BW Streamfeeder XT-1200 User manual

Manual

XT-1200/Conveyor

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: service@streamfeeder.com

Web: www.streamfeeder.com

Printed in the USA.

i

XT-1200 Manual

Contents

Before You Begin ..........................................................ii

Message Conventions ............................................................................................... ii

Safety ............................................................................iii

Specications ........................................................................................................... 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

ii XT-1200 Manual

Message

Conventions

DANGER signies an action or specic equipment area that can result in

serious injury or death if proper precautions are not taken.

WARNING signies an action or specic equipment area that can result in

personal injury if proper precautions are not taken.

CAUTION signies an action or specic equipment area that can result in

equipment damage if proper precautions are not taken.

ELECTRICAL DANGER signies an action or specic 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 signies 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 signies 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 afxed to this product signify an action or specic

equipment area that can result in serious injury or death if proper precautions

are not taken.

iii

XT-1200 Manual

Make sure you thoroughly read this section to become familiar with

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

iv XT-1200 Manual

speCifiCations

Maximum Porduct Size: ............... 9 in. W x 7 in. L (229 mm x 178 mm)

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

1

XT-1200 Manual

The XT-1200 Dropper is designed to effectively feed, count, and ac-

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

2 XT-1200 Manual

Feature Description

Main Assemblies Feature Descriptions

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" ns (ns), 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.

3

XT-1200 Manual

Control Box Features

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 n.

(4) DR902 Connection point for right dropper n.

(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).

4 XT-1200 Manual

2 Preparing for Operation

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 nal 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 n 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 efciently

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.

5

XT-1200 Manual

Procedure

To adjust the gate assembly for proper gap, follow these steps:

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.

6 XT-1200 Manual

Step 2

Side Guides Setting

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).

7

XT-1200 Manual

Step 3:

Back Wedge

Adjustment

There are a number of feeding problems,

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.

8 XT-1200 Manual

Procedure

To adjust the back wedge for proper initial positioning, follow these

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 congurations are

available for feeding various products. Setup

of the wedge shown in the following photos is

similar to all wedges.

9

XT-1200 Manual

Step 4: Photo

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

10 XT-1200 Manual

Step 5: Dropper Fin

Adjustment

Review

The dropper ns provide a landing area for the product as it exits the

feeder. After the product is accumulated, the ns rotate to drop the batch.

Objective

Fin adjustment is product-dependent. For optimum performance, ns are

set to match the width of the products being fed, plus 1/4". Be sure the

ns are aligned with the product as it discharges from the feeder.

Procedure

To adjust the dropper ns:

1. Press the STOP button to take the feeder out of READY mode.

2. Loosen the wing lever and slide the dropper n assembly to the

desired location.

3. Tighten the wing lever.

4. Repeat with other dropper n.

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

11

XT-1200 Manual

Step 6: Dropper

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 ns.

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 ns.

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.

12 XT-1200 Manual

Now that you have made all the necessary adjustments for operation,

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 ns. To ensure good

feeding reliability the product ow 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 difculty 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.

13

XT-1200 Manual

Successful power-up and operation of the unit is assured if you apply

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

14 XT-1200 Manual

Operational Sequence

(continued)

Starting a Feed Cycle

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 ns).

3. Press CYCLE button again to drop the batch onto the conveyor

and complete another feed cycle.

4. Observe to verify good product ow 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 ns.

Product accumulated on the dropper ns 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 ns 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.

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BW Streamfeeder XT-1200 User manual

BW Streamfeeder XT-1200 User manual

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