, see page 19).
• The assignment of the "Fast stop" or "Freewheel" functions will prevent the drive starting if the corresponding logic inputs are not powered
up. The ATV12 then displays nSt in freewheel stop and FSt in fast stop, it will display rdY en freewhell stop. This is normal since
these functions are active at zero so that the drive will be stopped safely if there is a wire break. Assignment of LI to be checked in COnF/
FULL/FUn-/Stt- menu.
• Make sure that the run command input(s) is activated in accordance with the selected control mode (parameters Type of control tCC
page 47 and 2 wire type control tCt page 50, in COnF/FULL/ I_O-menu).
• If the reference channel or command channel is assigned to Modbus, when the power supply is connected, the drive displays "nSt"
freewheel and remain in stop mode until the communication bus sends a command.
• In factory setting "RUN" button is inactive. Adjust parameters Reference channel 1 Fr1 page 60 and Command channel 1 Cd1 page
61 to control the drive locally (COnF/FULL/CtL-menu). See How to control the drive locally page 45.
Fault detection codes that cannot be reset automatically

The cause of the fault must be removed before resetting by turning off and then on.
SOF and tnF faults can also be reset remotely by means of a logic input (parameter Detected fault reset assignment rSF page 77 in
COnF/FULL/FLt-menu).
InFb, SOF and tnF faults can be inhibited and cleared remotely by means of a logic input (parameter Detected fault inhibition
assignmentInH page 81).
Code Name Possible causes Remedy
CrF1 Precharge • Charging relay control fault or • Turn the drive off and then back on again
charging resistor damaged • Check the connections
• Check the stability of the main supply
• Contact your local Schneider Electric
representative
InFI Unknown drive rating • The power card is different from • Contact your local Schneider Electric
the card stored representative
InF2 Unknown or incompatible power • The power card is incompatible • Contact your local Schneider Electric
board with the control card representative
InF3 Internal serial link • Communication fault between the • Contact your local Schneider Electric
internal cards representative
InF4 Invalid industrialization zone • Inconsistent internal data • Contact your local Schneider Electric
representative
InF9 Current measurement circuit failure • Current measurement is not • Contact your local Schneider Electric
correct due to hardware circuit representative
---- Problem of application Firmware • Bad application firmware update • Flash again the application firmware of the
using the Multi-Loader tool product
InFb Internal thermal sensor failure • The drive temperature sensor is • Contact your local Schneider Electric
not operating correctly representative
• The drive is in short circuit or open
InFE Internal CPU • Internal microprocessor fault • Turn the drive off and then back on again
• Contact local Schneider Electric
representative
BBV28581 04/2009 93
Fault detection codes that cannot be reset automatically (continued)
OCF Overcurrent • Parameters in the Motor control • Check the parameters

menu drC- page 55 are not • Check the size of the motor/drive/load
correct • Check the state of the mechanism
• Inertia or load too high • Connect line motor chokes
• Mechanical locking • Reduce the Switching frequency SFr
page 57
• Check the ground connection of drive, motor
cable and motor insulation.
SCF1 Motor short circuit • Short-circuit or grounding at the • Check the cables connecting the drive to the
drive output motor, and the motor insulation
SCF3 Ground short circuit • Ground fault during running status • Connect motor chokes
• Commutation of motors during
running status
• Significant current leakage to
ground if several motors are
connected in parallel
SCF4 IGBT short circuit • Internal power component short • Contact your local Schneider Electric
circuit detected at power on representative
SOF Overspeed • Instability • Check the motor
• Overspeed associated with the • Overspeed is 10% more than Maximum
inertia of the application frequency tFr page 55 so adjust this
parameter if necessary
• Add a braking resistor
• Check the size of the motor/drive/load
• Check parameters of the speed loop (gain
and stability)
tnF Auto-tuning • Motor not connected to the drive • Check that the motor/drive are compatible
• One motor phase loss • Check that the motor is present during auto-
• Special motor tuning
• Motor is rotating (being driven by • If an output contactor is being used, close it
the load, for example) during auto-tuning
• Check that the motor is completely stopped
94 BBV28581 04/2009
Fault detection codes that can be reset with the automatic restart function, after the
cause has disappeared
These faults can also be reset by turning on and off or by means of a logic input (parameter Detected fault reset assignment rSF page 77).
OHF, OLF, OPF1, OPF2, OSF, SLF1, SLF2, SLF3 and tJF faults can be inhibited and cleared remotely by means of a logic input (parameter
Detected fault inhibition assignmentInH page 81).
LFFI AI current lost fault Detection if: • Check the terminal connection
• Analog input AI1 is configured as
current
• AI1 current scaling parameter of
0% CrL1 page 51 is greater
than 3 mA
• Analog input current is lower than
2 mA
ObF Overbraking • Braking too sudden or driving load • Increase the deceleration time
too high • Install a module unit with a braking resistor if necessary
• Check the line supply voltage, to be sure that it is under
the maximum acceptable (20% over maximum line supply
during run status)
OHF Drive overheat • Drive temperature too high • Check the motor load, the drive ventilation and the
ambient temperature. Wait for the drive to cool down
before restarting. See Mounting and temperature
conditions page 12.
OLC Process overload • Process overload • Check the process and the parameters of the drive to be
in phase
OLF Motor overload • Triggered by excessive motor • Check the setting of the motor thermal protection, check
current the motor load.
OPF1 1 output phase loss • Loss of one phase at drive output • Check the connections from the drive to the motor
• In case of using downstream contactor, check the right
connection, cable and contactor
OPF2 3 output phase loss • Motor not connected • Check the connections from the drive to the motor
• Motor power too low, below 6% of • Test on a low power motor or without a motor: In factory
the drive nominal current settings mode, motor phase loss detection is active
• Output contactor open Output Phase loss detection OPLpage 80 = YES. To
• Instantaneous instability in the check the drive in a test or maintenance environment,
motor current 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 page 56, Rated motor
voltageUnS page 55 and Rated motor current nCr
page 55 and perform an Auto-tuning tUn page 58.
OSF Main overvoltage • Line voltage too high: • Check the line voltage
- At drive power on only, the
supply is 10% over the
maximum acceptable voltage
level
- Power with no run order, 20%
over the maximum line supply
• Disturbed line supply
BBV28581 04/2009 95
Fault detection codes that can be reset with the automatic restart function, after the
cause has disappeared (continued)
PHF Input phase loss • Drive incorrectly supplied or a fuse • Check the power connection and the fuses.
blown • Use a 3-phase line supply.
• Failure of one phase • Disable the fault by setting Input Phase loss detection
• 3-phase ATV12 used on a single- IPL page 80 = nO.
phase line supply
• Unbalanced load
• This protection only operates with
the drive on load
SCF5 Load short circuit • Short-circuit at drive output • Check the cables connecting the drive to the motor, and
• Short circuit detection at the run the motor’s insulation
order or DC injection order if
parameter IGBT test Strt page
81 is set to YES
SLF1 Modbus • Interruption in communication on • Check the connections of communication bus.
communication the Modbus network • Check the time-out (Modbus time out ttO parameter
page 83)
• Refer to the Modbus user manual
SLF2 SoMove • Fault communicating with SoMove • Check the SoMove connecting cable.
communication • Check the time-out
SLF3 HMI communication • Fault communicating with the • Check the terminal connection
external display terminal
ULF Process underload • Process underload • Check the process and the parameters of the drive to be
fault • Motor current below the in phase
Application Underload threshold
LUL parameter page 53 during a
period set by Application
underload time delay ULt
parameter page 53 to protect the
application.
tJF IGBT overheat • Drive overheated • Check the size of the load/motor/drive.
• IGBT internal temperature is too • Reduce the Switching frequency SFr page 57.
high according to ambient • Wait for the drive to cool before restarting
temperature and load
96 BBV28581 04/2009
Faults codes that will be reset as soon as their causes disappear

The USF fault can be inhibited and cleared remotely by means of a logic input (Detected fault inhibition assignmentInH parameter page
81).
CFF Incorrect • HMI block replaced by an HMI • Return to factory settings or retrieve the backup
configuration block configured on a drive with a configuration, if it is valid.
different rating • If the fault remains after reverting to the factory settings,
• The current configuration of contact your local Schneider Electric representative
customer parameters is
inconsistent
CFI Invalid configuration • Invalid configuration • Check the configuration loaded previously.
(1) The configuration loaded in the • Load a compatible configuration
drive via the bus or communication
network is inconsistent. The
configuration upload has been
interrupted or is not fully finished.
CFI2 Download invalid • Interruption of download operation • Check connection with Loader or SoMove.
configuration with Loader or SoMove • To reset the default re-start the download operation or
restore the factory setting
USF Undervoltage • Line supply too low • Check the voltage and the parameters of Undervoltage
• Transient voltage dip Phase Loss Menu USb- page 81.
(1) When the CFI is present in the past fault menu, it means the configuration has been interrupted or is not fully finished.
HMI block changed

When an HMI block is replaced by an HMI block configured on a drive with a different rating, the drive locks in Incorrect configuration CFF
fault mode on power-up. If the card has been deliberately changed, the fault can be cleared by pressing the ENT key twice, which restores
all the factory settings.
BBV28581 04/2009 97
Remote keypad error messages
Code Name Description
InIt: On initializing itself • Micro controller initializing

• Communication configuration search
COM.E Communication error • It has 50ms time out error.
(1) • This message is shown after 220 retry attempts.
A-17 Key alarm • Key has been pressed consecutively for more than 10 seconds.
(1) • Membrane switch disconnected.
• Keypad woken up while a key is being pressed.
cLr Confirm Fault reset • This message appears if the STOP key is pressed when there is a keypad fault.
(1)
dEU.E Drive mismatch • Drive type (brand) did not match with keypad type (brand)
(1)
rOM.E ROM abnormality • Keypad ROM abnormality detected by the checksum calculation.
(1)
rAM.E RAM abnormality • Keypad RAM abnormality detected.

(1)
CPU.E The other defect • The other defectt.

(1)
(1) Flashing
98 BBV28581 04/2009
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E1000-010 Altivar 12 AC Variable Speed Drive Parameters
PARAMETER CODE 1VFD 2VFD 3VFD
MENU MENU MENU MENU MENU FILM CARR.
PARAMETER DESCRIPTION TURNTABLE PRESTRETCH
LEVEL 1 LEVEL 2 LEVEL3 LEVEL 4 LEVEL 5 ELEVATOR
Light green shaded cells indicate default factory settings
FIRST LEVEL ADJUSTMENT PARAMETERS
ConF Configuration Menu
bFr Standard Motor Frequency 60 Hz 60 Hz 60 Hz
Fr1 Reference Channel 1 (AI1 = terminal) AI1 AI1 AI1
ACC Acceleration time 4.0 sec. 0.5 sec. 0.1 sec.
dEC Deceleration time 4.0 sec. 0.1 sec. 0.1 sec.
LSP Low speed (motor freq. @ min. reference) 0.0 Hz 5.0 Hz 0.0 Hz
HSP High speed (motor freq. @ max. reference) 60.0 Hz 60.0 Hz 50.0 Hz
nPr Rated Motor Power (HP) 0.5 HP 0.5 HP 0.5 HP
nCr Nominal motor current on nameplate 2.0 Amps 2.0 Amps 2.0 Amps
AI1t AI1 Type 10V 10V 10V
SCS Store customer parameter set nO nO nO
FCS Factory / recall customer paramter set nO nO nO
FULL SECOND LEVEL ADJUSTMENT PARAMETERS

CFG Macro-configuration (not used - skip this)
I_O - Input Output Menu
Type of Control (press the “ENT” key for 2 sec.
tCC 2C 2C 2C
to change)
2-wire type control - This parameter is only
tCt LEL LEL LEL
accessible if tCC = 2C.
nPL Logic inputs type POS POS POS
AI1 - Configuration of the analog input
AI1t AI1 type 10V 10V 10V
CrLI AI1 current scaling parameter of 0% N/A N/A N/A
CrHI AI1 current scaling parameter of 100% N/A N/A N/A
r1 R1 assignment FLt FLt FLt
LO1 - LO1 configuration menu
LO1 LO1 assignment nO nO FtA
LO1S LO1 status POS POS POS
tOL Application Overload time delay 0 sec. 0 sec. 0 sec.
Ult Application Underload threshold 0 sec. 0 sec. 0 sec.
Ftd Motor Frequency threshold N/A N/A 3.0 Hz
AO1 - AO1 configuration menu
AO1 AO1 assignment nO nO nO
AO1t AO1 type 0A 0A 0A
drC - Motor Control menu
bFr Standard motor frequency 60 Hz 60 Hz 60 Hz
nPr Rated motor power (HP) 0.5 HP 0.5 HP 0.5 HP
UnS Nominal motor voltage on nameplate 230 Volt 230 Volt 230 Volt
nCr Nominal motor current on nameplate 2.0 Amps 2.0 Amps 2.0 Amps
FrS Nominal motor frequency on nameplate 60.0 Hz 60.0 Hz 60.0 Hz
nSP Rated motor speed 1725 1725 1725
tFr Maximum frequency 72.0 Hz 72.0 Hz 72.0 Hz
Ctt Motor control type Std PErF PErF
UFr IR compensation 100 % 100 % 100 %
SLP Slip compensation 100 % 100 % 100 %
StA Frequency loop stability (only if Ctt = PErF) N/A 15% 28%
FLG Frequency loop gain (only if Ctt = PErF) N/A 25% 12%
SFr Switching frequency 4.0 Hz 4.0 Hz 4.0 Hz
SFt Switching frequency type HF1 HF1 HF1
nrd Motor noise reduction nO nO nO
tUn Auto-tuning yES yES yES
MPC Motor parameter choice nPr nPr nPr
CtL - Control menu
FrI Reference channel 1 AI1 AI1 AI1
LFr External reference value - - -
AIUI Analog input virtual - - -
rIn Reverse inhibition yES nO yES
Stop key priority (press the “ENT” key for 2
PSt yES yES yES
sec. to change)
CHCF Channel configuration SEP SEP SEP
Command channel 1 - This parameter is only
CdI tEr tEr tEr
accessible if CHCF = SEP.
FLO Forced local assignment nO nO nO
Forced local reference - Visible only if Forced
FLOC nO nO nO
local assignment FLO is not set to nO.
E1000-010_VFD_Parameters_r0.xls Page 1
E1000-010 Altivar 12 AC Variable Speed Drive Parameters
PARAMETER CODE 1VFD 2VFD 3VFD
MENU MENU MENU MENU MENU FILM CARR.
PARAMETER DESCRIPTION TURNTABLE PRESTRETCH
LEVEL 1 LEVEL 2 LEVEL3 LEVEL 4 LEVEL 5 ELEVATOR
FUn Function menu
rPt - Ramp menu
ACC Acceleration ramp time 4.0 sec. 0.5 sec. 0.1 sec.
dEC Deceleration ramp time 4.0 sec. 0.1 sec. 0.1 sec.
rPt Ramp shape assignment LIn LIn LIn
rPS Ramp switching commutation nO nO nO
brA Decel ramp adaptation assignment yES dYnA yES
Stt - Stop configuration menu
Stt Type of stop rMP rMP rMP
nSt Freewheel stop assignment nO nO nO
FSt Fast stop assignment nO nO nO
rrS Reverse nO L2H nO
AdC - Auto DC injection menu
AdC Operating mode YES YES YES
SdCI Auto DC injection current (default 70% of nCr) 1.3 1.3 1.3
tdCI Automatic DC injection time 0.5 sec. 0.5 sec. 0.5 sec.
JOG Jog assignment nO nO nO
PSS - Preset speed menu
PS2 2 Preset speeds nO nO nO
JPF Skip frequency 0.0 Hz 0.0 Hz 0.0 Hz
PId - PID menu
PIF PID feedback assignment nO nO nO
CL I - Current limitation menu
LC2 2nd current limitation commutation nO nO nO
CL I Current limitation (1.5 x nom. drive current) 3.0 Amps 3.0 Amps 3.0 Amps
SPL - Speed limit menu
LSP Low speed 0.0 Hz 5.0 Hz 0.0 Hz
tLS Low speed operating time nO nO nO
HSP High speed 60.0 Hz 60.0 Hz 50.0 Hz
SH2 2 HSP assignment nO nO nO
SH4 4 HSP assignment nO nO nO
FLt - Fault detection menu
rSF Fault reset L4H L4H L4H
Atr - Automatic restart menu
Atr Automatic restrart nO nO nO
FLr Catch on the fly nO nO nO
tHt - Motor thermal protection menu
ItH Motor thermal current (nameplate rating) 2.0 Amps 2.0 Amps 2.0 Amps
tHt Motor protection type ACL ACL ACL
OLL Overload fault management (yes = freewheel sto yES yES yES
MtM Motor thermal state memo nO nO nO
OPL Output Phase loss yES yES yES
USb - Undervoltage menu
Usb Undervoltage fault management 0 0 0
StP Undervoltage protection nO nO nO
StM Undervoltage ramp deceleration time 1.0 sec. 1.0 sec. 1.0 sec.
Strt IGBT test nO nO nO
LFL I 4-20 mA loss behaviour nO nO nO
InH Detected fault inhibition assignment nO nO nO
SLL Modbus fault management yES yES yES
drn Degraded line supply operation nO nO nO
rPr Reset power run nO nO nO
COM - Communication menu (not used - skip this)
E1000-010_VFD_Parameters_r0.xls Page 2
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INSTRUCTION

1:0 BEFORE STARTING THE MACHINE......................................................... 9

2:0 SPECIFIC CAUTIONS AND WARNINGS................................................. 11

3:0 MACHINE DESCRIPTION ........................................................................ 13

4:0 INSTALLATION ........................................................................................ 15

5:0 SET-UP AND OPERATING PROCEDURES ............................................ 21

5:2:4:2:3.1 Base/Top Wraps First Mode Selection............................31

6:0 WRAPPING A LOAD................................................................................ 43

7:0 REMEDIAL ADJUSTMENT ...................................................................... 51

8:0 MAINTENANCE REQUIREMENTS .......................................................... 57

9:0 MAINTENANCE AND ADJUSTMENTS.................................................... 59

10:0 TROUBLE-SHOOTING .......................................................................... 69

11:0 PARTS LISTS ........................................................................................ 85

12:0 COMPONENT MANUALS

13:0 MECHANICAL DRAWINGS

14:0 ELECTRICAL DRAWINGS

15:0 VFD PARAMETERS

1:0 BEFORE STARTING THE MACHINE

4. DO NOT START THE MACHINE BEFORE REMOVING STRAPPING

5. Before operating the machine, remove any Styrofoam, strapping, or

9. During the winter months, gear-reducer lubricants will thicken when

10. If the machine is loaded by forklift truck, it is recommended that a stop

11. READ THE MANUAL!

2:0 SPECIFIC CAUTIONS AND WARNINGS

This designation indicates that a failure to observe can cause EQUIPMENT

This designation indicates that a failure to observe can cause DAMAGE TO

This designation indicates that failure to observe can cause DAMAGE TO

The manufacturer strongly recommends that all personnel involved in

The manufacturer endeavors to supply the safest equipment possible. The

3:0 MACHINE DESCRIPTION

The PILOT stretch-wrapping machine is a floor level (2.75” turntable elevation),

PILOT Low Profile

3:1 Machine Specifications

Power 115 volt, 1 Phase, 15 Amp (unshared) line service required. A

Control The machine is controlled by microprocessor board with an

Speed Turntable speed is manually controlled from 0 to 12 RPM by

The Film Carriage elevator speed is manually controlled from

The Film Carriage elevator is driven from a right-angle oil-filled

Environment The PILOT semi-automatic stretch wrapper is designed for

Capacity Loading of 4,000 pounds turning, and 10,000 pounds static.

Film The PILOT semi-automatic stretch-wrapper accepts film up to

4:1 Moving the Machine

4:2 Unpacking and Inspection

Before applying power or operating the machine, a general inspection is

IT IS THE END-USER’S RESPONSIBILITY TO REPORT ANY DAMAGE

 WARNING! Failure to thoroughly test the operation of the

5. Operate all control panel push-buttons and switches. Their actions

 CAUTION! The film carriage limit switches must operate

4:3 Knock-down Tower Assembly

Pilot machines will normally be shipped in “knocked-down” condition. The tower

Erect the tower and secure it to the machine as follows:

1. Remove all packaging from the machine.

2. Round up the necessary personnel and a forklift truck or other lifting

 WARNING! At this stage the tower is not secured to the

4:4 Pre-Operation Check and Final Assembly

1. Visually check all chains for proper tension and alignment.

 CAUTION! The film carriage limit switches must operate

4. Operate all control panel push-buttons and switches. Their actions

4:5 General Power Requirements

 CAUTION! Power the system only from an adequately

If it is necessary to use an extension cord temporarily, a #14 AWG (minimum)

5:0 SET-UP AND OPERATING PROCEDURES

5:1 Operating Controls – Exterior Control Panel