Barry-Wehmiller Thiele Technologies Streamfeeder Reliant 1500, Manual

Page 1: ...Manual Reliant 1500 ...

Page 2: ...ed photocopied stored on a retrieval system or transmitted without the express written consent of Thiele Technologies Inc Streamfeeder Thiele Technologies Inc Streamfeeder 103 Osborne Road Minneapolis MN 55432 3120 USA Tel 763 502 0000 Fax 763 502 0100 E Mail service streamfeeder com Web www streamfeeder com Printed in the USA ...

Page 3: ...About the Machine 1 Section 2 Installing the Machine 7 Section 3 Preparing for Operation 15 Section 4 How to Operate 27 Section 5 Troubleshooting 31 Section 6 Inspection and Care 33 Section 7 Additional Wedges 41 Section 8 Electrical Schematics 43 Section 9 Mechanical Components 47 ...

Page 4: ...y or death from an electrical haz ard if proper precautions are not taken 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 IMPORT...

Page 5: ...dous voltage Contact will cause electric shock or burn Turn off and lock out power before servicing Moving parts can crush and cut Keep guards in place Lock out power before servicing Pinch point Keep hands and fingers clear Moving parts can crush and cut Keep guards in place Lock out power before servicing ...

Page 6: ...in 235 x 152 mm Contact us for longer insert length Minimum Product Size 2 125 W x 2 25 L in 54 x 57 mm Min Max Product Thickness 003 25 in 076 6 35 mm Belt Speed 1000 ipm 25 400 mmpm Electrical Requirements 115 230vac 1A Weight 23 lbs 10 43kg Specifications ...

Page 7: ...ty of cut sheets and non nested material After material is loaded into the hopper the rest is automatic With photo sensor monitoring feed cycling is always sychronized with the in serter gripper jaw Figure 1 shows a typical setup on the inserter Introducing the Reliant 1500 Universal Friction Feeder Figure 1 Reliant 1500 Universal Friction Feeders Mounted on an Inserter Insert Track Feeder x Stati...

Page 8: ... The machine is entirely powered by a single AC synchronous mo tor that runs off of either a 120 or 240 VAC electrical power source Once the machine is prepared for operation the power up and opera tion of the feeder is relatively easy But to get the most out of your machine you should first become fa miliar with all of the features including controls and sensors connec tors and cables Please read...

Page 9: ... and Adjustments Feeder Top Panel Table Top Gate Bracket Assembly Discharge Assist Assembly Photo Sensor and Flex Arm Extension Gate Assembly and Adjustment Feed Belts The Reliant 1500 Universal Friction Feeder is designed for reliability flexibility and ease of use All control sensing and feeding assem blies are combined into one compact unit The main components and adjustments of the feeder are ...

Page 10: ...le to the material Feed belts Provides the friction and motion necessary to pull individual material from the bottom of the stack and through the gate assembly area Discharge assist assembly A series of small rollers mounted on movable brackets help to gently hold material down on the feed belts as material exits the gate assembly area These brackets and rollers are part of the gate assembly and a...

Page 11: ...and then feeds the next sheet The machine stops as the sensor sees the leading edge The sensor uses two LED indicators A green LED functions as the power indicator and is constantly lit during normal operation The second LED is amber and indicates the pres ence of product staged under the sensor Amber LED on indicates the sensor sees product off when no product is present Read the following descri...

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Page 13: ...tion 8 Securing feeder to inserter 9 Initial feeder photo sensor positioning When performing initial installation always make sure you turn Off the main power switch and disconnect all equipment from the electrical power source Failure to do so can expose you to a potential start up and therefore moving parts which can cause serious injury Do not attempt feeder installation while the inserter is r...

Page 14: ... STEP 3 Repositioning Separator Foot Locate the separator foot at the front side of the inserter station at tached to top rotating shaft With a screwdriver loosen the inserter separator foot and tilt away slightly from insert station assembly opposite feeder so the foot does not interfere with material being fed Figure 7 Retighten to secure Figure 7 Repositioning Separator Foot at Front of Inserte...

Page 15: ...vacuum assembly See Figure 8 Lower and tilt the adjustable vacuum assembly forward by turn ing the built in thumbscrew The vacuum assembly may be moved down and to one side if it interferes with the material being fed Close off the vacuum hose opening any convenient plugging method will do Figure 8 Removing Suction Cup from Vacuum Assembly Suction cup Vacuum assembly ...

Page 16: ...there be adequate clearance between the guide tabs surface and the gripper jaw use a flat thin rule or gauge to test for clearance Ideally with the gripper jaw should be fully open when testing Center the gauge on the guide tabs and slide the gauge back and forth on the tabs making sure the gripper jaw does not touch the bottom of the gauge See Figure 9 Figure 9 Respositioning Guide Tabs and Testi...

Page 17: ...t plate guide during placement Position the insert plate guide so the top surface is slightly above the bottom of the gripper arm jaw Tighten to secure As it is important that there be adequate clearance between the guide tabs surface and the gripper jaw use a flat thin rule or gauge to test for clearance Ideally the gripper jaw should be fully open when testing Center the gauge on the guide tabs ...

Page 18: ...ng Hold Down Spring Assemblies and Testing for Drag Feeder hold down spring Feeder hold down springs Use this configuration for Bell Howell Mailstars and 825 models Knowing how far from each edge of the material to place the hold down spring assemblies is a combination of intuition and testing TIP With material inserted between the springs and the insert guide tabs test the spring tension by slidi...

Page 19: ...ailing edge of material fits between the feeder exit rollers 25 in to 5 in or 6 4 mm to 12 7 mm of material Carefully slide the feeder into the inserter station and center the leading edge of your material under the inserter hold down springs Ensure the front edge of the material is in line with the front hopper plate See Figure 12 Once you are satisfied with the feeder alignment press down on the...

Page 20: ...sor you need to actu ally load material into hopper turn the feeder Off and cycle the inserter See Section 3 Preparing for Operation for more infor mation NO TE The final photo sensor adjustment will align slightly to the rear of the leading edge This is because when the photo sensor signals the feeder to stop the motor will over travel slightly Figure 13 Initial Photo Sensor Adjustment Photo sens...

Page 21: ...preshingle mate rial and provides the proper gap to help the feed belts pull material through the gate assembly area one at a time The downward pres sure or weight of the stack in the hopper will provide the force to help push the material against the curvature of the gate assembly and help it contact the feed belts This preshingling will allow the gate as sembly to separate and singulate material...

Page 22: ... feed belts Procedure To adjust the gate assembly for proper gap 1 Slide one envelope under the gate assembly figure 15 It may be necessary to pull up on the adjustment knob to allow the piece to be inserted figure 15 2 Test the piece for clearance Grasp the envelope with two hands and slide it front to back under the gate assembly A proper adjustment allows a slight amount of drag on the top of t...

Page 23: ... turn the other adjustment roller clockwise 1 8 turn 4 Repeat drag tests and adjust as needed until equal drag is achieved You may need to repeat this procedure after observ ing the feeder cycling refer to Section 4 How to Operate NO TE When feeding product with varying thickness throughout it may be necessary to turn both adjustment rollers 1 2 full turns counterclockwise to compensate for the di...

Page 24: ...e before moving 2 Remove the gate assembly from gate bracket assembly To do so pull cylinder down with one hand lift up on knob with other and tip at slight angle to remove 3 Remove the adjustment knob by turning counter clockwise Figure 18A Then lift the cylinder off of top of spring Figure 18B 4 Turn the cylinder around so that the cylinder collar faces up Figure 18C Then place the cylinder on t...

Page 25: ...ac commodate the size of the material being fed Consider the following as you adjust the guides horizontally An initial starting point should always be that each guide is of equal distance from the center point of the machine Each edge of the material should rest equally on feed belts at either side of gate assembly However there can be certain instances where guides do not need to be centered due...

Page 26: ...ter The bow will stiffen the material to promote better singulation of thinner material Pivoting the back wedge from its perpendicular to the gate assem bly Figure 20B will increase or decrease the amount of drag or contact or traction on the feed belts for a given side This can also be used to control twisting or skewing of material as it leaves the gate assembly area STEP 3 Back Wedge Setting Fi...

Page 27: ... premature buildup of ink or varnish on the belt surfaces It can also cause more than one piece of material at a time to be forced under the gate assembly thus creating a double feed By moving the back wedge forward only the bottom material can make contact with the belt surface Slippage is reduced minimizing buildup on the belt surface Double feeding is also reduced If the back wedge is positione...

Page 28: ...ds and backwards until the bot tom sheet is not touching the table top Figure 23 A good starting point is to measure about 5 8 in 16 mm from the bottom sheet to front edge of table top Then as you test you can fine tune from this point Refer back to the previous page for other helpful guidelines Figure 21 Preshingling a Small Stack of Material By Hand Figure 22 Positioning Material Prior to Loosen...

Page 29: ... parallel to stack x x 5 Make sure the edge of the back wedge assembly is paral lel with the edge of the material stack Figure 24 Adjust as required and then tighten knob 6 Check that individual triangle wedges are evenly spaced to provide enough support to lift the material off the table top and feed belts without any bowing or twisting Figure 25 Refer back to page 20 for guidelines on adjusting ...

Page 30: ... thumb on the drive belt or one of the feed rollers to manually move the bottom sheet of material through the gate assembly area and under hold down springs Con tinue until material leading edge is in line with front hopper plate then stop Figure 26 3 Turn the feeder power On by pushing the horizontal line at the Power On Off rocker switch STEP 4 Final Photo Sensor Adjustment Standard photo sensor...

Page 31: ...a qualified technician Align slightly to rear of leading edge Front hopper plate 2 in 5 08 cm maximum Sensing range from the lens to the paper should not exceed 2 in 5 08 cm IMPOR TANT 4 Simulate gripper jaw action by manually grasping the leading edge of the bottom sheet and pulling completely away from the gate assembly area Once a piece is removed from the gripper jaw the sensor sends a signal ...

Page 32: ...hen move the wedge in towards the gate assembly Test again 4 If sheets are overlapping excessively or if the machine is feeding doubles then reduce the gap slightly by moving the knob about 1 8 turn counter clockwise Test again 5 As individual sheets of material move through the hold down springs check for any skewing or jamming Also check for damage to the material 6 If this or other feeding prob...

Page 33: ...racket assembly and front edges of the hopper guides Figure 30 At the back wedge notice how it helps lift the trailing edges of the material off the table top and feed belts Also notice how the lifting helps to push the preshingled edges against the curvature of the gate assembly Figure 31 Figure 30 Leading Edges Against Gate Bracket Assembly and Side Guides Figure 31 Trailing Edges Lifted by Back...

Page 34: ...s rest firmly against front of side guides Turn the feeder power On by pushing the horizontal line at the Power On Off rocker switch With power On the feeder motor should immediately move the bot tom sheet of material from the stack and through the gate assembly area to stage the first piece As the photo sensor sees the lead ing edge the feeder motor should turn Off Check the leading edge of botto...

Page 35: ... doing so try to determine the cause of the jam see Section 5 Trouble shooting 3 Verify whether any adjustments are loose If so refer back to Section 3 Preparing for Operation for proper adjustment procedures 4 Reposition photo sensor as required STEP 5 Final Check Make sure Leading edge of bottom sheet stops at proper location Proper separation is occurring at gate assembly area Effective preshin...

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Page 37: ...pressure 2 Product binds at side guides 3 Slippery feed belts due to buildup of glaze on belt surface 4 Sheet adhesion or interlocking between bottom and next sheet 5 Gate assembly may be down too tight Solution Move switch to On or position Check and secure power cord at AC outlet Check and secure cord at AC power inlet at rear of feeder Review gate assembly adjustment in Sec tion 3 Preparing for...

Page 38: ... causes stack to be aligned off center from machine center line Review gate assembly adjustment in Sec tion 3 Preparing for Operation See also Section 6 Inspection and Care If wear is excessive consult with a qualified techni cian Consult with a qualified technician 1 Turn the power switch to Off 2 Remove jammed material Attempt to determine the cause of the jam 3 Verify each adjustment by reviewi...

Page 39: ... secured Failure to do so can cause damage to equipment Visual Inspection Checking for Drive Belt Wear Referring to Figure 35 check for visual signs of Fraying Replace as required see the Technical Information Guide for more information Missing teeth Replace as required see the Technical Infor mation Guide for more information Cracking Replace as required see the Technical Information Guide for mo...

Page 40: ... more information Improper roller adjustment see the Technical Information Guide for more information Feed belt drift Ensuring Proper Drive Belt Tracking Referring to Figure 37 check for visual signs of Misaligned timing pulleys See the Technical Information Guide for more information Figure 36 Ensuring Proper Feed Belt Tracking Drive Belt Figure 37 Ensuring Proper Drive Belt Tracking ...

Page 41: ...of wear Standard O Ring Flat areas along the O rings Figure 38 Bar Gate Angled wedge begins to flatten excessively Figure 39 See Preventive Care to follow Bar Gate II Horizon Adjust Standard O Ring Gate Flattened O rings Figure 38 Checking Standard O Ring Gate for Wear Figure 39 CheckingBarGate II for Wear ...

Page 42: ... assembly and restore power 7 Return feeder to original position marked on back deck plate Restore power Flattened edge rotated 1 8 to 1 4 3 to 6 mm Figure 40 Adjusting Worn O Rings Bar Gate Replacing Worn Angled Wedge To replace a worn angled wedge 1 Turn Off feeder and remove power cord from outlet 2 Move the feeder back from the gate plate to allow working clearance You can save much re alignme...

Page 43: ...ate pressure 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 Taking a dry portion of the cloth go back to the first feed belt cleaned and use moderate pressure against the belt for several revolutions to ensure the belt is dried Repeat for each belt 6 Restore power Use only isopropyl alcohol 98 concentration Other ...

Page 44: ...material To clean gate assemblies 1 Turn Off feeder and remove power cord from outlet 2 Move the feeder back from the gate plate to allow working clearance You can save much re alignment time if you mark the current position on the back deck plate before moving 3 Remove gate assembly from gate bracket assembly 4 Apply a small amount of isopropyl alcohol to a soft cloth 5 Wipe across O rings Figure...

Page 45: ...sing a soft dry cloth wipe across the face of the photo sen sor lens 3 Recheck the adjustments to make sure it is still in alignment to the target 4 Restore power Preventive Care continued Do not use any solvents or cleaning agents when cleaning the photo sensor lens This can result in surface damage and eventual faulty performance ...

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Page 47: ...narrow 7 Additional Wedges Load Compensating When to use Effective for moderately thick material Due to charac teristics of material no mid range support is required Setup guidelines Adjust so that top angle of wedge preshingles the stack against curvature of gate assembly Edges of material should not extend beyond the tip of wedge Ideal separation should be where as the stack moves down the wedge...

Page 48: ...o separate 4 to 5 sheets of material at the bottom to provide some air space Figure A2 Articulating Roller Wedge Setup Extended Narrow Side Setup guidelines Effective for moving in close to the gate assembly for supporting very small material Due to characteristics of material no mid range support is required Ideal setup Adjust so that wedge preshingles the bottom of stack against the curvature of...

Page 49: ...43 Relaint 1500 Manual 8 Electrical Schematics 120V Electrical Schematic ...

Page 50: ...44 Reliant 1500 Manual 240V Electrical Schematic ...

Page 51: ...45 Relaint 1500 Manual 120V Electrical Schematic with Vacuum Select ...

Page 52: ...46 Reliant 1500 Manual 240V Electrical Schematic with Vacuum Select ...

Page 53: ...47 Relaint 1500 Manual 9 Mechanical Components ...

Page 54: ... ASSEMBLY 23511214 DIAGRAM PART NUMBER QTY DESCRIPTION NUMBER 1 1 1 SHSS 10 32 X 5 16 LG 00002217 1 2 1 Bracket Wedge Hold Down 33560213 1 3 4 Wedge Material Support 33560212 1 4 1 Shaft Wedge Guide 23560214 1 5 2 Ring Grip 3 8 Waldes 00001110 ...

Page 55: ...ook 44841011 2 SHCS 8 32 X 5 8 LG 00002215 2 4 4 SHCS 8 32 X 5 8 LG 00002215 2 5 1 Bar Support Gate Top 44846005 2 6 2 Clamp Adjustment Side Guide Rear 44846010 4 FHSS 10 32 X 1 2 LG SS 00002830 2 7 1 Bar Pre Gate 44846007 2 8 1 Pre Gate 44846016 4 FHSS 10 32 X 1 2 LG SS 00002830 2 9 1 BHCS 10 32 X 3 8 LG 00002305 2 10 1 Bracket Sensor Mounting 44846051 2 11 1 Block Mount Reference 44846015 2 12 1...

Page 56: ...Shaft Gate Lift 23560084 1 Spring Gate Compression 23500083 3 4 1 Mount Gate Lift Shaft 15000001 3 5 1 BHCS 10 32 X 1 2 LG 00002334 3 6 2 Screw Adjustment 44872005 3 7 12 O Ring Gate Cylinder 23500089 3 8 1 BHCS 10 32 X 1 LG 00002340 1 Washer Flat 10 00002607 3 9 1 Gate Cylinder Not Sold Separately 51101001 2 SHSS 10 32 X 3 4 LG Cup Pt 00002216 3 10 2 Roller 44872003 2 SHSS 10 32 X 3 8 LG Nylon Ti...

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Page 58: ...nt 00002216 1 SHSS 10 32 X 5 16 LG Cup Point 00002217 1 Key Woodruff 1 8 X 3 8 00003351 2 Clip E 1 2 Waldes 00001155 2 Bearing Ball R8 23500094 2 Holder Outboard Bearing Cup 23500032 4 3 1 Shaft 15000075 1 Belt Support Tube 44846018 2 Bearing Ball R6 23500095 2 Clip E 3 8 Waldes 00001150 1 Guard Pinch 15000017 4 4 1 Idler Shaft 23560047 1 Tube Driven 44846017 4 Bearing Ball R8 23500094 3 Ring Grip...

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Page 60: ...7 1 Key Woodruff 1 8 X 3 8 00003351 5 3 1 Shaft Belt Support Bearing 23500040 5 Roller Support Driven with Bearing 23511030 10 Ring Grip 3 8 Waldes 00001110 1 Guard Pinch 15000017 5 4 1 Shaft Drive 1 2 SS 23560211 1 Pulley Rear Belt 435SO248 4 Roller Driven with Bearing 23511031 2 Roller Feed 1 2 Bore 23500026 10 Ring Grip 1 2 Waldes 00001115 1 Pulley 20T 1 2 Bore w Flange Driven 23500097 2 Holder...

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Page 62: ...IPTION NUMBER 6 1 5 Bearing Ball R6 23500095 6 2 4 Clip E 3 8 Waldes 00001150 6 3 2 Ring Grip 3 8 Waldes 00001110 6 4 1 SHCS Nylock 10 32 44350017 6 5 2 Bracket Discharge 44841040 6 6 1 Shaft Discharge 51101003 6 7 1 Washer Lock 10 00002608 6 8 1 SHCS 10 32 X 1 2 LG 00002315 6 9 1 Knob Small Black 23500091 ...

Page 63: ... NUMBER QTY DESCRIPTION NUMBER 7 1 4 Bearing Ball R6 23500095 7 2 8 Ring Grip 3 8 Waldes 00001110 7 3 1 SHCS Nylock 10 32 44350017 7 4 2 Bracket Discharge 44841040 7 5 1 Shaft Discharge 51101003 7 6 1 Washer Lock 10 00002608 7 7 1 SHCS 10 32 X 1 2 LG 00002315 7 8 1 Knob Small Black 23500091 ...

Page 64: ...Control 230V R1500 230V Only 15022024 4 Phillips Pan Head Screw 6 32 X1 4 LG 00002221 8 6 1 Motor w Connector 115V R1500 115V Only 15011052 1 Motor w Connector 230V R1500 230V Only 15022052 8 7 4 SHCS 10 32 X 1 2 LG 00002315 4 Washer Lock 10 00002608 8 8 8 Washer Flat 10 00002607 8 9 1 Bracket Upper Motor 23500011 8 10 1 Bracket Lower Motor 23500012 8 11 1 Ring Grip 3 8 Waldes 00001110 8 12 2 Bear...

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Page 66: ...t 15000067 9 6 4 Foot Suction Cup 44846058 9 7 1 Bracket Left Mount 15000066 9 8 1 Side Guide Right 11 524 44846013 9 9 1 Side Guide Left 11 524 44846014 9 10 1 Knob Extension Assembly 23511023 NS 1 Wire Assembly Light Blue 13511055 NS 2 Wire Assembly Brown 13511056 NS 1 Wire Assembly Green Yellow 13511057 NS 1 Ruler Kit 15000064 NS 1 Clamp Cable 23500078 NS 1 Power Cord 115V Only 53500002 NS 1 Ty...

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Page 68: ... Universal Guide 23500050 10 5 1 Washer Flat 10 00002607 10 6 1 SHCS 10 32 X 3 8 LG 00002310 10 7 1 SHCS 8 32 X 3 8 LG 00002213 10 8 1 Extension Material Hold Down 33500023 10 9 1 Spring Material Hold Down 23500102 10 10 1 BHCS 8 32 X 1 4 LG 00002210 33511008 RH MATERIAL HOLD DOWN ASSY Contains same part numbers and quantities as above assembly Note change in orientation of parts OTHER 10 11 2 BHC...

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Page 72: ... 2009 Thiele Technologies Inc Streamfeeder Printed in the USA ...