BW Streamfeeder XT-1200 Manual 

No part of this publication may be reproduced, photocopied, stored on a retrieval system, or transmitted without the express written consent of Thiele Technologies, Inc. - Streamfeeder. Streamfeeder - BW Integrated Systems 315 27th Avenue NE Minneapolis, MN 55418 USA Tel: (763) 502-0000 Fax: (763) 502-0100 E-Mail: [email protected] Web: www.streamfeeder.com Printed in the USA.

Message Conventions................................................................................................ ii Safety.............................................................................iii Specifications............................................................................................................ iv Section 1: About the Machine........................................................1 Section 2: Preparing for Operation................................................4 Section 3: Operation......................................................................13 Section 4: Operational Troubleshooting.....................................16 Section 5: Inspection and Care....................................................18 Section 6: I/O Detail.......................................................................24 Section 7: HMI Operator Screen ..................................................26 Section 8: Mechanical Components............................................34 Section 9: Electrical Diagrams.....................................................62

serious injury or death if proper precautions are not taken. WARNING signifies an action or specific equipment area that can result in personal injury if proper precautions are not taken. CAUTION signifies an action or specific equipment area that can result in equipment damage if proper precautions are not taken. ELECTRICAL DANGER signifies an action or specific equipment area that can result in personal injury or death from an electrical hazard if proper pre- cautions are not taken. Before You Begin TIP signifies information that is provided to help minimize problems in the installation or operation of the feeder. NOTE provides useful additional information that the installer or operator should be aware of to perform a certain task. CHECK signifies an action that should be reviewed by the operator before proceeding. IMPORTANT alerts the installer or operator to actions that can potentially lead to problems or equipment damage if instructions are not followed prop- erly. WARNING LABELS affixed to this product signify an action or specific equipment area that can result in serious injury or death if proper precautions are not taken.

all the safety issues relating to the safe operation of this product. Please read all of the warnings that follow to avoid possible injury. Although Streamfeeder has made every effort to incorporate safety features in the design of this feeder, there are residual risks that an installer or operator should be aware of to prevent personal injury. Please read all of the cautions that follow to prevent damage to this product. This product is built with the highest quality materials. However, damage can occur if the system is not operated and cared for within design guidelines as recommended by Streamfeeder. Equipment interior contains incoming 115 or 230VAC electrical power. Bodily contact with these high voltages can cause electro- cution, which can result in serious injury or death. Safety Danger

Minimum Product Size: . . . . . . . . . . . . . . . 3.38 in. W x 2.13 in. L (86 mm x 54 mm) Min/Max Product Thickness: . . . . . . . . . . .003 in to .500 in. (.076 mm - 12.7 mm) Batch Size: . . . . . . . . . . . . . . . . . . . . . . . . . . Maiximum accumulation thickness 1 in. (25.4 mm) Belt Speed: . . . . . . . . . . . . . . . . . . . . . . . . . . 13,800 in/min (350,520 mm/min) Air Requirements: . . . . . . . . . . . . . . . . . . . . 5 CFM Electrical Requirements: . . . . . . . . . . . . . . 230vac, 50/60Hz, 10A

cumulate product at high speed, producing high levels of automated productivity. Review the main assemblies below to become familiar with names and locations of feeder parts and adjustments. This will help to prepare you for initial setup. 1 About the Machine Main Assemblies Side Guides Back Wedge Assembly Dropper Assembly HMI Gate Assembly

Gate assembly and adjustment Mounted on a gate plate assembly above the feed belt, this device provides a curvature to help preshingle stacked product. When properly adjusted, a gap is created to help one piece of product to be fed at a time. Side guides and adjustments Holds a stack of product to be fed and helps keep it straight for proper entry through the gate assembly area. Two adjustment knobs allows you to move each side guide together or apart for different size product. Can be positioned equally or offset. Back wedge assembly Lifts the product to keep it off the belt to reduce excessive contact, and helps push the product against the curvature of the gate assembly. To achieve proper lift, an adjustment knob allows you to slide the wedge to various positions along the feed belt. HMI All operator functions, including Ready, Cycle Feeder, Fault Reset, Speed, Stop, Cycle, Batch Size, and Jog are controlled at this location. Dropper assembly Consists of two driven "star" fins (fins), the dropper assembly accumulates product, then rotates to drop the batch and ready for the next feed cycle. NOT SHOWN: Hold-down assembly Used to gently force the product onto the discharge belt so it can be controlled after it exits the gate assembly area. The proper amount of downward pressure is automatically adjusted based on the gate setting. Back stop and knock-down The backstop and knockdown in the dropper assembly provide the product control necessary to manage each piece of product as it enters the dropper. Control Panel The control panel contains all the controls to manipulate the feeder. See Feeder Control Panel Overview page. Stand The stand supports the feeder. Locking Casters The locking casters provide easy mobility and the ability to lock the feeder into place next to the printer. O-Ring Belts The o-ring belts provide support for the edges of the product in the discharge area.

Item Description (1) System I/O This 14-pin connector sends DC voltage or ON/OFF control signals to other devices. (2) Trigger Input The photo sensor sends the signal to begin a feed cycle via this 4-pin connector. (3) DR702 Connection point for left dropper fin. (4) DR902 Connection point for right dropper fin. (5) Power Entry The cordset plugs into this IEC320 connector, providing power to the feeder/dropper from a grounded/ fused 115V or 230VAC outlet. (6) Main Power ON-OFF Turns main power on (I) and off (O).

To prepare the feeder for operation a series of simple adjustments need to be made for the product you are going to run. After all the adjustments have been completed, the final step is to test run the feeder to verify the settings are correct. The adjustments that must be made (in order) are as follows: 1. Gate assembly adjustment 2. Side guide setting 3. Back wedge adjustment 4. Photo sensor adjustment 5. Dropper fin adjustment 6. Dropper back stop adjustment 7. Test cycle to verify proper settings Review The gate assembly provides the curvature to help preshingle product, and provides the proper gap to help the feed belts pull product through the gate assembly area. The gate assembly preshingles the product to help the feed belts move one piece of product at a time based on the gap between the gate assembly and the feed belts. The downward pressure (or weight) of the stack in the hopper will provide the force to help push the product against the curvature of the gate assembly, and help it contact the feed belt. This preshingling will allow the gate assembly to efficiently separate (and singulate) product. To achieve the optimum separation, you have to use the adjustment knob to either increase (clockwise) or decrease (counter-clockwise) the gap between gate assembly and the feed belts. Objective Adjust the gate assembly for minimum gap, with minimum pressure on the product. Your objective is to adjust the clearance so that only a single piece of product passes under the gate at one time, and not damage product as it separates. Overview Step 1 Gate Assembly Adjustment Condition of Installment: Warning decals must be visible to machine operator.

1. Raise the gate assembly so that the gap is greater then one piece of sample product. Then slide one piece of sample product under the gate assembly. 2. Test for gate clearance by sliding the product under the gate to verify clearance. Lower the rotating gate until a slight pressure or pinch is felt between the rotating gate and the feed belt. Too much pressure or pinch will cause product damage, skew and erratic feeding. Too loose will result in double feeds, no gap and erratic feeding. Step 1 Gate Assembly Adjustment (continued) Excessive lowering of the gate assembly can damage product or lead to premature wear of the rotating gate nip rollers or feed belt, and cause the product to skew. Not enough gate pressure can cause double feeds, and lead to no gap between the product being fed.

Review The side guides hold the stack of product being fed, and they guide the product through the feeder in a straight line of movement. Side guides are adjusted to accommodate different widths of product. Objective Adjust the side guides so that the product stack maintains uniformity from top to bottom, with no drifting or binding. Adjustments are made horizontally. Make sure the space between the side guides can accommodate the size of the product being fed (product width + 1/16"). Consider the following as you adjust the guides: • The initial starting point should always be that each guide is of equal distance from the center point of the machine. • Each edge of the product should rest equally on the belt, on both sides of the gate assembly. However, there can be certain instances where guides do not need to be centered due to prod- uct characteristics. This is called offset spacing. • Adjust both side guides to be as close as possible to either sides of the product, without causing binding, curling of edges, or resistance to movement. A good starting point is typically 1/16" greater than the product width. Procedure To adjust each side guide for proper horizontal spacing follow these steps: 1. Loosen each side guide adjustment knob (counter-clockwise), and move the guide to a width greater then the product. 2. Place one piece of sample product in the hopper, and center it on the gate assembly. 3. Grasp the lower part of each guide and slide to the recom- mended distance from the product: 1/16 in. (1.6 mm) from each edge, 1/8 in. (3.1 mm) overall. Tighten the side guide adjustment knob after you establish proper position for each guide. 4. Visually check both guides for proper spacing from product (centered on the gate).

which can be solved by simply adjusting the back wedge to different positions. Some of these problems include double feeds, no feed or slipping, skewing, twisting, poor singulation, ink or varnish buildup on the belt, and jamming at the gate assembly area. Review The back wedge provides proper lift to keep the weight of the product on the feed belt, and it creates the force necessary to push product against the gate assembly. By adjusting it in and out from the gate assembly, you can create the lift and force necessary to preshingle product against the curvature of the gate assembly. Also, it keeps other sheets off the feed belt until proper separation of the bottom sheet at the gate assembly has occurred. Objective Adjust the back wedge for proper support of the product off the feed belt, without creating any pinch or stress points between the wedge and the product.

steps: 1. Grasp a handful of product, approximately 2 to 2.5 in. (5 to 6cm) thick, and preshingle the edges with your thumb to match the curve of the gate assembly. 2. Place the preshingled product in the hopper so that the edges rest against the curvature of the gate assembly. 3. Turn the back wedge adjustment knob counter-clockwise to loosen the wedge. 4. Move the back wedge forwards and backwards until the bot- tom few sheets are touching the feed belt, and the remainder of the stack is being supported by the wedge. Step 3: Back Wedge Adjustment (continued) Customized wedge configurations are available for feeding various products. Setup of the wedge shown in the following photos is similar to all wedges.

Sensor Adjustment Review The photo sensor detects the leading edge of each piece of product to verify it is present enabling batch counting functionality and various error detection capabilities. The sensor can be positioned along a slot. The product will drift past the sensor depending on the speed setting and the product weight, size and shape. The ideal position of the sensor is determined with consideration for the distance the product drifts after the sensor detects the leading edge. Objective Correctly position the photo sensor to stop the product in the desired location without overhanging the edge of the discharge. Procedure The photo sensor has a green LED and a yellow LED. When green is on it indicates the sensor is powered and functional. When yellow is on it indicates the sensor has detected something. If yellow is on and no product is present, it can still tell the feeder to stop. It could be detecting something such as a shaft or glare from surrounding hardware. Move the sensor until the LED turns off. Verify the sensor functionality by placing a piece of product under the sensor to see if the LED illuminates. To adjust the photo sensor: 1. Stop the feeder and open the guard. 2. Loosen the round knob and slide the sensor to the desired loca- tion within the slot. 3. Perform a feeder cycle to evaluate adjustment. 4. Make additional adjustments as needed until proper stopping position is attained. 5. Tighten round knob and close guard. 6. Press FAULT RESET to put feeder/dropper in READY mode. Press the STOP button to take the feeder out of READY mode. This prevents a feed cycle during photo sensor adjustment

Adjustment Review The dropper fins provide a landing area for the product as it exits the feeder. After the product is accumulated, the fins rotate to drop the batch. Objective Fin adjustment is product-dependent. For optimum performance, fins are set to match the width of the products being fed, plus 1/4". Be sure the fins are aligned with the product as it discharges from the feeder. Procedure To adjust the dropper fins: 1. Press the STOP button to take the feeder out of READY mode. 2. Loosen the wing lever and slide the dropper fin assembly to the desired location. 3. Tighten the wing lever. 4. Repeat with other dropper fin. 5. Press FAULT RESET to return the feeder to READY mode. 6. Run several test cycles to verify correct adjustment. Press the STOP button to take the feeder out of READY mode. This prevents a feed cycle during photo sensor adjustment

Backstop Adjustment Review The backstop and knockdown assembly halts the discharged product, aligning the front and back product position to provide necessary control of the accumulating batch. Objective Backstop/knockdown adjustment is product-dependent. Proper adjustment maintains product control and allows the accumulation of a batch. Procedure 1. Manually place one piece of product onto dropper fins. 2. Loosen the lock knob and slide the backstop toward the product, leaving a 1/8 inch gap. 3. Tighten knob to secure in place. 4. Place product equal to the desired batch plus one onto the land- ing area of the dropper fins. 5. Adjust the knockdown plate by loosening its locking knob and raising/lowering until light contact is made with the product stack. The addition of one piece to the batch (in Step 5) ensures that the knockdown place is not too tight on the desired batch count.

it is recommended that you verify the singulation and separation of product through the gate assembly area. Before you power-up and run your machine with a full hopper, jog several sheets of product through the gate assembly area. Prepare your test by loading the hopper with approximately 2 to 2-1/2 in. (5 to 6 cm) of product. Make sure you preshingle the stack so that product rests against the curvature of the gate assembly. 1. Manually feed several sheets of product slowly through the gate assembly area. Move the drive belts by pressing the jog button. 2. Observe how individual product enters and exits the gate as- sembly area. The feeder will tolerate a slight overlap at the gate assembly area. The overlap occurs as the bottom sheet is exiting and the next sheet is entering. 3. If sheets are overlapping excessively or if double feeds occur, reduce the gap slightly by turning the gate adjustment knob about 1/8 turn. 4. If double feeds continue, move the wedge in toward the gate assembly. 5. As product moves through the hold-down area, check for any skewing or jamming. Also check for damage to the product. 6. If this or other feeding problems still persist (slipping, skew- ing, jamming), then review all the adjustment procedures in Section 2, “Preparing for Operation”. Verify proper setup by setting the Feeder Speed near the second notch on the control. While holding the Jog button observe the product as it discharges out of the feeder and into the dropper fins. To ensure good feeding reliability the product flow should be all single pieces and the gap between them consistent in length. Step 7: Manual Test to Verify If the gate assembly is too tight, the feeder will have difficulty pulling the product through the gate assembly area. This will cause “missed” feeds. Moving the back wedge too far forward to the gate assembly can create a pinch point between the tip of the wedge and the product. If moving the back wedge in is not effective, then an optional wedge may be required. See Section 6 for more information.

each of following sets of procedures where needed: 1. Loading product 2. Powering on the feeder/dropper 3. Setting and adjusting speed 4. Starting a cycle 5. Stopping the feeder 6. Clearing a jam Loading Product 1. Preshingle a small stack of product and load in hopper. 2. With one end of the stack resting against the gate assembly, the other end will be resting on the back wedge. 3. Gradually add more product to the hopper. As stack height will have a preferred minimum and a maximum, you will have to experiment to determine the effective range of height. 4. As you add product, tamp each hand-full of product with your hand to make sure it rests evenly against the back plate. Operational Sequence Preshingling prevents multiple sheets from jamming under the gate assembly at start-up. Stack height affects the downward pressure on the feed belts. Greater downward pressure can increase the chances for misfeeds or double feeds. 3 Operation

1. With speed and batch size set, verify the feeder is in READY mode with the green CYCLE button illuminated. 2. Press the CYCLE button to initiate a complete feed cycle (a full batch delivered to dropper fins). 3. Press CYCLE button again to drop the batch onto the conveyor and complete another feed cycle. 4. Observe to verify good product flow through the feeder/dropper. Stopping the Feeder/Dropper To stop the feeder at any time, press the red STOP button. This will stop the feeder and disengage the dropper fins. Product accumulated on the dropper fins may fall onto the conveyor when the STOP button is pressed. To return the feeder/dropper to READY mode, press the FAULT RESET button. The green CYCLE button will illuminate. Dropper fins automatically return to “home” position when the machine enters READY mode. Keep clear of this area to avoid injury. Refer to the HMI Operator Screen section in this manual.

If a jam occurs during operation, complete the following steps: 1. Press the STOP button. 2. Open the safety guard. 3. Verify the FAULT RESET led changes from blinking to steadily on. This indicates the machine is now safe to enter. 4. Remove the jammed product. While doing so, attempt to deter- mine the cause of the jam. 5. Verify adjustments, paying specific attention to any loose compo- nents. Refer to “Preparing for Operation” for proper adjustment procedure. 6. Close the safety guard. 7. Reset the machine by pressing FAULT RESET. Preshingling prevents multiple sheets from jamming under the gate assembly at start-up. Stack height affects the downward pressure on the feed belts. Greater downward pressure can increase the chances for misfeeds or double feeds. Dropper fins automatically return to “home” position when the machine enters READY mode. Keep clear of this area to avoid injury. Operational Sequence (continued) Refer to the HMI Operator Screen section in this manual.

No AC power to feeder 1. On/off switch in "off" (or "O") position. 2. Power cord loose or not plugged into outlet (or AC power source). 3. Female end of power cable loose or not plugged into AC power inlet at rear of control panel. Check that switch is in "On" (or "I" position). Check and secure power cord at AC outlet. Check and secure cord at AC inlet (rear of feeder) Feeding doubles 1. Gate assembly improperly adjusted (pos- sibly more that one sheet thickness). 2. Back wedge improperly adjusted. 3. Worn rollers on gate assembly. 4. Product interlocking. 5. Static buildup. Review gate assembly adjustment in Section 2: "Preparing for Operation". Review wedge adjustment in Section 2: "Pre- paring for Operation". Replace rollers. If wear is excessive, consult with a qualified technician. Check product and source. Check product and source. Product belts are operating, but product not feeding 1. Product stack height is too low, resulting in reduction of down pressure. 2. Binding in side guides. 3. Slippery feed belts (product buildup). 4. Sheet adhesion or interlocking between the bottom and next sheet. 5. Gate assembly too tight. 6. Too much weight in hopper. Review loading product in Section 3: "How to Operate". Adjust side guides further apart to allow free- dom of movement between sheets. Review cleaning feed and discharge belts in Section 5: "Inspection and Care". Review loading product in Section 3: "How to Operate", also review back wedge adjustment in Section 2: "Preparing for Operation". Review gate assembly adjustment in Section 2: "Preparing for Operation". Remove product from stack. Test again. Cause Problem Solution This section is intended to provide you with quick solutions to the more common day-to-day problems you may encounter.

on roller 1. Excessive weight in hopper. 2. Excessive down pressure on gate as- sembly. 3. Product off-centered from center point of machine. 4. Belt wear. Review loading product in Section 3: "How to Operate". Rotate clockwise 1/8 turn and manually test. Also review gate assembly adjustment in Sec- tion 2: "Preparing for Operation". Review setting side guides in Section 2: "Pre- paring for Operation". Review gate assembly adjustment and back wedge adjustment in Section 2: "Preparing for Operation". If wear is excessive consult with a qualified technician. Jamming occurs during operation 1. Improper adjustment in one or more of the following areas: • Gate assembly • Back wedge • Discharge alignment rails 1. Turn the power switch to "off" (I) position. 2. Remove jammed product from the feeder. While doing so, try to determine the cause of the jam. 3. Verify adjustment by reviewing Section 2: "Preparing for Operation". Product skewing 1. Back wedge not properly aligned. 2. Excessive gate pressure on one side. Review back wedge adjustment in Section 2: "Preparing for Operation". Review gate assembly adjustment in Section 2: "Preparing for Operation". Cause Solution Problem

Check for visual signs of: • Walking. Replace as required. • Cracking. Replace as required. • Thinning. Replace as required. Please read this Section to learn how to: • Visually inspect your machine to detect part problems which may require adjustment or replacement. • Periodically care for your machine to prevent any operational problems. When performing initial adjustments prior to operation, always make sure you turn Off the main power switch, open the discharge safety shield and disconnect feeder from the electrical power source. To do so can expose you to a potential start-up, and therefore moving parts which can cause serious injury. Do not attempt to make any adjustments while the machine is running. Failure to do so can expose you to moving parts which can cause serious injury. Do not wear loose clothing when operating the feeder. Do not make adjustments with loose or unsecured parts. This is cause for potential injury. Checking for Timing and Drive Belt Wear Check for visual signs of: • Fraying. Replace as required . • Missing teeth. Replace as required. • Cracking. Replace as required. 5 Inspection and Care Timing Drive Belt Discharge Belt Feed Belt

Check for visual signs of: • Misaligned timing pulleys. carriage, idler and servo motor. Adjust as necessary. Visual Inspection (continued) Feed Belt Tracking Adjustment Screws Ensuring Proper Feed and Discharge Belt Tracking Check for visual sign of: • Stretching. • Improper roller adjustment. Feed belt tracking is adjustable by increasing or decreasing the tension on the two screws identified below. The discharge belt alignment is adjustable by moving the rollers either left or right.

To ensure good feeding reliability, visually check the surface of the rotating gate rollers. The rollers should be round with no flat spots detectable by touch, and no gouges or cracks. The drive belt should be in good physical condition with no gouges, missing teeth or excessive fraying. It should be tight enough to make good contact with the gear cogs. Check for good pulley alignment. Visual Inspection (continued)

1. Turn Off feeder and remove power cord from outlet. 2. Remove gate assembly from gate plate for easier access to belts. 3. Apply a small amount of isopropyl alcohol to a soft cloth. 4. Use your hand to move the discharge belt, start with one feed belt at a time and carefully press the moistened area of the cloth to the belt. As you rotate the belt, use moderate pres- sure to wipe across the belt, making sure to wipe in direction of grooves also. After several rotations of the belt, repeat for each belt. 5. Allow the belt to air dry, approximately 30 seconds. 6. Repeat steps 3 – 5 for the discharge belt also. 7. Reinstall gate assembly and restore power. Use only isopropyl alcohol (98% concentration). Other solvents can cause belts to wear prematurely, and even total breakdown of product. Timing Drive Belt Discharge Belt Feed Belt

Use only isopropyl alcohol (98% concentration). Do not use any other types of solvents. They can cause premature wear of the belts, or even total breakdown of the product. To clean gate assemblies: 1. Turn Off feeder and remove power cord from outlet. 2. Remove gate assembly from gate plate. 3. Apply a small amount of isopropyl alcohol to a soft cloth. 4. Wipe across the rollers, first in one direction, then the other. 5. Taking a dry portion of the cloth, go back and wipe all sur- faces to ensure they are dried. 6. Reinstall gate assembly and restore power. Refer to page 21 " Checking for Gate Assembly Wear".

To clean the photo sensor lenses: 1. Turn Off feeder and remove power cord from outlet. 2. Open the discharge safety shield (to access sheet-detect sen- sor). 3. Using a soft, dry cloth, wipe across the face of each lens. 4. Repeat step 3 above for flight-detect sensor. 5. Recheck the adjustments of the photo sensor to make sure it is in alignment. 6. Close discharge safety shield and restore power. Do not use any solvents or cleaning agents when cleaning the photo sensor lenses. This can result in surface damage and eventual faulty performance. Do not use any solvents or cleaning agents when cleaning the keypad or display. This can result in surface damage. Do not spray any cleaning solutions directly on the keypad or display surfaces, as this could lead to faulty performance. Preventive Care (continued) Photo Sensor Inside Bracket

power cord before performing any service activity. I/O Cable Wiring External I/O Cable Wiring Table Pin # Wire Color Function Relay # Relay Type 1 Blue 1410 Miss/Dbl Output (-) 1206 CR 2 Blue 1411 Miss/Dbl Output (+) 24VDC 3 Orange +24 VDC Supply (150ma. max) - 6 Blue Ready Output (-) 1221 SSR 7 Violet Ready Output (+) 24 VDC 10 Black & Shield DC Supply Ground - 11 Blue 1604 E-Stop - 12 Gray 1604A E-Stop - 13 Red /Yellow External Trigger Input (-) 1416 CR 14 Red / Green External Trigger Input (+) 24 VDC A qualified service technician should perform the electrical integration of this equipment to the host machinery. Always disconnect the AC inlet power cord before performing any service activity. 6 I/O Detail

This is the main run screen from which the feeder oper- ates. CYCLE – Actuates the dropper paddles first, then dis- penses the Batch Size onto the dropper paddles. Button is only visible in running mode. JOG - Activates the main feed belt to run at a set speed while the button is depressed. STOP – Removes the feeder from Run mode. Batch Size – Sets the amount of product to dispense into the dropper for each CYCLE (range from 0-999). Speed (rev/s) – Sets the speed of the main feed belt (range from 1 – 75 rev/s). Up/Down Arrows – Increases/Decreases the speed of the main feed belt. Main Menu – Press to exit run screen for other feeder options/setup features. Feed State display window – Indicates the feeders operating state: Running – Feeder is in READY mode Stopped – STOP button was pressed. Aborting – Faulted due to feeder time out (no product under product sensor or failed to see transition of HI to LOW or LOW to HI state on the product sensor). Resetting – Feeder in process of clearing or resetting the fault on the feeder. Fault Status Window

following conditions of the feeder control drives. Display blank: No fault conditions present. Power Up: Feeder powering up as normal. Module Not Ready: Feeder may be still pow- ering up, but checking status of drives and motors. Module Fault: One or more of the drives or motors has been determined to have a fault condi- tion. Possible reasons for this fault: - Front Dropper guard open. - Product jammed in feeder carriage. - Product jammed in dropper paddle wheels Failed to RESET Feeder Timed Out: When trying to reset the feeder to place in READY mode, the product is not able to stage up to the sheet detect sensor. Failed to START: Indicates the one or more of the drives is faulted - refer to drive status window (located on front of drives, inside control cabinet) to determine which drive has the fault. Failed to STOP: Indicates the one or more of the drives is faulted - refer to drive status window (located on front of drives, inside control cabinet) to determine which drive has the fault. Failed to CLEAR: Indicates the one or more of the drives is faulted - refer to drive status window (located on front of drives, inside control cabinet) to determine which drive has the fault. HMI Operator Screen (continued)

when the feeder is dispensing product. RESET – This button appears when the feeder is not in READY mode. Pressing this button places the feeder in stand-by mode. Either the feeder has just started up or there is a fault condition. CLEAR – This button appears when the feeder is in stand-by mode. Press this button to place the feeder in READY mode. Clears the fault condition. HMI Operator Screen (continued) special settings: Setting the Batch Size to ‘0’, enables the JOG function to run the feed belts continuously at 40 rev/s. Setting the Batch Size greater than ‘0’, enables the JOG function to inch the feed belts for product setup. Pressing the STOP button then reseting the stop condition cycles the dropper paddles.

screen. Goto Diagnostics Screen – Advances to the main diagnositics screen. Goto Reports Screen – Advances to the report screen which lists the current and past running data col- lection information. Pause On Miss Disable/Enable – Pressing this button either enables/disables the pause the feeder on miss detection feature of the feeder. Miss detection is relating to the feeder dispensing product for a given batch then being asked to feed another batch (via either the flight sensor or the external trigger signal) simulta- neously. This feature stops the feeder if this condition is true. Machine Status: Indicates the machine condition. OK: Green box indicates drives and motors are working without fault. Ready: Green box indicates feeder is ready to dis- pense. Safe Speed: Green box indicates the feeder has been placed into safe speed mode due to several factors (over speed drive errors, motor issues, etc…) State: Indicates the feeder operating state. Running – Feeder is in READY mode Stopped – STOP button was pressed. Aborting – Faulted due to feeder time out (no prod- uct under product sensor or failed to see transition of HI to LOW or LOW to HI state on the product sensor). Resetting – Feeder in process of clearing or resetting the fault on the feeder. Main Menu Options Diagnostics Screen

pensing and places feeder in READY mode. RESET/CYCLE – Resets the feeder so that is can be placed into READY mode Stop – Stops the feeder from dispensing product CLR Faults – Clears a feeder fault and reset the drives, places the feeder in stand-by mode FeedBelt: Pressing this button, displays various operational in- formation about the main feed belt as displayed below. Several tab buttons in this window display different information relating to this axis. Press the ‘X’ to exit this window at any time. L Paddle: Pressing this button, displays various operational information about the left dropper paddle as displayed below. Several tab buttons in this window display dif- ferent information relating to this axis. Press the ‘X’ to exit this window at any time. Diagnostics Screen (continued)

formation about the right dropper paddle as displayed below. Several tab buttons in this window display dif- ferent information relating to this axis. Press the ‘X’ to exit this window at any time. Cycle System: This button actuates the dropper paddles first, then dispenses the Batch Size onto the dropper paddles. Cycle Feeder: This button actuates the feeder dispensing only. Batch Size: Sets the amount of product to dispense into the dropper for each Cycle System (range from 0-999). Speed (rev/s): Sets the speed of the main feed belt (range from 1 – 75 rev/s). Goto Menu Screen: Returns operation to the Main Menu Screen. Diagnostics Screen (continued)

dispensed from the feeder. TOTAL PieceS: Displays the current resettable piece count for each piece dispensed from the feeder. TOTAL FaultS: Displays the current resettable fault count on the feeder. Goto Menu Screen: Returns operation to the Main Menu Screen. Counter Screen

2 1 16681150 Carriage Assembly 3 1 17391109 Assy, Belt Drvn 4 1 311-1193 Assy, Hold Down 5 1 311-1188 Assy, XT1200 Dropper 6 1 311-1192 ASSY, XT1200 HEX LARGE KNOB 7 1 17031107 Assy, Volt Convrt SV 8 2 17711109 Assy, Cable Dropper Motor 9 1 311-0093 Assy, Sensor Harness 10 1 311-0180 XT1200 Card FDR 11 1 611-0004 Buhrs Interface Cable 12 1 63011038 Assy, Sensor ST Flight 50mm 13 1 64911012 Assy, Cbl Ext Systm 14 1 311-0301 Assy, Vacuum Pump 15 1 903839 Enclosure, HMI 16 2 903867 Bracket, Side Operator 17 6 102688B07 SHCS BLACK OXIDE 10-32 X 1.00 18 1 311-1189 Assy, Accumulator Cover 19 1 17651106 NS ASSY, HOPPER 20 1 16680001 Assy, Linear Transport 21 1 17711116 FEEDER BASE 22 1 904090 ENCLOSURE, XT1200 23 1 311-1185 Assy, HD. Guide LH 24 1 311-1186 Assy, HD. Guide RH 25 1 17651109 Assy, Wedge Compensating XT-1200 ASSEMBLY Assembly # 311-1187

ITEM QTY. PART NUMBER DESCRIPTION 1 1 51668196 Left Carriage Discharge 2 1 51668197 Carriage Discharge Right 3 2 51668202 Front Idler Shaft 4 1 51668199 Drive Shaft 5 1 51668207 Drive Shaft 6 1 51668205 Idler Shaft 7 1 51668200 Idler Shaft 8 1 51668217 Left Material Support 9 1 51668206 Vacuum Manifold 10 1 51668218 Right Material Support 11 1 44450085 Fitting, ElbTb3/8 12 1 44947041 Tube Driven 13 1 51668203 Discharge Idler Roller 14 6 51668215 R8 Bearing w\Collar 15 4 51668216 R6 Bearing w/Collar 16 1 51668237 Roller, Lower 17 1 23560106 1-5/8 CROWN PULLEY W\SET SCREW 18 1 51668225 19 Tooth HTD Pulley 19 1 51668227 24 Tooth HDT Pulley 20 1 51668243 Flat Roller Middle 21 2 51668244 Outer Flat Roller 22 1 44947037 Vacuum Belt 23 1 51668231 Discharge Belt 24 1 51668230 Timing Belt 25 1 44852080 Key, Stock 1/8 26 2 44872007 SHSS 10-32 X 3/8 27 2 102729B03 SSSCPPT 8-32NC X .24 28 2 102733B03 SSSCPPT 1/4-20NC X .25 29 2 102732B03 SSSCPPT #10-32 X 1/4 30 6 102732B04 SSSCPPT #10-32 X .31 31 6 102688B08 SHCS 10-32 x 1.25 32 2 102688B05 SHCS #10-32 X .75 33 4 102689B05 SHCS 1/4-20 X 3/4 34 2 102637B05 FHCS #10-32 X 3/4 35 2 102732B01 SSSCPPT #10-32 x 1/8

Assembly # 17391109 ITEM QTY. PART NUMBER DESCRIPTION 1 1 51632059 Dowel Block 2 2 51632060 Dowel Pin 3 2 51692018 CU Spring, Rotating Gate 4 1 23560084 GATE LIFT SHAFT 5 1 51739052 CU Plate, Gate 6 1 51739051 CU Plate, Gate 7 1 51632058 Gate Sleeve Block 8 1 51435013 Block, Gate Spacer 9 2 51668216 R6 Bearing w/Collar 10 2 51739161 Roller, Feed Blue D95 11 1 51739056 CU Shaft, Gate 12 1 51739049 CU Plate, Motor Mount 13 1 51739057 CU Motor, Gate 14 4 51739093 CU Standoff 15 1 51277082 Mounting Flange Knob 16 1 43555090 Pulley, Tmng 16XL037 17 1 51739054 CU Pulley, Gate Motor 18 1 51739096 CU Cover, Motor 19 1 44854030 Belt, Timing 80XL037 20 1 23500104 O Ring, Standard 21 1 51277083 Knob 22 1 23500084 GATE ADJUSTMENT 23 1 51277081 KNOB INSERT 24 1 44852080 Key, Stock 1/8 25 1 16321136 Harness, Powr Rotating Gate 26 1 17391124 Harness, Extnsn Rotating Gate 27 3 102685B06 SHCS #8-32 X 7/8 28 4 102705B03 BHCS #6-32 X .50 29 3 102685B07 SHCS 8-32 X 1.00LG 30 4 102688B10 SHCS 10-32NC X 1.75 31 3 102732B03 SSSCPPT #10-32 X 1/4 32 2 102732B01 SSSCPPT #10-32 x 1/8 33 5 102688B03 SHCS #10-32 X 1/2 34 1 102733B12 SET, SCREW 1/4-28 X 1-1/4 35 2 102912B01 SHCS #5-40 X 1/4 36 2 102688B05 SHCS #10-32 X .75

Assembly # 311-1193 ITEM QTY. PART NUMBER DESCRIPTION 1 1 51739084 Hold Down Block 2 3 51277052 Shaft, Hold Down 3 3 51277077 SPRING PIN, 1/8 DIA X 1.75 SST 4 3 51277076 Spring, Hold Down 5 3 51277090 Spring, Hold Down 6 3 51277138 SPRING, HOLD DOWN MEDIUM 7 1 51722003 Hold Down Block 8 6 44380039 Roller, Hold Down 9 2 51327006 Mount, Photo Eye 10 1 51277085 Bracket, Photo Eye 11 1 435SO270 Knob, 1/2 Dia. #8 W/O Screw 12 1 103240B03 FLAT WASHER #8 13 1 102685B02 SHCS BLACK OXIDE 8-32 X .38 14 2 102688B05 SHCS BLACK OXIDE 10-32 X .75 15 2 102688B03 SHCS BLACK OXIDE 10-32 X .50 16 4 102708B02 BHCS BLACK OXIDE 10-32 X .38 17 12 104308B04 E-Type, Steel Clip for 3/8 shaft 18 2 600624B07 MSSH #2-56UNC X .63

Assembly # 311-1188 ITEM QTY. PART NUMBER DESCRIPTION 1 1 44947014 ADJUSTMENT SHAFT 2 1 44947006 ROTATING SHAFT 3 2 51765001 DROPPER FINS 4 2 51327012 CENTER SUPPORT 5 2 44947023 ADJUSTMENT LOCKING 6 2 44947153 RATCHET HANDLE ¼-20 X .75 7 2 43555097 RATCHET HANDLE 10-32 X .50 8 4 44947015 IGUS BEARING 9 4 102688B07 SHCS BLACK OXIDE 10-32 X 1.00 10 8 103238B01 LOCK WASHER SPRING SST #10 SCREW 11 12 102688B03 SHCS BLACK OXIDE 10-32 X .50 12 8 102729B02 SSSCPPT BLACK OXIDE 8-32 X .19 13 2 102637B14 FHCS BLACK OXIDE STEEL 10-32 X .88 14 4 102689B10 SHCS 1/4-20 X 1.75 15 2 903869 Extended Mount 16 2 903447 SHAFT MOTOR 17 2 MPL-x1530xxJ72AA MOTORT 8LB-IN 7000RPM 230V 18 2 903444 MOTOR SLIDE BLOCK

Assembly # 311-1192 ITEM QTY. PART NUMBER DESCRIPTION 1 3 44681021 THUMB KNOB W/10-32 INSERT 2 1 51668174 FRONT SUPPORT 3 1 51771073 STOP BLOCK 4 1 44947105 DISCHARGE 5 1 51771041 BACK STOP BRKT, 6 1 51765007 BACK STOP BAR 7 1 51771047 KNOCK DOWN BLOCK 8 1 51771063 PIVOT BAR 9 2 51668248 TENSIONER 10 1 51771066 CLEVIS PIN 11 2 51771067 SHIM WASHER 14 1 51771065 PIVOT MOUNT 13 1 51771064 PIVOT BASE 16 2 51379081 COMPRESSION SPRING 15 1 51765005 BACK STOP PAD 16 2 900677 Spacer, Handle 17 1 900880 Knock Down Top Plate 18 1 51739122 CU Ruler, Hopper Left 19 1 51739124 CU Ruler, Hopper Right 20 1 51765004 Knock Down, Discharge 21 2 902227 Collar, 7/8 Hex 22 1 902228 Shaft, 7/8 Hex 23 11 102688B05 SHCS BLACK OXIDE 10-32 X .75 24 4 102688B06 SHCS BLACK OXIDE 10-32 X .88 25 4 102688B03 SHCS BLACK OXIDE 10-32 X .50 26 2 102732B15 SSSCPPT 10-32 x 2.00 27 2 104308B03 E-Type, Steel Clip for 1/4 shaft 28 1 102732B13 SSSCPPT BLACK OXIDE 10-32 X 1.50 29 2 102729B04 SSSCPPT 8-32 X .31 30 2 311-1207 1/4-28 X 2 LOBE KNOB

Assembly # 17031107 ITEM QTY. PART NUMBER DESCRIPTION 1 1 51703011 Mount, DC to DC Convertor 2 1 51703012 Converter, DC to DC 3 4 44649048 STANDOFF, MALE/FEMALE 4 2 51703013 CU Screw, Plastic 10/32 x 1/4 5 1 17031103 CU Harness, SV Gate 6 1 17031105 CU Harness, SV Gate 7 4 102760B07 PHMSPH #6-32 x .5

Assembly # 63011038 ITEM QTY. PART NUMBER DESCRIPTION 1 1 44846052 Bracket Sensor Mount 2 1 44640016 Collar, Locline 1/4 Mounting 3 14 44608041 Locline Adjustable 1/4 4 1 44608042 Lockline NPT Connector 1/4 x 1/8 5 1 102683B05 SHCS 6-32 X .75 6 1 103240B02 FLAT WASHER #6 7 1 53500038 Sensor, EZ Beam 50mm Diffuse Reflective 8 1 44699007 BLOCK BRUSH MOUNTING 9 1 44681020 SSSNYLTIP 10-32 X .75 10 1 44681021 THUMB KNOB W/10-32 INSERT 11 1 53500506 PLUG, CABL CIRCULAR 4 PIN AMP 12 4 53500502 PIN, CONTACT MLE 24-20 AWG AMP 13 1 53500504 Plug, 4 Pin 206429-1 AMP 14 2 903121 TIE, CABLE BLACK UL 4in 15 1 102732B03 SSSCPPT BLACK OXIDE 10-32 X .25

Assembly # 311-0301 ITEM QTY. PART NUMBER DESCRIPTION 1 1 51771083 Adapter, Male Female 2 2 901148 Plug, 1/8” NPT 3 1 51771034x1 Gauge, Air Flow 4 1 901147 Manifold, 2 Port 1/8” NPT 5 3 44450085 Fitting, ElbTb3/8 6 1 51771082 CU Elbow, Male Female 7 1 51771080 CU Regulator 8 1 901145 Elbow, 10mm OD x 1/4” NPT 9 1 51771034 CU Piab 10 1 51771079 CU Filter, Large 11 1 901146 Elbow Fitting, 3/8” x 1/2” NPT 12 1 51771057 CU Fitting, Barbed 13 1 51739076 CU Plate, Clamping 14 5 113853B07 Tubing, PVC 3/4 15 1 44450084 Fitting, Tb3/8 TB to 1/4 16 1 102685B08 SHCS BLACK OXIDE 8-32 X 1.25 17 2 102685B10 SHCS 8-32 X 1.75 18 94.5 150095 Polyethylene Tubing

ITEM QTY. PART NUMBER DESCRIPTION 1 1 51668232 CU Gate Plate 2 2 44633033 KNOB, 3 ARM 3 1 44963102 KNOB, 5 LOBE WITH 10-32 THREADED INSERT 4 1 51277115 Ruler 5 1 51668111 CU Bar, Track RH 6 2 51668112 CU Spacer, Track Bar 7 1 51668113 CU Bar, Track LH 8 1 51668115 CU Mount, Photo Eye 9 1 51668130 CU Bracket, Hopper 10 1 51668131 CU Bracket, Photo Eye 11 1 51668142 CU Cover, Photo Eye 12 2 51755040 CU Spacer, Hopper 13 1 51765013 NS SIDE GUIDE, RH 14 1 51765014 NS SIDE GUIDE, LH 15 1 51765018 BLOCK, RIGHT SIDE GUIDE 16 1 51765019 BLOCK, LEFT SIDE GUIDE 17 1 51771021 PLATE, HOPPER 18 1 44681020 SSSNYLTIP 10-32 X .75 19 6 102938B05 SHCS SSL 1/4-20 X .50 20 4 102914B03 FHCS SST 8-32 X .50 21 4 102914B03 FHCS SST 8-32 X .62 22 2 102934B02 SHCS/S 8-32 X .38 23 2 102954B03 BHCS SST 6-32 X .50 24 2 102937B05 SHCSS/S 10-32 X .75 25 2 23500078 Cable Clamp ¼” DIA

Assembly # 16680001 ITEM QTY. PART NUMBER DESCRIPTION 1 1 51668005 CU Plate, Rail 2 2 51668003 Kit, Low Profile Rail 3 1 51668007 CU Rod, Lead Screw 4 1 51668006 CU Block, End Cap 5 1 51668014 CU Cover, Nut 6 1 51668039 CU Block, Stop 7 1 51668004 CU Block, Nut 8 2 51668254 Spacer, UHMW 9 1 51668010 Hand Wheel 10 4 51668012 CU Block, Pillow Base 11 4 51668013 CU Block, Pillow Leg 12 4 51668009 Block, Pillow Frelon Lined 13 1 51668001 CU Plate, Mounting 14 1 51668008 Spacer 15 2 51668167 CU Jamnut, 7/16-14 16 1 51668165 Shim 17 2 51668166 CU Jamnut, 5/8-11 18 16 102689B03 SHCS 1/4-20 X 1/2 19 12 102937B03 SHCSS/S 10-32 x .50 20 4 102685B03 SHCS 8-32 X .50 21 10 102683B04 SHCS #6-32 X 5/8 22 16 102937B02 SHCSS/S 10-32 x .38 23 8 102937B08 SHCSS/S #10-32 X 1.25 24 4 102638B03 FHCS 1/4-20 X 1/2 25 2 102732B03 SSSCPPT #10-32 X 1/4

Assembly # 17711116 ITEM QTY. PART NUMBER DESCRIPTION 1 1 51771084 MOUNTING BAR LEFT 2 1 51771075 Mounting Bar 3 2 51771085 MOUNTING PAD 4 8 91263A582 FHCS 3/8-16 X 3/4 BL OX 5 4 903354B07 SHCS/BLACK OXIDE 5/16-18 X 1.00 6 4 51771032 BHCS M10-1.5 X 45mm BL OX

Assembly # 17651109 ITEM QTY. PART NUMBER DESCRIPTION 1 1 51765025 CU Mount, S Wedge 2 1 51765033 Pad, Slide 3 1 51765040 CU Block, Wedge Mounting 4 1 51765039 Mount, Threaded Rod 5 1 51765038 Screw, Thumb 6 1 23500133 Shaft, Rnd .250 x 2.50 7 1 44963102 Knob, 5 Lobe 8 1 51632047 T-NUT 1/4-20 9 1 51765034 Mount Guide 10 2 51765037 Curved Wedge 11 2 23500130 Wedge 12 2 23500134 Spring, Cmprs 1/4 x 1 13 4 103274B02 Snap Ring 1/4 14 2 103228B01 Roll Pin 1/16 X 1/2 15 1 104308B04 E CLIP 3/8 16 1 102732B12 SET SCREW, #10-32 X 1-1/4 17 2 102637B03 FHCS #10-32 X 1/2 18 2 102683B02 SHCS #6-32 X 3/8 19 4 102706B05 BHCS 8-32NC X .75 20 2 102689B06 SHCS 1/4-20 X 7/8

Assembly # 311-0927 1 1 167824TTI Extension, Carriage 2 1 167837TTI SHAFT, SUPPORT 3 1 167831TTI Extension, Carriage 4 4 44582021 BEARING, BALL R4 .25 BORE 5 1 23560106 1-5/8 CROWN PULLEY W\SET SCREW 6 2 168714TTI Side Plate Extension 7 2 167893TTI Bar, Hold Down 8 2 44846050 Holder, R4 Bearing 9 1 167889TTI Shaft, Lower 10 1 167896TTI Plate, Ext Support 11 1 167971TTI Cover, Protective EX 12 1 168721TTI Bar, Cross Support 13 1 902885 Belt, V1000 Extended 14 1 43555302 PULLEY, TIMING 12T XL 1/2 BORE 15 4 44340015 Ratchet Handle, 1/4 16 2 168219TTI Rail, Extended Support 17 1 168939TTI Bracket, Sht Sensor 18 1 49994HS Belt, Timing XL, 105 TEETH 19 3 44963102 KNOB, 5 LOBE WITH 10-32 THREADED INSERT 20 1 904489 Rail, Extended Support 21 8 102957B11 BHCSS SST 10-32 x .31 22 2 102733B05 SSSCPPT BLACK OXIDE ¼-20 X .38 23 2 102916B03 FHCS SSTL 10-32 X .50 24 3 102732B11 SSSCPPT BLACK OXIDE 10-32 X 1.00 25 12 44340017 O-Ring 7/16

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