Flowmaster RS Manual

Transcription

Pitney Bowes Sure-Feed Engineering
FlowMaster RS
Servo Drive Inserter with
Rotary Servo Drive Feeder Technology
1
Special Note:
Some pictures and illustrations may have color, hue and contrast graphically altered for clearity when printing in black and
white and may not necessarily reflect the actual color of the product when viewed on compact disk.
Documentation
Created By
Technical Writer: Bill Spencer - Manager, Training / Service
Photographs By: Bill Spencer - Manager, Training / Service
.
Line Drawings and Illustrations By: Bill Spencer - Manager, Training / Service
Bitmap Screens Provided By: Ron Kinney - Manager, Software and Electrical Engineering
Subject Matter Experts: Bill Spencer - Manager, Training / Service
Layout and Editing By: Bill Spencer - Manager, Training / Service
Hand Models: Katherine Mitchell, Carrie Brand, Lashawna Hammond, Debbie Eaton
© Pitney Bowes Inc.
All rights reserved. This book may not be reproduced in whole or in part in any fashion or stored in a retrieval system of any type or
transmitted by any means, electronically or mechanically, with out the express written permission of Pitney Bowes.
The use of this information by the recipient or others for the purposes other than the training of customers on Pitney Bowes equipment
may constitute an infringement of patent rights and/or other intellectual property rights of Pitney Bowes or others and Pitney Bowes
assumes no responsibility for any such use of the information.
We have made every reasonable effort to ensure the accuracy and usefulness of this manual. However, we cannot assume
responsibility for errors or omissions or liability for the misuse or misapplication of our products
Except as provided in writing, duly signed by an officer of Pitney Bowes, no license either expressed or implied, under any Pitney
Bowes or third party’s patent, copyright or other intellectual property rights is granted by providing this information.
2
Table of Contents
Topic
Page Number
Section I
Physical Dimensions of the FlowMaster RS inserter
6
Section II
Safety Features
Safety Recommendations
9
13
Section III
Material Specifications
15
Section IV
Environment
Electrical Requirements
18
19
Section V
Collator installation
22
Section VI
Front Table Installation
29
Section VII
Envelope In-Feed Conveyor Installation
42
Section VIII
Turnover Installation
51
Section IX
Flap Moistener Brush Installation
55
Section X
Shingle Conveyor installation
58
Section XI
Servo Drive Box installation
61
Section XII
Cable Connections
65
3
Table of Contents
Topic
Page Number
Section XIII
General Job Set Up
Homing the FlowMaster RS Inserter
Overhead Vacuum Assist Envelope Opener, Lift
Insert Air Plate, Selecting and Installing
Air Pressure Setting
Envelope Setup
Front Table Setup
Envelope Entry Finger Alignment
Material Track Setup
Material Drag Strap Setup
Friction Feeder Setup
Rotary Feeder Setup
Envelope Turnover Setup
Shingle Conveyor Setup
Envelope In-Feed Conveyor
Pusher Finger Configuration
74
84
87
93
96
108
113
119
123
125
132
149
151
154
159
Section XIV
Optional Overhead Vacuum Assist Envelope Opener, Setup
164
Section XV
Remote Control Operation
Battery Removal / Replacement, Remote Control
171
172
Section XVI
Touch Screen Menus
Factory Settings
174
190
Section XVII
Electronic Timing
202
4
Section - I
Physical Dimensions
Of the
FlowMaster RS Inserter
5
10.25’
Width
Length
4.25’
6’
Location of Air Drop for
Speed Sort Conveyor
with * Pattern Match
Scan Base
9.42’
9’
9’
220 VAC / 30 Amp.
Single Phase
13.75’
1.25’
4.4’
Special Note:
Additional 220 VAC /
30 Amp. Single
phase. Drop is
required if in line with
the F.B.I.
6
Please see the following
page for additional lengths
and widths when adding
other inline equipment to the
FlowMaster RS inserter
(Fig. 1-1)
The standard FlowMaster RS inserter, when assembled measures 10.25’ wide by 13.75’ long using a total of
141 square feet of floor space.
Please add the approximate dimensions shown to the overall width depicted in the diagram on the previous page for the
following components:
Postage Meter, R-150 base – 1.25’
Postage Meter, Infinity Base – 1.6’
Ink Jet Base – 3.5’
Heater Base – 2.5’
Diverter Base – 1.5’
*Pattern Match Scan Base, Speed Sort Conveyor 2.5’
Please add the approximate dimensions shown to the overall length depicted in the diagram on the previous page for the
following components:
Bulk Loader for Feeder #1 - 8.4’
Flexible Bindery Interface – 8.2’
Hi-Boy Ink Jet Base – 1.8’
Collator Section of the FlowMaster RS inserter can be ordered in various lengths in increments of three (3) stations.
Please add the approximate dimensions shown to the overall length depicted in the diagram on the previous page for the
following collator sizes:
9 Station Collator – 3.6’
21 Station Collator – 18’
7
Section - II
Safety Features
and
Safety Recommendations
8
Safety Features:
All Servo Drive FlowMaster RS inserters manufactured have been designed with several safety features to safeguard
persons operating and or working on or around the inserter. These features include:
¾
Hard lexan hinge mounted door covers, cover the side of each feeder at the material transport area
as well as the material pathway of the collator under each feeder. These cover doors are
electronically wired with safety interlock switches, programmed to stop the machine in the event one
of the cover doors is opened.
¾
A lexan cover is hard mounted over the top of the material transport area of each feeder.
¾
A hard lexan hinged door is mounted over the side of each material feeder and is electronically wired
with a safety interlock switch, programmed to stop the machine in the event the cover door is opened.
¾
Each feeder is equipped with a low paper sensor programmed to stop the feeder in the event the
paper supply becomes so low that the possibility of exposing the friction feed belts is critical.
¾
A metal cover is hard mounted over the material pathway behind feeder #1, covering the material
pusher pins at the point where they enter the track of the material pathway.
¾
A hard lexan hinged door is mounted over the material pathway between the last feeder and the
pusher finger assembly. This cover door is electronically wired with a safety interlock switch,
programmed to stop the machine in the event the cover door is opened.
¾
A hard lexan hinged door is mounted over the pusher finger assembly. This cover door is
electronically wired with a safety interlock switch, programmed to stop the machine in the event the
cover door is opened.
¾
Three hard lexan hinge mounted door covers, cover the envelope transport area and the insert area
of the front table. These cover doors are electronically wired with safety interlock switches,
programmed to stop the machine in the event one of the cover doors is opened.
¾
The envelope feeder is equipped with a low paper sensor programmed to stop the machine in the
event the envelope supply becomes so low that the possibility of exposing the envelope vacuum
shuttle is critical.
¾
The service doors of the front table are electronically wired with safety interlock switches,
programmed to stop the machine in the event one of the cover doors is opened.
¾
Two hard lexan hinge mounted door covers, cover the envelope turnover transport area. These
cover doors are electronically wired with safety interlock switches, programmed to stop the machine
in the event one of the cover doors is opened.
(Warning: The safety features, covers, doors and electrical sensors are installed by the manufacture to safeguard all
persons operating and or working on or around the FlowMaster RS inserter. Removing, altering, disabling and or
bypassing any of these items will void any and all warranties, either real or implied, purchased or offered with the
FlowMaster RS inserter. All companies connected with the manufacturing, promotion and sale of the FlowMaster RS
inserter shall be held harmless in the event the safety features, covers, doors and / or electrical sensors are removed,
altered, disabled and / or bypassed after installation by a factory authorized representative. )
9
All Servo Drive FlowMaster inserters have various caution and or warning labels or stickers visibly posted at certain
points of concern. These labels and or stickers must not be removed, defaced or obstructed in any way. These are as
follows:
Black and yellow “Caution” label.
Posted on the top cover next to the
envelope feeder, alerting the operator
to avoid certain conditions that may
become a contributing factor resulting
in a possible injury.
Red and Black “No Water Symbol”
stating “Unsafe to Drink”. Posted on
the side of the water tank for the
envelope flap moistener, indicating that
the water, once placed into the tank is
no longer fit for human consumption.
10
Posted on the side guide of one or
more feeders, alerting the operator
to the proximity of moving parts
and stating to “Use care when
reloading the feeders”.
Red and black Danger warning sticker.
Posted on the center frame of the front
table visible when the service doors are
open. Visual warning and alerting
persons operating and or working on or
around the FlowMaster of moving gears
and or pulleys. Sticker states, “Pinch
points. Watch your hands”
11
Located on the top of the main
power switch box.
States, “High Leakage Current.
Earth connection (Ground)
essential before connecting
supply.
12
In addition to the safety devices and warnings installed on the FlowMaster RS inserter by the manufacturer, the following
recommendations for safe operation and maintenance of the FlowMaster RS inserter are as follows:
¾
Any persons designated to operate, work on or near the FlowMaster RS inserter should be fully trained by a
factory-authorized representative.
¾
Do not operate or perform any type of maintenance on the FlowMaster RS inserter while under the influence of
drugs or alcohol.
¾
Do not operate or perform any type of maintenance on the FlowMaster RS inserter in or around free standing
water.
¾
Do not wear loose or baggy fitting shirts, shirts with billowing sleeves, bracelets, rings, necklaces, neckties or
other loose apparel that may come into close proximity with moving parts of the machine.
¾
Wear protective safety eyeglasses or goggles and use a particle mask or similar device when cleaning off the
FlowMaster RS inserter with compressed air. Alert all other persons in the area to stand a minimum of thirty (30)
feet from the area where compressed air is put to such use.
¾
All persons having hair greater than shoulder length who operate, work on or near the FlowMaster RS inserter
should keep their hair pulled back in ponytail fashion then pinned up or otherwise retained to the top of their head
or confined under the back of their shirt.
¾
Turn off the main power to the FlowMaster RS before opening the front table service doors, removing the side
covers of the collator, removing the side covers of the envelope turnover or performing any other maintenance.
¾
Any persons working near any of the electrical motors of the FlowMaster RS inserter should use caution.
Electrical motors give off heat, contact with or exposure to bare skin may result in burns.
¾
The FlowMaster RS inserter was designed to feed, transport and insert paper into paper envelopes. Do not
attempt to feed and / or run materials made of or containing glass, metal, wood, hard or brittle plastics, liquids,
foods, powders, gasses, explosives or toxic and hazardous chemicals on the FlowMaster RS inserter. (Note: The
manufacturer recognizes and acknowledges that the FlowMaster RS inserter is capable of successfully inserting
compact disk and audio cassettes into paper envelopes, however the manufacture and other companies
connected with the promotion and sale of the FlowMaster RS inserter do not assume any responsibility for any
damage to the FlowMaster RS inserter or product and shall be held harmless for any damages and or injuries
resulting in this practice.)
\
13
Section - III
Material Specifications
For
FlowMaster RS Feeders
14
The FlowMaster RS Inserter can be equipped 3 basic types of feeders.
1.
The Standard Friction Feeder with Dynamic Rotating Separator offered in (6 X 9) or (10 X 13) size configuration.
2.
The Standard Thin Sheet Feeder with an Adjustable Separator Gate offered in (6 X 9) or (10 X 13) size
configuration.
3.
The Servo Drive Rotary Feeder.
These feeders are capable of running a wide range of materials
Feeder Model
#1
Standard Friction Feeder with
Dynamic Rotation Separation
Paper Stock Specification
20# / 50# bond paper
Embossed foil print cards, folded or flat
Business Cards
Credit cards with or without embossed print
Stapled bound booklets, catalogs
Glue Bound booklets / Catalogs
Z Folded paper or Hy-Bulk
Die Cut paper or card stock
Sticker sheets
Die Cut Crack and Peel Stickers
1/2 Folded - Paper, Hy-Bulk or Card Stock
End Folded - Paper, Hy-Bulk or Card Stock
End Staple bound Payment Booklets
End Glue bound Payment Booklets
Business Reply Envelopes (In any direction)
Paper Banded Groups of BRE's (In any Direction)
Gloss and Coated paper, text weight to cover weight
Folded Letters with Cards affixed (In any Direction)
Feeder Model
#2
Standard Thin Sheet Feeder
with Adjustable Separator Gate
20# / 50# bond paper (Non-Folded single sheet)
Business Cards
Paper Banded Groups of BRE's (In any Direction)
End Staple bound Payment Booklets
End Glue bound Payment Booklets
(Non-Folded single sheet)
15
Feeder Model
#3
Rotary Servo Drive Feeder
Multiple Coupons in loose stack with hole drilled
through all but top piece
Prospectus (onion skin) paper folded edge only
or in booklet form spine first
20# / 50# bond paper shingle sheet or folded edge first
16
Section - IV
Environment
and
17
Environment:
The installation of the FlowMaster RS inserter is intended for operation in a specific environment. See Operating
Environment Table below for details.
Operating Environment Table
Item
Place
Ambient Temperature
Relative Humidity
Atmosphere
Altitude
Vibration
Radiation
Specifications
Indoor
+40 to '+90° F or '+13 to '+30° C
5 to 95% RH no condensation allowed
Must not be exposed to; corrosive gas
inflammable gas, oil mist, vapor or water.
There must be no water condensation due to
sudden changes in temperature
3300 feet or 1000m or less
Air Pressure 86 kPa to 106 kPa
Not Applicable
Should not exceed tolerable levels other
than associated with UV dryer lamps
18
Inspection of Installation Area
Once the FlowMaster inserter has been removed from the shipping container and / or transport vehicle, perform the
following:
1.
Inspect the location where the machine is to be set up.
(Note: The manufacture recommends that the area be a relativity flat and smooth concrete or hard wood
surface, similar substrates are acceptable. The area should be free of holes, divots, loose floorboards, etc.
and not subject to retaining moisture from water seepage.) ( ! Warning: In the event the floor does not meet
the recommended requirements, seek an alternate location or reschedule the installation after repairs to the
floor have been completed)
2.
Inspect the line current at the point where the power cable of the machine is to be plugged in. (Note:
Conventional wall sockets, ceiling line drops and D-Boxes should be free of cracks, rust, visible signs of heat
stress and flash marks.) (Special Note: For installations in Europe check the condition of the voltage
converter box or other voltage reducing device that may be in use. In the event of a line voltage inspection
failure, report your findings to the person or persons in charge of the building and postpone the installation
until corrections are made.)
3.
Check the line voltage to ensure that the minimum and maximum requirements are present. In the event the
line voltage has a consistent reading lower than 200 Volts or a momentary drop below 200 Volts advise the
customer that a “Buck-Boost Transformer” must be installed on the line to ensure the longevity of the
electronic motors and components. (Note: The FlowMaster RS inserter must have a dedicated line on a 30
AMP service.)
4.
Check to see what volt value the machine transformer is pinned out to at the voltage selection block, see
figure 4-1. If the volt value is different from the line voltage you checked in step 3, the transformer will need to
be re-pinned to the best match. If you are unsure what pin to select, refer to the chart below.
Transformer Voltage Table
Line
Voltage
Reading
Transformer
Pin
Selection
200 volts to 206 volts
200
210
220
230
240
*** Less than 200 volts ***
Recommend a Buck Boost Transformer
19
To change the pin setting on the transformer, perform the following:
a. Using a medium tip Phillips head screwdriver, loosen the retaining screw in the connection block that the
“Dark Gray Voltage Select Wire” is currently connected to, see figure 4-1.
( ! Caution: The “Dark Gray Voltage Select Wire” is located on the side of the connect block next to
the “Volt Value Labels”. It is the only wire that occupies this side of the block. Do not move or in any way
re-locate any of the stripped or gray wires from the side of the connect block opposite the “Volt Value
Labels”).
Re-locate this gray
wire, if necessary,
to the port that
best matches the
line voltage
Do not move or in any
way re-locate any of
the striped or gray
wires from this side of
the connection block.
200 V
210 V
220 V
230 V
240 V
Fig. 4-1
b. Insert the “Dark Gray Voltage Select Wire” in the connection port that is labeled for the best match for the
line voltage discovered in step 3, see figure 4-2. Secure by tightening the retaining screw using a medium
tip Phillips head screwdriver. ( ! Caution: Do not over tighten.)
200 V
210 V
220 V
230 V
Line voltage tested at 215 V, the
“Dark Gray Voltage Select Wire” was
originally pined to the 240V contact
port, now shown re-located to the
best matching volt value, the 210 V
contact port.
240 V
(Helpful Tip: If the line voltage falls in the middle of two listed voltages, pin to the lower voltage)
20
Fig. 4-2
Section - V
Preparation and Installation
of the
Collator
21
Installation of the FlowMaster inserter:
The FlowMaster inserter may be shipped to the customer location without a shipping crate. The standard machine will be
delivered in five (5) sections. The separate sections are as follows:
Collator
Front Table
Envelope Continuous Feed Conveyor
Envelope Turn Over
Envelope Collecting Conveyor
All five (5) sections will be shipped with all electrical connections, airlines and water lines, coiled and secured with
electrical tie wraps. The main power line coming from the FlowMaster will have a Hubble 30 Amp / 250 Volt Male plug on
it, the customer will be responsible for supplying the correct electrical female plug or receptacle. The service technician
will be responsible for connecting the power supply line from the building to the FlowMaster RS inserter. Should the
customer request changing the Hubble 30 Amp / 250 Volt Male plug on the FlowMaster inserter to a different name brand
plug with electrical capacities equal to or greater than the Hubble 30 Amp / 250 Volt Male plug, the service technician
should accommodate the request providing the plug presented by the customer is in good working order. Under no
circumstances should the service technician attempt to wire, modify or make any changes to the electrical outlet or
breaker box servicing the building. The FlowMaster inserters can be purchased with an optional “Air Leg” conveyor
containing a combination compressor and vacuum pump. If the optional air leg was not purchased, the customer would be
responsible for supplying the air compressor and airline with a 5/8” X ¼” female fitting. The service technician will be
responsible for connecting the compressor line to the pneumatic system. If the electrical and pneumatic components
supplied by the customer are not in good condition and proper working order, do not use them; see the customer for
suitable replacements.
A diagram depicting the requirements for air pressure, space and electrical needs for the FlowMaster RS should be sent
to the customer, before the FlowMaster RS arrives at the customer’s location.
Step 1: Initial Set up
1. Position the collator section of the machine in the work area previously established by the customer.
2. Remove all of the side collator covers exposing the pneumatic and electrical connections.
3. Raise the collator section to a height of thirty-four inches, (34”) see figure 5-1, by using the threaded leveler feet
and pads, see figure 5-2. The objective is to distribute the weight of the collator evenly between the leveler feet so
check the height setting at several different locations around the collator. (Note: It is imperative to have the
collator as close to level as the floor will allow.)
Measure from the top of the
console cover 34” to the floor
34”
(Fig. 5-1)
22
(Fig. 5-2)
Turn the leveler bolt
counter clock-wise to
lower the bolt to the
floor to raise the
collator
After all the leveler bolts have
been set, tighten the lock nut to
the frame by turning it in a clockwise direction
Place a pad under
each leveler bolt
23
4. Make sure the front frame area of the collator is free of all obstruction and the insert pusher fingers are not over
hanging the insert air plate. (Note: The Pusher Fingers can be moved by turning the silver knob located at the
right end of the box cam assembly, see figure 5-3.)
Make sure the Pusher Fingers not out over
the front of the insert air plate
Turn knob in a counter
clock-wise direction to
move the pusher fingers
back away from the front
of the Collator
(Fig. 5-3)
24
5. Make sure the Entry Fingers are not over-hanging the insert air plate. (Note: They can be manually moved by
using a 5/32 Allen wrench, loosen the socket-head Allen screw located on the Entry Finger Operating Bar,
then lift the Entry Fingers out of the way and re-tighten the socket head Allen screw, see figure 5-4.)
(Fig. 5-4)
Using a 5/32 Allen
wrench loosen the
socket head screw by
turning it counter
clock-wise
Swing the entry fingers
up out of the way and retighten the Allen screw
25
6. Using a 9/16 open-end wrench remove the Collator Centering Yoke for the Front Table Timing Belt,
see figure 5-5. (Note: Set the centering yoke assembly aside at this time)
(Fig. 5-5)
(view from inside collator)
Using an open-end
wrench remove the
two (2) outside bolts
by turning them in a
counter clock-wise
direction.
Remove the centering yoke
assembly and set it aside.
(Note: It is not necessary to
remove the bolts shown in
this view to remove the yoke
assembly)
(view from outside collator)
26
8. Make sure the Envelope Flap Detect Sensor is not over hanging the collator, see figure 5-6.
Using a 5/32 Allen wrench, loosen the
retaining screw to pivot the sensor
Pivot the sensor so that it does
not over hang the collator and
re-tighten the retaining screw.
(Fig. 5-6)
27
Section - VI
of the
Front Table
28
1. Remove the socket head screws from the bottom center of the four (4) leveler pads located on the outer back
surface of the front table, see figure 6-1. (Note: The outer back surface will be the surface of the front table that
makes contact with the collator section.)
Using a 5/16 Allen Wrench, remove
the socket head screw by turning it
counter clock-wise. (Note: Do not
miss-place these screws, they will be
needed latter in the install)
(Fig.6-1)
29
2. Slide the front table up to the exposed frame section at the front of the collator. Leave a four (4) to six (6) inch
gap between the collator and the front table. Guide the blue vacuum lines from the Front Table Vacuum Dishes at
the insert area through the center frame section of the collator, see figure 6-2. (Help Tip: The Vacuum lines may
be secured inside the front table with an electrical tie wrap for shipping, use caution when cutting the tie wrap to
avoid damaging the vacuum lines.) (Note: Do not attempt to join the front table and the collator at this time)
(Fig.6-2)
Guide the blue vacuum
lines through the collator
pin-belt frames and over
the center frame
30
3. Line up the each of the four (4) centering studs, located on the collator frame, to the guide holes at the center of
the leveler pads located on the front table frame, see figure 6-3
Slide Front Table to Collator
Centering Stud on the
Collator Frame
Guide Hole in the center
of the Leveler Pad
(Fig.6-3)
31
4. Slid the front table up to the collator using the centering studs on the collator frame to mate both frame surfaces
correctly. (Helpful Tip: No floor is perfectly level, it may be necessary to adjust the threaded leveler feet of the
front table in order to mate with the collator guide studs correctly)
5. Bolt the two sections together using the socket head bolts removed from the front table in step # 6. Insert the
bolts from the inside frame of the collator, accessible through the opening provided after the side cover was
removed in step # 2, into the center bottom hole of each leveler pad attached to the front table frame. Hand
tighten the bolts until the heads are flush with the inside collator frame, then tighten firmly with an allen wrench
following the sequence shown in figure 6-4.
(Fig.6-4)
Bolt tightening
sequence shown
via numbers and
dotted line
1
2
3
4
View from inside of the Collator
(Note: Incomplete machine photographed, missing
floor pans and pump for clear view of bolts)
32
Set the Height of the Front Table
The front table must be positioned so that the top surface of the envelope vacuum plates is .025” lower than the
top flat surface of the insert deck. To set this height perform the following:
1. Loosen all 16 leveler pad bolts located on the inside back frame of the front table. These are accessible through
the service doors of the front table see figure 6-5. (Note: Use a 7/32” allen wrench for the 8 button head bolts
located on the top frame section and a 9/16” open-wrench for the hex-head bolts located on the lower frame
section.)
Using a 7/32 Allen
wrench loosen each of
the 4 button head Allen
screws found in both of
the top leveler pad on
the Front Table frame
!
Caution: “Line of Sight Inhibited”
The screws and bolts depicted in the
expanded view are located on the
“Back” frame sections behind the
motor, gear box, index box and
electrical box. Use caution when
loosening and tightening.
Using a 9/16 open-end wrench loosen each of
the four bolts found in each of the lower leveler
pads found in the Front Table bottom frame
(Fig.6-5)
33
2. Lay any type of object having a flat straight surface on the flat surface of the insert deck extending out over the
front table for a height reference see figure 6-6. (Note: Make sure that the straight edge you are using is
supported by the insert deck. Resting it solely on the insert air plate is not recommended for the following
reasons; the insert air plate could flex providing you with a false collator height, machine specifications for the
insert deck manifold allow for a tolerance of + 0.003” / - 0.000”, machine specifications for the insert air plates
allow for a tolerance of + 0.000” / - 0.003” (Helpful Tip: A 3/8” Allen wrench will do very well for this.)
Note: It is very
important to check
the 0.025” gap at
each side of the
insert deck to ensure
the height differential
is uniform across the
insert area
Place straight edge under pusher drive shaft, flush against the insert deck.
(Advisement: Do not use the Insert Air Plate as a base to set the height differential from)
Set the height differential to 0.025”
between the insert deck and the front table
(Fig.6-6)
34
3. Adjust the leveler feet of the front table until a gap of .025” is obtained between the top of the envelope vacuum
plate of the front table and the reference tool placed on the insert deck as stated in step 2. (Note: Be sure the
check the gap at each side of the insert air plate to ensure an even gap has been established across the width of
the insert area.)
4. After the .25” gap has been established, tighten the 8 button head bolts on the top frame section, then check the
gap once more to ensure it has not changed after the bolts were tightened. Next tighten the 8 socket head bolts
on the lower frame section. Use the sequence pattern shown in figure 6-7 to tighten the bolts in both frame
sections.
(Fig.6-7)
Front Table Bolt Pattern
To be used for both button head and socket bolts
4
3
1
2
7
5
6
8
!
The screws and bolts depicted in the expanded view are
located on the “Back” frame sections behind the motor, gear
box, index box and electrical box. Use caution when loosening
and tightening.
35
5.
Re-install the Timing Belt Centering Yoke, previously removed in step 6 of the Collator installation section by
performing the following:
(A)
Start the two long bolts with the flat washers, previously removed in step 6, page , through
the side frame, fee figure 6-8.
(Fig.6-8)
Start the 2 bolts with washers
through the side frame just enough
to be held in place by the frame.
(B)
Set the block spacer onto the exposed thread of the bolts now showing on the inside of the
frame, see figure 6-9.
Slide the Spacer Block
onto the bolts
Front View of Spacer Block
(Fig.6-9)
Special Note: The photographs in this figure are staged. The
front table that would have already been installed onto the
collator is not shown.
36
(C)
Place the single Yoke Gibb onto the exposed thread, capturing the timing pulley and belt on
the square shaft in the front table, see figure 6-10.
(Fig.6-10)
Place one of the Gibb Yoke sides onto
the exposed bolts now showing
through the spacer block
Front View of Yoke Gibb
Placement of
the timing pulley
and belt
Special Note: The photographs in this figure are staged. The front table that would have already
been installed onto the collator is not shown. Placement is shown for the timing belt and pulley
(D)
Hold the opposing Yoke Gibb, (still mounted to the Yoke Block) up to the exposed threads,
capturing the timing belt and pulley in the front table and begin threading the bolts into the
open side of the Yoke Block, see figure 6-11. (Note: Do not tighten the bolts at this time)
Hold the Yoke Gibb, still mounted to the center block, up
the exposed threads and begin threading the bolts into
the open side of the center block
(Fig.6-11)
Front View of Yoke Gibb and center block
Placement of the timing pulley and belt
Special Note: The photographs in this figure are staged. The front table that would have already been
installed onto the collator is not shown. Placement is shown for the timing belt, pulley and square shaft.
37
(E)
Adjust the Center Yoke assembly to allow clearance around the square shaft as well as
clearance above the front table mount plate, see figure 6-12.
(Fig.6-12)
Inside, Left view
Inside, Right view
Adjust the center
yoke to provide
clearance for free
movement of the
square shaft
Make sure that the center yoke
assembly does not drag or make
any contact with the front table
mount plate
The Center Yoke Gibbs
must be set to provide
clearance around the
square shaft
The through holes for
the mounting bolts are
over-sized. Adjust by
rotating Center Yoke
Gibb assembly before
tightening the bolts
The Center Yoke Gibbs
must be set to provide
clearance over the
mount plate
38
(F)
Pull the timing belt between the center yoke gibbs, back to the timing pulley on the collator
and start the belt onto the pulley at the 6 o’clock position and roll the belt up towards the
9 o’clock position, see figure 6-13. (Note: Push the belt up far enough so that it will stay on
part of the pulley. Do not try to force the belt all the way onto the pulley. At this point there
should be only enough pressure on the belt to prevent it from falling off.)
(Fig.6-13)
Pull timing belt from front table
Start the timing belt at the 6
o’clock position and roll the
belt up towards the 9 o’clock
position
(G)
Open the front service doors of the Front Table, insert the crank handle into the manual
cycle slot and manually cycle the front table by turning the crank handle in a clock-wise
direction, see figure 6-14. (Note: This will effectively position the timing belt the rest of the
way onto the pulley.)
(Fig.6-14)
Turn the crank handle clock-wise to
advance the Front Table and finish setting
the timing belt into the pulley
39
(H)
After the timing belt has been seated into the pulley, tighten the belt using the tension roller. Push up on the
tension roller and tighten the retaining screw using a ¼” Allen wrench, see figure 6-15.
(Fig.6-15)
Test the tension of the belt by grasping the belt, mid way
between the front table pulley and the Collator timing pulley,
with your thumb and forefinger and flex-twist it. You should be
abler to twist the belt almost 45 degrees
Push the tension
roller up to tighten
the belt
Using a ¼” Allen
wrench, tighten the
retaining screw by
turning it in a clockwise direction
Push the tension
roller up
Special Note: When the belt is properly tensioned, you should be able to grasp the belt,
mid way between the front table pulley and the Collator timing pulley, with your thumb and
forefinger and flex it almost 45 degrees
40
Section - VII
of the
Envelope In-Feed Conveyor
(Air Leg)
41
1. Position the In-Feed Conveyor close to the back side of the front table, near the back side of the collator and
remove the “Mount Bars” found in-side the Air Leg console, see figure 7-1.
Using a 9/16” open-end
wrench, remove the two
hex head bolts, by
turning them in a counter
clock-wise direction.
Remove the two mount
bars. (Note: One spacer
bar has an additional
short spacer)
(Fig.7-1)
2.
Screw the mount bars into the threaded studs located on the back of the front table, see figure 7-2. Tighten the
mount bars as tight as you can by hand. ( ! Caution: Do not use any type of jaw tool to tighten the mount bars
to the front table.)
Screw the mount bars onto the
threaded studs and hand tighten
(Fig.7-2)
42
3.
Push the Envelope In-Feed Conveyor up to the mount bars and align the mount holes in the Envelope In-feed
conveyor to the mount bars.
To obtain proper alignment, perform the following:
A.
Remove the retaining nuts found on each of the four (4) leveler castors
B.
Turn the castor body, counter clock-wise to raise, clock-wise to lower, until the bolt holes align with
the mount bars, see figure 7-3.
Retaining nuts have been
removed in this view
Turn the castor body,
raise, clock-wise to lower
(Fig.7-3)
C.
Thread one of the mount bolts into the outer most mount bar. (Note: Hand tighten only.)
D.
Slide the short spacer between the in-feed conveyor leg and the inner most mount bar, then tread the
other mount bolt through the short spacer and into the threads of the mount bar, see figure 7-4.
(Fig.7-4)
Slide the short spacer between
the in-feed conveyor leg and
the inner most mount bar
E.
Using a 9/16” open-end wrench, tighten both mount bolts using moderate force.
43
4.
Remove the Cross Bracket from the back of the envelope in-feed conveyor, then remove the bolt, nut and washer
from the slotted end of the cross brace, see figure 7-5.
(Fig.7-5)
Remove
the bolt,
nut and
washer
from this
end
Cut Plastic Tie Wraps to remove the
Cross Brace from the back panel of the
envelope in-feed conveyor
5.
Push the “Hooked” end under the collator lower frame panel and pull the hook back to seat it to the
panel, see figure 7-6.
Outer Frame Panel
Collator Frame
Slide the “Hooked” end under the collator
and rotate the hooked end up to catch the
lower part of the frame panel
Pull back to seat
(Fig.7-6)
44
6.
Slide the slotted end of the Cross Brace down and against the bottom frame of the in-feed conveyor and secure it
with the bolt, nut and washer removed from the cross brace in step 4, see figure 7-7.
Pivot the cross brace
down to the bolt
opening in the base,
insert the bolt and
secure the washer and
nut under the base.
Push towards Conveyor Base
(Fig.7-7)
7.
Establish the “Pass Line” between the envelope guide fingers located at the feed end of the envelope in-feed
conveyor and the envelope guide block of the envelope hopper located on the front table, see figure 7-8. To
establish a pass line perform the following:
a.
b.
Place a straight edge inside the envelope hopper flush against the envelope guide fingers of the
conveyor, see figure 7-8.
While maintaining contact with the envelope guide fingers, gently slide the straight edge towards
the envelope feed gate, it should pass by the envelope guide block without touching, see figure 7-8.
45
Envelope guide block
Envelope Conveyor Guide Finger
Slide the straight edge against
the guide fingers up to and past
the envelope guide block
(Fig.7-8)
46
In the event the straight edge strikes the envelope guide block make the following adjustments shown in figures 7-9,
7-10 and 7-11.
(Note: Do not deviate from the order shown.)
To gain access to the Envelope
Guide Block assembly to make
the adjustment, reach through
the open space between the
Envelope In-Feed Conveyor and
the Front Table, under the
conveyor bed
!
The screws depicted in the
expanded view are located on the
“Back” frame section of the
separator gate. Use caution when
loosening and tightening.
Pivot the Envelope Guide Block back or
forward to make adjustment. Tighten the
socket head screws when adjustment has
been made
Loosen the two (2) socket head screws
located on the inner most side of the
“Envelope Separator Gate”
(Fig.7-9)
47
Pivot the
mounting
block forward
or backward
Remove End Cover
Adjust the envelope guide
fingers to improve the pass
line. Loosen the two button
head screws on each side of
the finger mounting block to
pivot the fingers forward or
backwards.
Helpful Tip: Never
adjust the fingers out
further than the
conveyor belts
Pivot the
mounting
block forward
or backward
(Fig.7-10)
48
Adjust Conveyor Bed Forward or Backward
(Fig.7-11)
49
Section - VIII
of the
Envelope Turnover
50
To set up the envelope turnover, perform the following:
1. Raise the height of the envelope turnover until the top belt of the turnover can be moved freely over the exit end
of the front table by adjusting the leveler feet of the envelope turnover. To do this:
a. Loosen the 5/8” lock nuts of the four (4) leveler feet by turning them in a counter clock-wise direction see
figure 8-1, page 52.
b. Turn each leveler foot in a counter clock-wise direction to raise the unit.
c. Tighten the lock nuts by turning them in a clock-wise direction.
2. Align the envelope turnover with the exit idler roller end of the front table. Position the tension roller of the top belt
squarely over the top center of the idler roller of the front table. (Note: When correctly positioned, there should be
approximately ¼” to 1/8” between the lower frame base of the turnover and the outer cabinet of the front table and
the overhang from the turnover above the front table, see figure 8-2, page 52.)
3. Set the tension roller of the envelope turnover to its lowest position. Do this by turning the adjustment knob,
located near the tension roller on the operator’s side, in a counter clock-wise direction until the retaining nut
bottoms out on the mounting frame, see figure 8-3, page 53.
4. Lower the height of the envelope turnover until the top belt just makes even contact with the exit idler roller of the
front table, by adjusting the leveler feet of the envelope turnover. To do this:
a. Loosen the lock nuts of the four (4) leveler feet by turning them in a counter clock-wise direction
b. Turn each leveler foot in a clock-wise direction to lower until the desired height is obtained.
c. Tighten the lock nuts by turning them in a clock-wise direction.
( ! Caution: Do not allow the weight of the turnover to rest on the exit idler roller of the front table.)
5. Manually place an envelope under the tension roller of the envelope turnover
6. Adjust the tension setting until there is moderate resistance felt on the envelope when it is pulled back. (Note:
Too much tension will cause the surface of the envelope to wrinkle, too little tension may cause the envelopes to
jam on the front table in front of the turnover.
51
Envelope Turnover Leveler Foot
5/8” Lock Nut
(Fig.8-1)
Envelope Turnover
Note: The space between the
surfaces of the Front Table and
the Envelope Turnover must be
maintained.
(Fig.8-2)
52
Tension Roller Adjustment Knob
Front Table
Retaining Nut
Top Tension Roller of
Envelope Turnover
Exit Idler Roller of Front Table
(Fig.8-3)
53
Section - IX
Installation
of the
Water Brush
54
To install the Water Brush perform the following:
1.
Remove the two (2) hex-head screws located on the right end of the box cam assembly next to
the sliver manual cycle knob.
2.
Thread the water line down between the water overflow tray and the collator top cover, see figure 9-1.
(Fig.9-1)
Thread the water line
down the back side of
the overflow tray
3.
Place the water brush assembly removed from the collator assemble during preparation, against the box cam side
frame and secure it using the two screws removed in step 1, see figure 9-2.
Using a 5/32 Allen
wrench turn the hexhead screw clockwise
to tighten
(Fig.9-2)
55
4.
Once the water line is threaded down behind the overflow tray, guide the line under the lower cross frame of the
collator and into the front table. Connect the water line to the fitting next to the water solenoid, see figure 9-3.
Push the water line firmly
into the fitting
The water solenoid and
valve is located on the inside
portion of the front frame
(Fig.9-3)
Special Note: Open the Flow Valve three (3) full turns when the FlowMaster inserter is
installed. This is the recommended starting reference for most climates and altitudes. Further
adjustments may be needed.
Turn the valve counter clock-wise to open and clock-wise to close.
(Fig.9-4)
56
Section - X
of the
Envelope Shingle Conveyor
57
Shingle Conveyor
1.
Position the edge of the shingle conveyor approximately three (*3) inches from exit end of the turnover also aligning
the center of the envelope knock down assembly with the center material transport belt of the turnover, see figure
10-1. (Note: (*3) inches stated in this step is a starting reference point for the approximate distance when running a
I-ounce, #10 envelope. The size and weight of the material as well as the selected running speed of the
FlowMaster RS inserter has a direct bearing on the distance between the shingle conveyor and the exit end of the
turnover. Increasing or decreasing this distance may be required to accommodate the weight of the material and the
speed you are running.)
Aprox. 3”
Align the red gum belt and exit
roller with the center of the stop
plate on the conveyor
(Fig.10-1)
58
2.
Raise the height of the conveyor using the leveler bolts located under each corner of the conveyor. Raise the
height of the conveyor until the conveyor bed is approximately 3 inched below the exit roller of the turnover, see
figure 10-2.
Turn lock-nut clock-wise to
secure leveler bolt after the
adjustment has been made
Turn Leveler Blot counter
clock-wise to raise conveyor
(Fig.10-2)
59
Section - XI
of the
Servo Drive Box
60
Preparation and Installation of the Servo Drive Box
1. Slide the Servo Drive Box under the conveyor bed of the envelope in-feed conveyor, position the servo drive box
so that the right mounting bracket is approximately 8” from the end of the conveyor bed, see figure 11-1.
(Note: Leave the box on the floor under the conveyor bed at this time. The mount bars will have already been
installed under the conveyor bed before the machine was shipped. Do not assume that they are correctly
positioned, they most likely need to be re-aligned.)
(Fig.11-1)
Set the back of the
right mount
bracket 8” from
the end of the
X
X
Slide box under conveyor
2.
Set the position of the mount bars under the conveyor bed to align left side of the bar with the right side of the
mount brackets of the servo drive box, see figure 11-2.
(Fig.11-2)
Align the left side of the
mount bars under the
conveyor bed to the right
side of the mount brackets
on the servo drive box
61
3. To change the position of the mount bars under the conveyor for optimum alignment, perform the
following steps:
(A)
(B)
Using a 5/32 Allen wrench loosen the retaining screw found at each end of the mount bar,
see figure 11-3.
Slide the mount bars along the lower side frame of the conveyor bed to align them with the mounting
brackets of the servo drive box.
Align the mount bars with the
mounting brackets by sliding them
along the lower side from of the
conveyor bed
Turn the Allen Screw
loosen, clock-wise to
tighten.
(Fig.11-3)
62
4.
Lift the servo drive box onto the mount bars, see figure 11-4. Once the mount bars have been seated into both of
the mounting brackets, release the servo box. It will stay under it’s own weight. ( ! Warning: The Servo Drive
Box weighs approximately 80 LBS, practice safe lifting techniques or acquire assistance to lift the box while
mounting it under the conveyor.)
! Warning
The Servo Drive Box weighs approximately 80 LBS, practice safe
lifting techniques or seek assistance to lift the box.
Lift up, then to the right to seat
the servo drive box mounting
brackets onto the mount bars
(Fig.11-4)
5. Slide the servo drive box back so the conveyor belts do not drag against the retaining screws on the mounting
brackets, see figure 11-5.
Slide the servo box back on the mounting bars so the conveyor
belts travel between the retaining screws of the mount brackets.
(Fig.11-5)
6.
Tighten the retaining screws in both of the mount brackets to secure the servo drive box to the mounting bars
under the envelope in-feed conveyor.
63
Section - XII
Cable Connections
64
1.
Recheck the line voltage as you did in step 3 of section 2 and recheck the pin-out on the transformer. If this
step was over looked during the installation perform the following steps now if the volt value is different from
the line voltage you checked. Re-pin the transformer for the best match. If you are unsure what pin to select,
refer to the chart below. ( ! Caution: This procedure is to determine required pin configuration for the
transformer only, Do Not connect the main power supply to line voltage at this time.)
Transformer Voltage Table
Line
Voltage
Reading
Transformer
Pin
Selection
200
210
220
230
240
*** Less than 200 volts ***
Recommend a Buck Boost Transformer
To change the pin setting on the transformer, perform the following:
b. Using a medium tip Phillips head screwdriver, loosen the retaining screw in the connection block that the
“Dark Gray Voltage Select Wire” is currently connected to, see figure 12-1.
( ! Caution: The “Dark Gray Voltage Select Wire” is located on the side of the connect block next to
the “Volt Value Labels”. It is the only wire that occupies this side of the block. Do not move or in any way
re-locate any of the stripped or gray wires from the side of the connect block opposite the “Volt Value
Labels”).
Re-locate this gray
wire, if necessary,
to the port that
best matches the
line voltage
Do not move or in any
way re-locate any of
the striped or gray
wires from this side of
the connection block.
200 V
210 V
220 V
230 V
240 V
(Fig. 12-1)
65
c.
Insert the “Dark Gray Voltage Select Wire” in the connection port that is labeled for the best match for the
line voltage discovered in step 3, see figure 12-2. Secure by tightening the retaining screw using a
medium tip Phillips head screwdriver. ( ! Caution: Do not over tighten.)
(Fig. 12-2)
200 V
210 V
220 V
230 V
Line voltage tested at 215 V, the
“Dark Gray Voltage Select Wire” was
originally pined to the 240V contact
port, now shown re-located to the
best matching volt value, the 210 V
contact port.
240 V
(Helpful Tip: If the line voltage falls in the middle of two listed voltages, pin to the lower voltage)
66
To complete the installation you will need to connect all of the electrical cables in the following manner:
1.
Locate the Cat. 5 cable which can be found on the floor of the Collator section near the front table of the
FlowMaster RS, route it under the lower frame section of the front table and plug it into the Variable Frequency
Drive Box located at the center of the front table floor, see figure 12-3.
Gently push in the male
Cat 5 connection plug into
the female receptacle until
it spans into place
(Fig. 12-3)
2.
Locate the round female 110 VAC cable which can be found on the floor of the Collator section near the front
table, route it under the lower frame of the front table and plug it into the male receptacle of the front table
electrical box, see figure 12-4.
Push in the female plug into
the male receptacle and turn it
in a clock-wise direction to lock
into place.
(Fig. 12-4)
67
3.
Locate the square 15 pin connector plug of the safety interlock harness which can be found on the floor of the
Collator section near the front table, route it under the lower frame of the front table and connect it to the square
15 pin plug found in the grey wire-way next to the Variable Frequency Drive, see figure 12-5.
Press the square 15 pin connector into the
matching receptacle until the retaining clips
on the side of the plug locks into place.
(Fig. 12-5)
4.
Locate the square female 240 VAC cable which can be found on the floor of the Collator section near the front
table, route it under the lower frame of the front table and plug it into the male receptacle of the Variable
Frequency Drive box, see figure 12-6.
Press the square 240 VAC connector into
the matching receptacle to seat it firmly in
place.
(Fig. 12-6)
68
5.
Locate the Encoder cable, which can be found on the floor of the front table, route it to the right of the up-right
center frame section then under the upper frame section of the front table and plug it into the encoder wire
harness found secured to the inside back-frame section of the Collator, see figure 12-7.
View of Back-Frame section
under the pusher assembly
6.
(Fig. 12-7)
Locate the 24-volt mocon signal cable, found on the floor of the right side of the front table, pass this cable
through the center frame section of the front table and plug it into the matching receptacle located on the front of
the air leg, see figure 12-8.
View from the
front table
service doors
Press the 24-volt mocon single plug into
the receptacle on the front of the airleg
until the retaining clips lock into place.
(Fig. 12-8)
69
Move to the area between the front table and the turnover and continue the following:
6.
Loosen all the retaining rings on the strain relief’s located at the exit end of the front table and pull all cables out of
the front table approximately 2 ½ to 3 feet then re-tighten the retaining rings, see figure 12-9. ( ! Caution:
Cables should come through easily. If they Do Not, open front table service doors and free cables from snag or
obstruction)
Turn retaining ring counter clockwise
to loosen, clockwise to tighten
Gently pull the cables
through the strain relief’s.
( ! Caution: Cables
should come through easily.
If they Do Not, open front
table service doors and free
cables from snag or
obstruction)
(Fig. 12-9)
7.
Connect the cables to the matching receptacle on the entry end of the turnover, see figure 12-10.
(Fig. 12-10)
70
8.
Route the Fiber Optic Cable from the main electrical box to the Servo Drive Box. ( ! Caution: Handle the Fiber
Optic Cable with extreme care. Scraping, stretching or kinking the fiber optic cable may cause damage to the
cable and render it inoperative.) Connect the Fiber Optic cable to the primary servo drive, see figure 12-11.
Holding the fiber optic cable
plug connector by the plug
handle, insert it into the servo
drive
Route the Fiber Optic Cable
from the main electrical box
to the Servo Drive Box
(Fig. 12-11)
71
Section - XIII
General Job Set-Up
72
Homing & Timing
the
FlowMaster RS Inserter
73
Homing the FlowMaster RS inserter
Once the assembly of the FlowMaster is complete, time the machine by performing the following:
1. Turn the machine power on by placing the main power switch in the up position.
2. Once the machine has booted up, press the Servo Menu button located in the upper right hand corner of the
operators run screen, see figure 13-1. (Note: For menu selection for all FlowMaster models see pages 79
through 82.)
Press this button to open the
“Home Servo” feature
(Fig. 13-1)
2. Once the Servo Menu has been opened, a single or multiple timing selection, depending on the model FlowMaster
you have, will appear, see figures 13-6 through 13-9.
3. Select the Pusher configuration and Pin spacing you plan to run the machine in and depress the “Home Servo’s”
button. (When the Home Servo’s is engaged, the selected button you pushed will light up) (To change Pusher
Finger configuration, see Pusher Finger Configuration, page 154 through 157.)
74
4. Press the “Blue Start” button and the “Green Run” button, located on the collator console, at the same time. (The
machine will advance at jog speed in stages, first the envelope gripper jaw chain will advance to the *“Home”
position, then the collator track pins will move until the pass a recognition sensor, then the pusher fingers will move
until they pass a recognition sensor and then the collator track pins and the pusher fingers will move in unison.)
The machine is now timed.
(Note: The “Home” position is an encoder reference position designated by the number located below the Homing
Selection in the Homing menu. This number value can be changed by pressing the number, a numeric touch pad
will appear, entering a new number value and pressing the return arrow to enter the new number value. The
electronic events taking place are as follows, when the envelope gripper jaw chain stops at the Home position, the
PLC sends a signal through an output module via a fiber optic cable to the primary servo drive labeled “Servo 1”.
Servo 1 then begins running the homing program which triggers Servo 2 to run the collator track pins first followed
by the pusher fingers and finally both. It should be noted that his program is embedded in the servo drive and can
not be altered.)
5. Check the timing references of the FlowMaster RS inserter to ensure that the Homing program ran completely and
accurately. To check the timing references perform the following:
(A)
Jog the envelope gripper chain to the full stop mark, jog the machine until the envelope gripper
opens, continue jogging until the gripper jaw closes completely, then STOP. In this position you
should see one of the pusher finger shafts at the “Three O’clock” position on the drive shaft
sprocket, see figure 13-2. The timing reference between the pusher fingers and the envelope
gripper jaw ensures that the pusher finger has completed it’s stoke before the gripper has
completed closed. (Note: In this position you can also check the reference encoder in the timing
menu. If the encoder has been properly set it should read 45 degrees plus or minus 5 degrees.)
Pusher shaft and lug
at the 3 O’clock
position to the drive
sprocket
Inside of the Gripper
jaw aligned with the
full stop mark
Full Stop Mark
(This is a factory applied machine index mark)
(Fig. 13-2)
75
(B) Jog the FlowMaster RS inserter until one of the pusher finger shafts completes the return cycle and
begins the forward stroke along the insert deck. Stop the jogging when the clamp seam of the pusher
fingers aligns with the left end of one of the insert deck grooves, see figure 13-3. In this position you
should see one set of collator track pins with the back side of the pin aligned with the front of the pusher
finger. This timing reference ensures that the pusher fingers have settled behind the collated material in
time to capture it before the collator track pins drop below the surface of the insert deck.
Back of Collator track pins even with the
front of the pusher finger
Pusher finger clamp seam
aligned with left end of insert
deck groove
(Fig. 13-3)
(Special Note: Should one of the jam sensors become blocked during the Homing process, the Homing program may be
aborted. If this happens, clear the obstructed sensor and re-home the machine.)
It is critical for these timing references to be maintained for consistent high speed inserting. If your machine does not
reflect these basic timing references adjustments can be made to restore them.
76
In the event the timing references need to be adjusted perform the following:
1. Re-home the machine to ensure the Homing program ran in its entirety and check the timing references again
before making any adjustments. If you find that one or more of the timing references are out continue with the
following:
To adjust the Pusher Finger timing:
(A)
Open the “Homing” menu on the operator’s run screen.
(B)
(C)
(D)
Press the number located at the bottom of the menu to engage a numeric touch pad, see figure 13-4.
Enter a new “Homing Position” number then press the “Enter” button to initiate the new setting.
(Note: To retard the timing of the pusher finger to the envelope gripper jaw, enter a higher number.
To advance the timing of the pusher finger to the envelope gripper jaw, enter a lower number.)
Re-home the machine for the change to take effect then re-check the timing reference.
Press the current Homing number to
open the numeric touch pad
x
150
150
7
8
9
AC
4
5
6
Del
1
2
3
+ /-
0
Enter
Using the numeric touch pad enter a
new Homing number then press the
enter button to initiate the new
setting
(Fig. 13-4)
77
To adjust the collator track pin timing:
(A) Remove the side cover located below the pusher finger assembly.
(B) Loosen the thumb lock screw of the collator track pin recognizing sensor, located on the inside frame, by
turning it in a counter clock-wise direction, see figure 13-5.
(C) Slide the sensor along the inside frame and secure it in a new position by turning the thumb lock screw in a
clock-wise direction. ( ! Caution: Do not over tighten the thumb lock screw)
(D) Relocate the opposing sensor located on the other inside frame section in the same manner. (Note: these
are reciprocating sensors make sure they are aligned with one another.) (Helpful Tip: Relocate the sensors a
distance equal to the distance you want the collator track pins to move. To advance the collator track pin
timing, move the sensors to the left. To retard the collator track pin timing, move the sensors to the right.)
Move Sensors to Left to
Advance Pin position
Move Sensors to Right
to Retard Pin position
Relocate the opposing sensor
in the same manner
Loosen the thumb screw
to relocate the sensor
(Fig. 13-5)
78
Servo Menu for Standard
FlowMaster LS
A
B
150
(Fig. 13-6)
Reference
Letter
A
B
Feature
Home Servo's
to designated pusher
configuration and pin
spacing
Homing Position
Function
Setting
Type
Automatically advances the
Touch Screen Button
Gripper jaws, Pusher fingers and
Collator Track Pins to the correct
timing position
Encoder reference set for
Encoder Setting
homing position
79
FlowMaster LS 12000 XL
A
B
150
(Fig. 13-7)
Reference
Letter
A
B
Feature
Home Servo's
spacing
Homing Position
Function
Setting
Type
Touch Screen Button
timing position
Encoder Setting
homing position
80
Servo Menu for the
FlowMaster RS 6X9
A
B
150
(Fig. 13-8)
Reference
Letter
A
B
Feature
Home Servo's
spacing
Homing Position
Function
Setting
Type
Touch Screen Button
timing position
Encoder Setting
homing position
81
Servo Menu for the
FlowMaster RS XL
A
B
150
(Fig. 13-9)
Reference
Letter
A
B
Feature
Home Servo's
spacing
Homing Position
Function
Setting
Type
Touch Screen Button
timing position
Encoder Setting
homing position
82
Lifting the Over Head Vacuum Assist
for
General Job Set Up
83
While continuing the job set up there will be various times that you wish to lift the Over Head Vacuum Assist Envelope
Opener assembly for greater access when positioning the Envelope Entry Fingers, changing the Insert Air Plate or
changing the pusher configuration. To lift the Over Head Vacuum Assist Envelope Opener, perform the following:
1. Manually lift the clear lexan cover up and towards the front table. This cover has a gas piston operating near the
cover hinge and will automatically hold this cover open when fully extended.
2. Manually pivot the Over Head Vacuum Assist Envelope Opener up and back towards the feeders, see figure
13-10. ( ! Caution: This device has a gravity operated position lock, visually check to see that it has fallen into
place before releasing the Over Head Vacuum Assist Envelope Opener assembly.)
Manually pivot the Over Head
Vacuum Assist Envelope
Opener up and back towards
the feeders
Make sure the gravity lock is in place
before releasing the assembly
(Fig. 13-10)
84
3. To return the Over Head Vacuum Assist Envelope Opener assembly to the operating position, lift up on the
assembly, manually pull back and up on the gravity lock and gently pivot the assembly down to the normal
operating position, see figure 13-11.
Gently lower the assembly
back to the operating
position
Lift the gravity lock and hold it
out of the way while lowering
the assembly
(Fig. 13-11)
85
Insert Air Plate
86
Insert Air Plate Set Up
The FlowMaster RS comes equipped with eight (8) standard size Insert Air Plates. The insert air plate works with
compressed air in synchronized time with two vacuum plates to form and open an envelope to the natural contour of the
throat without distortion, allowing for smooth insertion at any speed. The correct size insert air plate to use should
measure ¾” to 1” less in width at the front edge of the plate, than the inside width of the envelope, see figure 13-12. This
rule should be observed at all times for optimal inserting at any speed. (Note: If you match the envelope to the same size
insert air plate you will not be able to obtain consistent inserting at any speed.)
(Fig. 13-12)
The overall width of the insert air plate must
be ¾” to 1” LESS than the overall width of
the envelope you are running
87
Phillips head screw locations
Insert Air Plate Orifices
Front view of Insert Air Plate
Showing air orifice
(Staged)
(Fig. 13-13)
88
(Fig. 13-14)
18005-047
18005-046
18005-045
18005-042
18005-044
18005-012
18005-043
18005-048
89
Change the insert air plate at the insert deck to properly fit the size of
the envelope being used by:
1.
Jog the machine until the insert pusher fingers and the envelope entry fingers are in the back position.
2.
Note the position of the insert entry fingers leading edge, in relationship to the front edge of the insert air plate.
The leading edge of the entry fingers should be even with the front edge of the insert air plate. (You will need to
return them to this position as soon as the selected insert air plate is in place) Loosen the lock knobs of the insert
guide fingers, swing the insert finger arms up off of the insert air plate and set the lock knobs to temporarily
secure them in this position.
3.
Remove the two (2) button head Allen screws that hold the material side guides to the base of the insert air plate,
see figure 13-15. Following the material side guides towards the collator section of the machine you will find two
(2) more button head Allen screws. These do not need to be removed, but they do need to be loosened. (This will
provide enough play to remove the insert air plate as described in step “5”)
(Fig. 13-15)
Using a 1/8 Allen wrench,
remove the button head Allen
screws from the ends of the
material track guide rails
90
4.
Remove the four (4) Phillips head screws from the base of the insert air plate, see figure 13-16.
(Fig. 13-16)
Remove the four (4)
Philips head screws
shown to remove the
insert air plate
Note: View of this Philips head screw is obscured by the
over head vacuum assist envelope opener
5.
Lift up the front edge closest to the envelope chain, then pull the plate towards the envelope chain to remove it,
see figure 13-17.
(Fig. 13-17)
Lift the edge of the insert air plate up then
pull out over the top of the front table
91
6.
Holding the desired insert air plate by the front edge, set the base of the plate onto the insert deck, gently lower
the front edge of the plate into place, see figure 13-18. ( ! Caution: The top surface of the insert air plate must
be .025” above the top surface of the front table, make sure there is no dirt or debris in the manifold relief that the
insert air plate sets into before installing a different air plate. Avoid setting the insert air plate on top of the Insert
Hold Down Drag Straps)
Visually inspect the manifold
for dirt and debris
Holding the insert air plate by the front edge, slide
it back into the manifold
(Fig. 13-18)
7.
Secure the insert air plate to the insert deck using the four (4) Phillips head screws, set the screws flush with the
surface of the plate and tighten moderately. ( ! Caution: Do not over tighten)
8.
Reposition the material side guides to accommodate the width of the largest piece to be inserted.
9.
Return the envelope entry fingers to their original position as noted in step 2.
(Note: All Insert Air Plates are the same length, however the widths are different. If a narrower insert air plate is
now in use, make sure the outer entry fingers are supported on the plate.)
92
Insert Air Pressure Setting:
The amount of air pressure emitted through the insert air plate may need to be adjusted to accommodate the envelope
and insert stock you’re using. Most materials will run smoothly with a setting between 3 to 5 PSI. The objective here is to
open the envelope without distortion and insert the material without loss of control. (Note: Changing the air pressure
setting will only effect the insert air, it will not effect the envelope vacuum ports in front of the insert air plate. The timing
setting is common to both as stated in Section XVII, page 212.)
To adjust the air pressure setting:
1. Gently push down on the red retaining ring on the control knob located on the collator cabinet between the insert
box cam and the envelope feed conveyor see figure 13-19.
Insert Air Pressure
Control Knob
Air Pressure Gauge
Turn knob counter clockwise to
increase air pressure, clockwise to
decrease air pressure
(Fig. 13-19)
2. To increase the air pressure, turn the knob counter clockwise.
3. To decrease the air pressure, turn the knob clockwise.
4. Once the air pressure has been set, lift the red retaining ring up until it snaps into he lock position.
(Note: Setting the air pressure too high may result in a loss of control of insert material at the point of envelope entry.
See item #2, figure 13-20, page 94, showing the direction and path the air follows from the insert air plate.)
93
(Fig. 13-20)
1
2
4
3
2
2
6
9
8
7
1 - Insert Entry Finger Assembly
2 – Direction of Air Flow
3 – Cut Away Side View of Envelope
4 – Insert Material
5 – Insert Pusher Finger
6 – Insert Air Plate
7 – Static Flap Brush
8 – Cut Away Side View of Envelope
Chain Track
9 – Stationary Vacuum Port
94
Envelope Set Up
95
Envelope Settings:
From the Run Menu:
Set the envelope options:
1.
Press the Envelope Menu button to bring up the menu window.
2.
Press “Envelope On” button. This will engage the continuous envelope feed conveyor and activate the envelope
hopper and shuttle vacuum, see figure 13-21.
3.
Set the “Water Time” by pressing the “Number Area” located under “Water Time” on the envelope menu. This will
bring up a numeric touch pad, enter the water time setting and press the return arrow to close the touch pad
window. The time will now be displayed in the envelope menu. See figure 13-21. (Helpful Tip: Most envelopes
manufactured in the United States, seal well with the water time set at “01” or “02”)
(Note: Each number increment equals 10 milliseconds of real time. This regulates the amount of time the water
solenoid is open to feed water, through the valve, to the flap moistener brush)
4.
To set the envelope flap detector see, Section XVII, Electronic Timing Settings, page 216.
Envelope Menu
Press the ENV ON /
OFF button until it reads
ENV ON,
Press the “Number”
under Water Time to
change the duration
AUTO
MODE
ENV
OFF
WATER
TIME
02
ENV ASSIST
TIMING
MENU
CONTINUE
TRYING
Jog
MISS
315
Missed flap
Position
20 # OF DIVERTS FOR STOP
DIVERT MISS ONLY
DIVERT
FLAP
(Fig. 13-21)
96
Helpful Tip: If the water time is set at 01 and less water is required, turn down the water tank air pressure at the pressure
gauge, see figure 18-22. Alter air pressure by:
1. Gently pull up on the control knob to unlock it.
2. To increase the air pressure, turn the knob clockwise.
3. To decrease the air pressure, turn the knob counter clockwise.
4. Once the air pressure has been set, push the control knob back down to lock it.
Water volume can be further decreased by turning the flow valve in a clockwise direction, see figure 9-4, page 56, to limit
the water flow in the line.
Turn know counter clockwise to
increase air pressure, clockwise to
decrease
(Fig. 13-22)
97
Setting Options in the Envelope Menu Window:
The FlowMaster RS is programmed with two distinct options that deal with, missed envelopes. The first is the “Jog Miss /
Miss Stop” option that was primarily designed to be used with good envelope stock. The second is the “Continue Trying”
option that was designed to be used with envelope stock that is in less than optimum condition.
Jog Miss / Miss Stop Button
“Jog Miss”
When a missed envelope flap is detected, this feature will allow the machine to continue to run at
jog speed until it reaches a predetermined position. The ideal position for the machine to stop is
when the material being inserted is in front of the insert air plate, providing access for easy
removal, see figure 13-23.
Envelope Menu
ENV
OFF
AUTO
MODE
WATER
TIME
02
Each time this button is
pressed it will change
between “Jog Miss” and
“Miss Stop”
Jog
MISS
315
Missed flap
Position
DIVERT
FLAP
ENV ASSIST
TIMING
MENU
CONTINUE
TRYING
DIVERT MISS ONLY
(Fig. 13-23)
“Miss Stop”
This will stop the machine when the material being inserted is still on the insert deck. This will
occur when an envelope flap is not detected. (i.e. envelope miss feeds or the flap
doesn’t open properly.) The operator is now required to lift the cover over the pusher
fingers to remove the material manually from the insert deck or replace the missing or defective
envelope.
98
“Continue Trying”
To use this feature press the button, the button will light up indicating that the feature is engaged,
see figure 13-24. This feature will allow the front table to continue cycling two more times in an
attempt to pull an envelope while suspending all activity on the rest of the machine. If after two
more attempts to pull an envelope fail, the machine will stop indicating a missed envelope. The
logic program in the machine has assumed that the envelope at the vacuum shuttle is damaged
requiring operator intervention to correct it. When using this feature the machine speed must be
set no higher than 10,000 per hour. The reason for the speed reduction is this, the feature was
installed for the purpose of running curled or bent envelopes that tend to be difficult to run.
Lowering the speed gives the vacuum plate in the envelope shuttle more time to acquire each
envelope. The pusher assembly is driven by a servo motor. This motor will stop while the front
table attempts to pull an envelope, when the envelope is pulled the motor will resume running at
the speed set in the operator’s run screen. If the speed is set higher than 10,000 per hour, the
impact to the motor starting at the higher speed may cause the motor to exceed the torque
limitation set in the servo drive and error out the motor. The “Cascade” feature found in feeder #1
must be turned “OFF” to prevent a conflict in logic when using this feature.
Envelope Menu
This button will light up
when the feature is
engaged. (Reminder:
The machine speed
must be set to 10,000 or
less. The “Cascade”
feature in feeder #1
must be turned OFF.)
ENV
OFF
AUTO
MODE
WATER
TIME
02
Jog
MISS
315
Missed flap
Position
DIVERT
FLAP
(Fig. 13-24)
99
ENV ASSIST
TIMING
MENU
CONTINUE
TRYING
DIVERT MISS ONLY
Divert On/Off Button
“Divert Miss Only”
This feature allows the machine to continue to run the material group containing an
“Divert Double Only”
incomplete collated set or a set containing a double without disrupting the integrity of the other
“Divert Miss & Double” material groups in the material track or stopping the machine, see figure 13-25. When a feed
error is detected at a material feeder, a signal is simultaneously sent to the remaining feeders in
sequence, disabling the impulse to feed into the collated set where the error occurred. The
collated set containing the error will be inserted into a envelope and passed “Unsealed” through
the turnover to the Diverter where it will be automatically taken out of the mail stream.
(Note: You must have a Diverter installed in your system before this feature will work)
(Fig. 13-25)
Envelope Menu
ENV
OFF
AUTO
MODE
WATER
TIME
02
Jog
MISS
315
Missed flap
Position
DIVERT
FLAP
ENV ASSIST
TIMING
MENU
CONTINUE
TRYING
Press once to “Divert
Miss Only”. Press twice
to “Divert Doubles”
Only”. Press a third time
to “Divert Miss &
Doubles”.
DIVERT MISS ONLY
Press the number, a numeric touch pad will appear. Set the number of diverts
you wish to run before stopping the machine to make corrections on the feeder
set up causing the errors. The number range is from 1 to 999. (Reminder: Don’t
enter any number higher than the amount of envelopes you wish to correct.)
100
Envelope Feed Hopper Set Up:
1.
Press the Envelope Menu button on the operators run screen, then press the “Auto Mode / Setup Mode” button to
read “Set-Up Mode”, see figure 13-26. This feature will allow the envelopes to run without the material feeders
engaged. (Note: Do not leave the Set-Up Mode on while running a job. The Set-Up Mode by design will disable
the Envelope Detect Sensor. If the Envelope Detect Sensor does not register the presence of an envelope, the
CPU will not send a pulse to activate the water solenoid. Running a job in “Set-Up Mode” will result in unsealed
envelopes.)
Press button until it
reads “Set-Up Mode”
ENV
OFF
AUTO
MODE
WATER
TIME
02
MISS
STOP
315
Missed flap
Position
ENV ASSIST
TIMING
MENU
CONTINUE
TRYING
DIVERT
FLAP
DIVERT MISS ONLY
Envelope Menu
(Fig. 13-26)
101
2.
Standing in front of the “Front Table”, loosen the lock knobs that secure the envelope hopper side guide and
guide rail to the top of the “Front Table”, loosen the lock knobs that secure the envelope hopper back plat as well.
3.
Place an envelope into the envelope feed hopper, holding the bottom edge of the envelope flush against the
inside surface of the envelope guide rail of the envelope feed hopper, see figure 13-27.
4.
Move the envelop guide rail and sample envelope until the flap edge of the envelope is approximately 1/8” from
touching the stationary guide fingers of the envelope in-feed conveyor.
Set the envelope guide rail to provide
an 1/8” gap between the top of the
envelope and the guide fingers of the
envelope in-feed conveyor
Loosen lock knob to
adjust the envelope
guide rail
(Fig. 13-27)
5.
Go to the exit end of the front table and place the same sample envelope in the envelope track with bottom edge
flush against the inside surface of the envelope guide rail, see figure 13-28.
6.
Move the envelop guide rail and sample envelope until the flap edge of the envelope is approximately 3/16” to ¼”
from touching the inside surface of the stationary flap closer guide.
Set the envelope guide rail
to provide a 3/16” to ¼”
gap between the top of the
envelope and the
stationary flap closer guide
(Fig. 13-28)
102
Place a moderate stack of envelopes into the envelope feed hopper.
8.
Set the trailing back plate of the envelope feed hopper to “just” touch the stack of envelopes in the envelope
hopper, secure the adjustment with the retaining lock knobs, see figure 13-29.
Turn the retaining lock
knobs counter clockwise to
loosen, clockwise to
tighten.
Position back plate to “Just”
touch the stack of envelopes
in the hopper
(Fig. 13-29)
7. Jog the machine to the position where the envelope feed shuttle has retracted completely into the envelope feed
hopper.(Commonly known as the “Full Back Position”) Position the “Envelope Jog Wedge” so that the thinnest
edge rest approximately 1/8 under the envelope stack, see figure 13-30.
8. Adjust the height of the feed gate by turning the adjustment knob located on the top of the assembly, allowing free
passage of only one (1) envelope under the feed gate. (Note: Turning the adjustment knob clockwise will lower
the feed gate, turning the adjustment knob counter-clock wise will raise the feed gate. See figure 13-30.)
103
Adjust the separator gate by turning the
adjustment knob clockwise to lower the
gate, counter clockwise to raise it.
(View of Envelope Jog Wedge looking through the
envelope guide rail)
Position the jog wedge 1/8” under the envelope
stack with the envelope shuttle in the “Full Back
Position”
(Fig. 13-30)
104
Settings to Open the Envelope Flap:
The envelope opening features of the FlowMaster are made up of three different assemblies that work, in conjunction with
each other. The first is the Pre-Open Flex Guide. The flex guide starts the flap to lift by bending the top edge of the
envelope slightly below the surface of the envelope track. The second is the Envelope Wheel Opener Assembly. The
wheel opener allows for the continuation of flap lift, to a near vertical position, before passing under the Opener Plow.
The plow then forms the lifted flap into an open position and guides it under the insert air plate.
1.
Jog the machine forward until an envelope is fed into the gripper jaw and begins to move from the envelope feed
hopper. Stop the envelope when the leading upper left-hand corner is under the envelope pre-open flex bar, as
shown in figure 13-31.
Loosen screw located under
the front table jam detect
sensor to adjust the Pre-Flex
envelope opener bar
Manually adjust the position of the pre-flex bar and tighten the
retaining screw located under the front table jam detect sensor
(Fig. 13-31)
2.
Using a 5/32 Allen wrench, loosen the retaining screw located under the front table jam detect sensor, adjust the
envelope pre-flex bar , until the flap edge is slightly bent just below the surface of the envelope track and tighten
the retaining screw, see figure 13-31.
105
3.
Continue to slowly jog the envelope forward until the lead edge of the envelope approaches the “Opener Plow”.
The flap of the envelope should be raised enough so the opener plow can pass under it. The contour edge of the
plow will then finish opening the envelope as it passes under it and guide the flap under the insert air plate.
(Special Note: Some FlowMaster inserters have an optional “Over Head Vacuum Assist Envelope Opening
device on them. If the machine you are setting up has such a device it will be necessary to move it up and out of
the way. To accomplish this please see page .)
Adjust the position of the plow by:
A.
Using a 5/32 Allen wrench, loosen the two (2) socket head Allen screws holding the clamp on the
mounting bar for the plow, see figure 13-32.
B.
Change the position of the plow by sliding the clamp along the adjustment slots in the mounting bar.
When the plow is positioned as described in step 3, tighten the socket head Allen screws.
( ! Caution: When positioning the plow, be sure to leave enough clearance for the envelope gripper jaw
to pass.)
Adjust the opener plow for the style and size
of the envelope you are running by sliding it
back and forth along the adjustment slots in
the mount bar
Using a 5/32 Allen wrench, loosen
the retaining screws to adjust the
envelope opener plow
(Fig. 13-32)
106
5.
Continue to jog the envelope forward until it approaches the insert air plate, the curved “Flap Guide” should allow
the flap to slide under the insert air plate without creasing the flap. Adjust the position of the guide by:
A.
Using a 9/64 Allen wrench, loosen the two (2) socket head Allen screws holding the rod clamp on the
trailing end of plow, see figure 13-33.
B.
Extend or retract the rod as needed to provide guidance up to the insert air plate.
(Note: Do not extend the flap guide rod so far that it is under the insert air plate, see figure 13-33.)
C.
Rotate the guide until the end curves down just below the level of the bottom side of the insert air plate.
When properly adjusted, the guide should not touch the envelope flap when the envelope is in the stop
position at the insert air plate. (Helpful Tip: There are different guide groves in the flap plow and different
length of guides. Choose the guide length and placement that best accommodates the flap style you are
using, see figure )
Secure the adjustment using the two (2) socket head Allen screws, see figure
D.
(Fig. 13-33)
Extend the guide rod
up to the insert air
plate but never under
the insert air plate
Turn the socket
head screws counter
clockwise to loosen,
clockwise to tighten
107
Front Table Set Up
108
Front Table:
Setting the Front Table Position:
In order to obtain smooth and consistent inserting, it is important to have the envelope centered properly in relationship to
the insert air plate. The front table is designed to allow movement of the envelope feed hopper and envelope track and
can be repositioned to achieve this.
1. Place an envelope flush into an envelope gripper jaw at the envelope feed hopper.
2. Jog the machine forward until the lead edge of the envelope advances to the “Full Stop” mark in front of the
insert air plate, see figure 13-34.
(Note: The envelope chain should be stopped when forward movement has ceased and the gripper jaw is
still closed.)
3. Remove the envelope from the gripper jaw and fold it in half to establish a center crease, then return the creased
envelope back inside the gripper jaw, see figure 13-34.
(Fig. 13-34)
Lead edge of the envelope
shown at the “Full Stop”
mark
Center crease in envelope
shown aligned with the center of
109
4. To align the insert air plate with the envelope, go to the Run Menu:
A.
Press the “Front Table” button to bring up the Front Table menu, see figure 13-35.
B.
Select the type of movement, “Constant” or “Increment” (In the “Constant” mode the table will move
continuously until the movement is stopped by the operator pressing the direction button a second time or
the full range of motion is reached. The “Increment” mode will move the table 1/16” each time the
direction button is pressed)
E.
Press the right or left direction arrow buttons to move the Front Table and position the center of the
envelope throat to the center of the insert air plate.
Press the center button to
select between incremental
and constant motion
FRONT TABLE
ADJUSTMENT
CONSTANT
Press directional arrows for the direction you wish to move the front table
(Fig. 13-35)
110
There are two Envelope Insert Vacuum plates located on the front table between the insert air plate and the envelope
gripper jaw chain. One vacuum plate is stationary and contains only one (1) vacuum dish, which is always open. This
plate is positioned so that the leading edge of an envelope will be over the vacuum dish when the envelope chain stops.
(Providing the envelope gripper chain is in time with the front table) The other vacuum plate contains three (3 to 5)
vacuum dishes and is designed to be adjusted to the trailing edge of an envelope. Together, these two plates hold the
face of the envelope while the insert air plate directs air into the envelope, forming the envelope open for inserting.
5.
Set the “Envelope Insert Vacuum Plate” by:
A.
Jog the machine forward until an envelope stops in front of the insert air plate with the leading edge even
with the “Full Stop” mark, see figure 13-36.
Lead edge of the envelope is
at the “Full Stop” mark
(Fig. 13-36)
111
B.
Observe the location of the vacuum dishes in relationship to the trailing edge of the envelope. One of
these dishes needs be under the envelope approximately 1/8” from the trailing edge, see figure 13-37. If
this is already the case, skip to step “D” and proceed, if this is not the case, proceed with step “C”)
Actual location of the vacuum dishes under the envelope
The stationary vacuum dish
should automatically align to
1/8” from the lead edge of the
envelope
(Providing the gripper chain is
in time with the front table)
The adjustable vacuum
plate should have one of
the vacuum dishes located
1/8” from the trailing edge
of the envelope
(Fig. 13-37)
112
C.
Loosen the two (2) Phillips head screws, closest to the envelope chain, then slide the vacuum plate into
position so that one (1) of the vacuum ports is situated 1/8” under the envelope from the trailing edge, see
figure 13-38. ( ! Caution: Only loosen, removal these two (2) Phillips head screws could cause the
adjustment block to fall into the machine where damage may occur) Once the plate is in this position,
moderately tighten the two (2) Phillips head screws. ( ! Caution: Do not over tighten)
The vacuum plate has a 1” range of motion sliding parallel to the gripper chain
Loosen the two Philips
screws to adjust the position
of the vacuum plate
(Fig. 13-38)
113
D.
With the vacuum plate in position, open the selected vacuum port by:
(a) Insert a 5/64” Allen wrench into one of the three (3) port set screws, see figure 13-39.
(b) Turn the set screw in a clockwise direction until the head of the screw is below the bottom
surface of the vacuum plate. Then turn the set screws two (2) full turns more.
(c) Repeat steps (a) and (b) for the two (2) remaining set screws in the selected vacuum port.
(Note: Engage only one vacuum port on the adjustable plate at a time. Opening more that one
port may cause vacuum to bleed off)
Turn each of the set screws in the
dish clockwise to open, counter
clockwise to close
(Fig. 13-39)
114
Aligning the Envelope Entry Fingers
The envelope entry fingers are designed to enter the envelope before the insert material to prevent the insert material
from catching or snagging on the lifted edge of the open envelope. The air that is emitted from the insert air plate must
also be considered here. As the air enters the envelope to form it in an open position, it is deflected at the bottom inside
portion of the envelope and comes back out. (See item #2, figure 13-20, page 94, showing the path of the insert air) This
outward moving air can be disruptive to the insert material as it enters the envelope. It is extremely important to set the
insert air pressure and the envelope entry fingers properly for the material you are running. Because there are so many
different envelope styles and configurations, it is important to check the entry fingers at each set up and adjust them as
needed.
Align the insert entry fingers, to the envelope in the following manner:
1. Jog the machine forward until an envelope has been fed and is in the full stop position in front of the insert air plate.
2. Loosen the ratchet handles, located at the top of each entry finger arm, see figure 13-40.
Turn the Ratchet Handle
counter clockwise to
loosen, clockwise to
tighten.
( ! Caution: Do not
over tighten. Over
tightening may cause
damage.)
Using a 5/32” Allen
wrench, turn the
retaining screw counter
clockwise to loosen,
clockwise to tighten.
(Fig. 13-40)
115
3. Position the side entry fingers to enter the envelope just inside each end of the envelope. The side edges of the
material should be completely contained under the entry fingers, see figure 13-41. Tighten the lock knobs of the side
entry fingers.
(Note: Movement of the entry fingers should be from side to side or parallel with the control shaft they are mounted to.
Do not move the entry fingers into the envelope at this time. Movement towards or away from the envelope will be
accomplished when the timing of the entry fingers is set.)
4. Position the center entry fingers to enter the envelope where they best control the leading edge of the inserts. Tighten
the lock knobs of the center entry fingers, see figure 13-41.
(Helpful Tip: For diagonal seam envelopes, place the center entry fingers to enter the envelope at the top of each
seam. For end seam envelopes, place the center entry fingers near the lowest point of the envelope throat.)
( ! Caution: Be sure the envelope entry fingers have sufficient clearance to allow the insert pusher fingers to pass
between them.)
(Fig. 13-41)
Position the entry to completely
contain the side edges of the material
½”
Adjust the timing cam of the entry
fingers so they enter the envelope ½”
ahead of the material
Position the entry fingers in the throat of
the envelope where they will best control
the lead edge of the material
5. Check the insert material with the entry fingers for downward pressure. If the material curls up while going under the
entry fingers, the pressure is too sever, adjust the pressure using the socket head screw located on the side of the
entry finger block, see figure.13-40, page 115.
6. Place a complete set of collated material to be inserted into the envelope in the material track in front of feeder
number 6.
116
7. Jog the machine forward until the material is ½” from the throat of the envelope. In this position you should see the
insert entry fingers inside the throat of the envelope. If not, adjust the timing cam located between the box cam
assembly and the envelope in-feed conveyor, see figure 13-42.
Using a 1/8” T-Handle Allen wrench, loosen both set screws in
the cam. Move the cam towards the front table to advance the
timing. Move the cam towards the feeders to retard the timing.
(Fig. 13-42)
(Note: The tips of the envelope entry fingers should be just entering the envelope ahead of the insert material. If they
are not entering the envelope ahead of the material, the timing must be re-set, see figure 13-42.
117
-
Material Track Set Up
118
Setting Up the Material Track
3. Loosen the retaining knobs located in the top track cover at the end of the machine, near feeder #1, that secure
both material side rails to the material pathway, see figure 13-43.
2.
Using the widest piece of material being used in the job, fold it in half to create a center crease, then unfold the
sample piece.
3.
Place the crease of the unfolded piece on the center of the screw head located in the middle track section of the
material path way, under feeder # 1, see figure 13-43.
4.
Position the side rails so the end edges of the unfolded piece is on top of the bottom surface of each side rail and
approximately 1/4” from the side surface of each rail, see figure 13-43.
5.
Tighten the retaining lock knobs to secure the side rail to the material path.
Top View of Collator under and behind feeder #1
(Fig. 13-43)
Position each side approximately ¼”
from the edge of the material
Line up the center crease in
the material with the center
screws in the track
Place letter on center track rail align
center screw with crease in paper
then move side guide approximately
¼ inch from edge of each material
side guide
Turn the retaining lock
knob counter clockwise
to loosen, clockwise to
tighten
119
6.
Open the cover over the insert pusher assembly and loosen the button head Allen screws near each end of both
box cams that secure both material side rails to the material path way and insert deck.
7.
Place the unfolded setup piece under the hold down drag straps and over the end of the insert deck and insert air
plate. Position the crease in the center of the setup piece on the center groove in the insert deck.
8.
Slide the side rails over to almost touch the end edges of the unfolded piece, see figure 13-44.
( ! Caution: Make sure the holds down straps are not under either side rail)
9.
Tighten the button head Allen screws to secure the side rails to the end of the insert deck near the insert air plate,
then tighten the screws at the exit end of the material path way near the insert deck.
(Fig. 13-44)
Slide the side rails over to almost
touch the end edges of the set
up material. Tighten button head
screws to secure this adjustment
120
Setting Material Pusher Pins
The FlowMaster inserter is equipped with four (4) material belts, outer left, center left, center right and outer right. Each
belt has thirty-four (34) or more depending on the size of the FlowMaster RS that are aligned to form rows of pusher pins
in groups of four (4) to transport material in the pathway. These pins are pin set into a nylon block that is welded to the
material belt. In the event the material being setup fits an envelope measuring 4 3/4”X6 1/2”, it may be necessary to
disengage some of the material pusher pins on the material belts in the pathway, in order to narrow the material pathway.
Keep in mind that the FlowMaster RS is designed to run all material to the center of the material pathway. You may find
that the dimensions of the material seem to fit well after disengaging the material pusher pins from one of the material
belts, however it is vital to remove the pins from both of the outside material belts to maintain the center justification
required for smooth inserting. To remove the material pusher pins, perform the following:
A. Jog the machine forward until one (1) group of pusher pins is even with the Phillips head screws that secure the
material track sections to the material bed between the last feeder and the pusher assembly, as shown in
figure 13-45.
B. Lift the clear lexan cover. This will open a safety interlock circuit making it safe to interact with the material track belts
C. Using your finger, push the pusher pin to the right until it is below the surface of the material track rails, see
figure 13-45. Then jog the machine forward and repeat until all of the desired pins have been flipped down.
(Note: The position in which you flip the pusher pins is important, it places the pusher pins over a support bracket that the
material track sections and belt tracks are secured to and will eliminate unnecessary stress to the tracks and belts while
flipping the pusher pins.)
(Fig. 13-45)
Line up pusher pins with the center
screws in the material track rails between
the last feeder and the pusher assembly
Using your finger, push the pusher pins to the right until
they are below the surface of the material track rails
121
To return the pins to their up-right position, perform the following:
A. Jog the machine forward until one (1) group of pusher pins is even with the phillips head screws that secure the
material track sections to the material bed between the last feeder and the pusher assembly, as shown in figure 13-45.
B. Slid the eraser end of a pencil between the track rails just ahead of the pusher pin, move the pencil along the belt until
it engages the pusher pin, then flip the pusher pin to it’s original up-right position, see figure 13-47.
(Fig. 13-46)
Flip the Pusher Pin to the right until it is below the level of
the material track rail. (Tip: The eraser end of a pencil
works very nicely for getting the pins all the way down)
Material Track Rail
.
Pusher pin
mount block
Pusher Pin Belt
Flip the Pusher Pin to the left to bring it back to the
original up-right position. (Tip: The eraser end of a pencil
works very nicely for getting the pins above the track rail)
Material Track Rail
Pusher pin
mount block
.
Pusher Pin Belt
(Fig. 13-47)
(Note: The position in which you fold down the pusher pins is important, it places the pusher pins over a support bracket
that the material track sections and belt tracks are secured to and will eliminate unnecessary stress to the tracks while
removing or replacing the pusher pins.)
122
Setting Material Drag Straps
Depending on the characteristics of the material being run, it may be necessary to re-position the two (2) hold down drag
straps that control material in the material pathway between each of the feeders.
To do this:
(a)
Locate the hold down drag strap clamp on the same cross member of the feeder the
“Miss Sensor Emitter” is mounted to.
(b)
Loosen the lock knob on the clamp by turning it in a counter-clockwise direction.
(c)
Re-position each strap to gain optimum control of the material in the material pathway and tighten the
Lock knobs by turning them in a clockwise direction.
( ! Caution: Make sure the clamp is not pinching the lead wires to the emitter before tightening the
clamp. Make sure the hold down straps are positioned in-between or to the side of, the material pusher
pins in the material pathway, see figure 13-48.)
(Fig. 13-48)
Secure Drag Straps between
belts, on the lower bar.
! Caution:
! Caution:
Do Not place a drag strap in
the center of the feeder
lower bar. A drag strap in
this position will block the
“Collator Track Jam Sensor”
resulting in false jams.
Be careful not to pinch or
disrupt the electrical wire
when placing a drag strap
next to the emitter sensor
123
Friction Feeder Set Up
124
Setting Up the Material Friction Feeder Stations:
(The following instruction will accommodate friction feeders using rotating separator wheels or thin sheet separator gates)
From the Run Menu:
1.
Select the material feeder you wish to use by pressing the appropriate feeder button according to feeder number.
The setup menu, for the selected feeder will appear, see figure 13-49. (Tip: If using a window envelope, the
addressed piece must be positioned to feed with the address side down. Feeder number one (1) is the preferred
feeder to use for pre-addressed inserts because of the “Cascade” feature. For details of this feature see figure 162, page 177. )
Feeder Select
Buttons
Press this button until
it reads “ON” to
engage the feeder
265
318
200
09
(Fig. 13-49)
2.
Press the On / Off button to engage the feeder, see figure 13-49.
125
Special Note: If you are setting up a FlowMaster RS “XL” friction feeder, (A feeder with two (2) elevator belts near the
back wedge) using material measuring less then 8-1/2” linear running length you should lower the elevator belts to avoid
damage to them or the back wedge. To adjust the height of the elevator belts perform the following:
3. Open the clear lexan cover located at the side of the feeder. This will open a safety interlock circuit making it safe
to interact with the feeder.
4. Turn the adjustment knob clockwise to lower the elevator belts, counter clockwise to raise them, see figure 13-50.
( ! Caution: To avoid damaging the elevator belts before running material measuring less than 8-1/2” linear
running length.)
Top view of adjustable elevator belts
! Caution:
Lower the elevator belts before adjusting the
back wedge when running material measuring
less than 8-1/2” linear running length.
Turn the adjustment knob
clockwise to lower the elevator
belts, counter clockwise to raise
(Fig. 13-50)
126
Go to the material feeder you selected:
3.
Center the material in the feeder by:
A. Fold one (1) piece of material in half to establish a center crease
B. Loosen the two knobs, found on each side guide clamp. (The lever style knob at the top of the clamp,
aligns the side guide vertically, the round style knob at the back of the clamp, aligns the side guide
horizontally, see figure 13-51.)
C. Place the creased piece on the feeder friction belts
D. Align the crease with the phillips head screws located in the center of the separator shroud, on the
separator wheels, see figure 13-51
E. Set the side guides of the feeder, to the width of the material to be run. Allow a little extra room so the
material can slide freely to the friction belts of the feeder. (Note: Be sure the material is centered in
relationship to the Separator Wheels)
The ratchet handle locks the side
guide vertically
Round style knob, locks the side guide
horizontally
Line up the center crease in the
paper with the Phillips head
screws in the separator shroud
(Fig. 13-51)
127
5. Set the height of the “Separator Wheel” to allow the thickness of one (1) piece of material to pass under it. To do this,
turn the adjustment knob clock wise to raise the wheel, counter clock wise to lower the wheel, see
figure 13-52. (Note: There should be a little resistance felt by hand, when the material is directly under the separator
wheels, when this is properly set)
(Helpful Tip: The thinner the material is, the more critical this setting is)
(Fig. 13-52)
Rotate the separator adjustment know
clockwise to raise and counterclockwise to lower
5. Set the “Wedge” under the material to obtain the proper stack angle for feeding, see figure 13-53. The
variables of this setting may be dependent on the characteristics of the material. A “Wedge Extension” can
be used when setting up narrow material. To use a wedge extension, simply snap the anchor slots on the base of the
extension to the base center rod on the wedge of the feeder. (Helpful Tip: The more the wedge is pushed under
the material, the less critical the separator wheel setting becomes. If the wedge is placed out from the material, the
separator wheel setting will become more critical)
(Fig. 13-53)
Slide the back wedge under the material to
obtain the best stack angle for the material you
are running
Loosen the retaining lock knob
to move the back wedge
128
7. Set the gap or nip of the “Ejector Rollers”. Turning the adjustment knob (See figure 13-54) clock wise and counter
clock wise will change the position of the “Upper” ejector only. Turn the upper ejector roller down until it just touches
the “Lower” ejector roller, this is the recommended setting for common use of letters or letter style materials. It may
become necessary to raise the upper ejector roller if staple bound booklets or similar types of materials are used.
(Note: Placing a single piece between the ejector rollers, you should feel a greater degree of resistance by hand, than
was previously noticed at the separator wheels)
Turn the eject roller adjustment
knob clockwise to raise, counter
clockwise to lower.
(Note: Different model feeders
may have a different style knob)
(Fig. 13-54)
8. Fill the feeder with material. The feeders are designed to hold a stack of material up to eighteen (18) inches,
depending on the characteristics of the material or a maximum weight of fifteen (15) pounds
Test this part of the set up by pressing the “One Shot” button, found on the feeder menu, see figure 16-2, page177 to
advance one piece at a time. Check the pieces as they feed to ensure proper separation. (Tip: If you are resetting a
feeder after the initial setup and a running speed has already been set, you may wish to check the feeder at the running
speed. To ramp up to running speed, press the “One Shot” button one time then press and hold down the Blue Start
button located on the collator cabinet for four (4) seconds. The feeder will advance to the set running speed of the
machine and will respond at that speed each time the “One Shot” button is pressed. If a safety interlock is open during
this time, the feeder will go back to responding at “Jog” speed when the “One Shot” button is pressed and it will be
necessary to ramp up the speed again.)
(Note: The “Continuous Cycle” option, shown in the “Feeder” menu, can be used by pressing the “Continuous Cycle”
button. This will allow the feeder to run continuously, at “Jog” speed, so the “Separator Wheels” can be fine tuned.)
129
10a.
Set the “Double Detector” by: Method One, Presence of a Double
A.
Pivot the digital display screen facing the feeder you are setting up. (Make sure the correct feeder menu
is displayed. See step 1, figure 13-49, page 125.)
B.
Press the “One Shot” button on the “Feeder Set Up” menu. This will allow one piece to feed out to the
ejector rollers.
(Note: It is very important to position the piece with its thickest part under the double detector roller. Shift
the piece by hand if needed in order to achieve this)
C.
Manually place a second piece of material under the double detector roller. Check the digital display if
the double indicator icon is lit, turn the detector adjustment knob in a clockwise direction until this icon is
no longer lit, see figure 13-55. (Note: Just because you may find the double detector icon lit, it can not be
assumed that it is set properly for the material you are about to run)
D.
Very slowly turn the adjustment knob in a counter clock wise direction until the “Double Icon” light goes
off, see figure 13-55. (Note: Each time the latch light comes on while making this setting, it must be reset
by pressing the “Reset” button in the feeder setup window. The latch light is a setup tool to be used when
setting the double detector. The actual doubled detector light is designed to operate at high speeds and
may flicker too fast for the human eye to see during some steps of the setup))
Turn the double detect knob clockwise to
raise the detector away from the
material, counter clockwise to lower the
detector onto the material
(Fig. 13-55)
E.
Verify the setting by pressing the “One Shot” button on the “Feeder Set Up” menu two (2) to three (3)
times. Watch for the latch light to come on and manually check the pieces fed to ensure that no
doubles are present. (Note: When properly set, the latch light should not come on)
(There is no miss detector to set; the FlowMaster is designed with an automatic miss sensor at ever
feeder)
130
10b.
Set the “Double Detector” by: Method Two, Absence of a Double
A.
is displayed. See step 1, figure 13-26, page 101.)
B.
Press the “One Shot” button on the “Feeder Set Up” menu. This will allow one piece to feed out to the
ejector rollers. (Note: It is very important to position the piece with its thickest part under the caliper
roller. Shift the piece by hand if needed in order to achieve this)
C.
Turn the detector adjustment knob in a counter clock wise direction until the “Double Icon” icon light
comes on, see figure 13-55. (Note: The latch light is a setup tool to be used when setting the double
detector. The actual doubled detector light is designed to operate at high speeds and may flicker too fast
for the human eye to see during some steps of the setup)
D.
Very slowly turn the adjustment knob in a clock wise direction until the “Double Icon” light goes off, see
figure 13-55. Continue to turn the adjustment knob another quarter turn when setting up a tri-fold
letter. (Helpful Tip: Turn the adjustment knob more than a quarter turn when setting up thicker material
and less than a quarter turn when setting up single sheet material)
E.
Verify the setting by pressing the “One Shot” button on the “Feeder Set Up” menu two (2) or three (3)
times. Watch for the latch light, when properly set, it should not come on and manually check the
pieces fed to ensure that no doubles are present.
(Set all additional material feed stations by repeating steps 1 through #10a - A through E or #10b - A through E of
the “Setting Up the Material Feeder Stations” section)
F.
When the set up is complete, exit the set up menu simply by pressing the upper right-hand corner of the
set up menu window. This will automatically return you to the “Run Menu”.
131
Rotary Feeder Set Up
132
Setting Up the Rotary Feeder
The Rotary Feeders are servo driven. These feeders have to be turned on in the operator’s run screen and feeder type
must read “Rotary” before the machined is “Homed”. If you were running a job without the use of a rotary feeder and then
want to use one for the next job, open the rotary feeder menu, turn on the feeder and “Re-Home” the machine, see figure
13-56.
(Fig. 13-56)
Press the desired feeder button to open the feeder menu
Press this button until
the word “Rotary”
appears before Homing
the machine
Press the Feeder “ON
/ OFF” button in the
feeder menu until it
lights up and the word
“ON” appears
ON
265
Rotary
318
200
09
Special Note
After turning the rotary feeder “ON” “Re-Home” the machine. To re-home the machine
see Section XIII, page 74 through page 82.
133
Set up the Rotary Feeder in the following manner:
1.
Acquire a sample of the material you are setting up and fold it in half to create a center crease.
2.
Un-fold the sample and place in the feeder. Align the center crease with the center of the middle vacuum cup,
see figure 13-57.
(Fig. 13-57)
Secure each of the side guides by
tightening the ratchet handle.
Turn clockwise to tighten, counter
clockwise to loosen.
Align the center crease with the
center of the vacuum cup.
(Vacuum cup is currently under
the sample piece and not visible
in this photograph.)
Set both side guides to 1/16” from
the side edge of the sample piece.
3.
Slide each of the side guides over until they are approximately 1/16” from the side edge of the sample piece.
4.
Secure the side guides by tightening the ratchet handle, see figure 13-57.
5.
Place a small stack of material into the feeder.
134
6.
Slide the back guide up the stack of material until it lightly touches the material, secure the back guide in
place by tightening the ratchet handle, see figure 13-58. (Note: If all the guides are positioned correctly, the
material should slide freely in the feeder.)
(Fig. 13-58)
Turn ratchet handle
clockwise to tighten,
counter clockwise to
loosen.
Slide the back guide
until it lightly touches
the material
7. Loosen the retaining knob on the deck plate and slide the deck plate under the stack of material until ½ to ¾ of
the stack is supported by the plate, see figure 13-59.
(Fig. 13-59)
Loosen retaining knob by turning it
counter clockwise, tighten by
turning it clockwise
Slide the deck plate ½ to
¾ under the stack to
support the material
135
7.
Dial in the separator pins in the front of the stack to provide support to the front of the stack of material,
see figure 13-60. (Note: There are additional separator pins located in the back guide and side guides of the
feeder that are very useful in gaining controlled support for a wide range of different paper stocks, see
figure 13-61.)
(Note: The amount of separator pins use is directly proportionate to the amount of deck plate placed under
the stack of material in step 7. A balance between the two must be established for smooth operation.)
Turn the front separator pins
clockwise to increase the
amount of pin under the material
stack, counter clockwise to
decrease the amount of pin
under the material stack.
(Fig. 13-60)
Front Separator Pins, Inside view
Additional Separator Pins located in the Back Guide
Additional Separator Pin located in each Side Guide
(Fig. 13-61)
136
8. Dial in the vacuum cup until it approximately 1/8” under the lead edge of the material stack, see figure 13-62. The
thumb screw adjustment is located in the front of the feeder, turn it clockwise to dial it further under the stack, turn
it counter clockwise to dial out away from the stack. (Note: The amount of vacuum cup used is proportionate to
the resistance in the material stack created by the deck plate and separator pins.)
Inside View of the Center Vacuum Cup
Turn thumb screw clockwise to
place the vacuum cup further
under the material stack, counter
clockwise to move the vacuum
out from the material stack.
(Fig. 13-62)
The Rotary feeder has a total of three vacuum cups located under the lead edge of the deck plate the outer vacuum cups
can be turned on or off through the feeder menu, see figure 13-63.
(Fig. 13-63)
265
Press the “Outer Vac” button to turn the outer
vacuum cups “ON” or “OFF”
318
200
09
137
9.
The vacuum cup has no height adjustment. If you need to alter the height relationship between the vacuum cup
and the material stack, turn the height adjustment knob located on the top of the feeder, see figure 13-64. This will
raise or lower the feeder assembly from the material deck up.
Turn the height adjustment
clockwise to raise the feeder
up, counter clockwise to lower
(Fig. 13-64)
10.
Press the “One Shot” button in the feeder menu to cycle the feeder. Visually check the separation of the material
from the bottom of the stack. In the event the feeder cycles too fast to see all the parts of the feeder moving in
unison, press the “Slow Cycle” button in the feeder menu, the feeder will now cycle at 20 percent of it’s normal jog
speed, see figure 13-65.
(Fig. 13-65)
265
Press the “Slow Cycle button until it lights up
and reads “SLOW CYCLE ON”
200
318
09
138
When the Rotary Feeder cycles you should see the following events take place:
¾
The vacuum cup engages, comes up acquires the bottom piece in the material stack.
¾
The vacuum cup draws the bottom piece in the material stack down past the separator pins at the same time the
mechanical separator feet come out from under the material stack.
¾
The mechanical separator feet return to their original position, under the material stack at the same time the
vacuum is released from the vacuum cup.
¾
The gripper jaws in the rotary drum close on the piece pulled by the vacuum cup.
¾
The rotary drum moves forward under the product sensor and double detector holding the piece “Staged” for the
following cycle.
In the event the vacuum does not engage soon enough to acquire the material, set the timing for the vacuum to come on
sooner by performing the following:
A.
Open the timing menu by pressing the “Timing” button on the operator’s run screen, see figure 13-66.
B.
Press the “Password” button located in the bottom left corner on the timing menu, a numeric touch pad will
appear.
C.
Enter the password “12006” and press the “Enter” key on the numeric touchpad. (If this was done correctly a
message will appear indicating successful password entry, if this message does not appear you will have to
enter the password again)
D.
Press the “Close” window button X located in the upper right hand corner of the successful password
enter message. The red “Factor Settings” button should now be visible in the lower left corner of the Timing
Menu.
E.
Press the “Factory Settings” button to open the factory settings menu, see figure 13-66.
F.
Press the “Servo Setup” button located in the lower left corner of the Factory Setting menu to op the Servo
Settings menu.
G.
All factory default settings are “0”, locate the feeder number reference for the feeder you wish to make a
change to, press the “0” in the “VAC ON REF. column for that feeder. A numeric touchpad will appear.
H.
Enter a negative number such as [- 1] and press the enter button on the numeric touch pad. The new number
value will now appear in the VAC ON REF. column, see figure 13-66. (Note: If you want to delay when the
vacuum comes on, enter a positive number [1]. It is not necessary to enter a (+) symbol to indicate a positive
number.)
I.
Press the “Close” window button X
return to the Factory Settings menu.
J.
Press the “Timing” menu button located in the lower right hand corner of the Factory Settings menu to return
to the Timing menu.
K.
Press the “Run Screen” button located in the lower right hand corner of the Timing menu to return to the
operator’s run screen.
located in the upper right hand corner of the Servo Settings menu to
139
Press the Timing
button to open the
timing Menu
Press the “Password”
button, a numeric touch
pad will open. Enter the
password “12006” and
the “Factory Settings”
Button will become
visible
x
150
Press the “Factory Setting”
button to open the Factory
Setting menu
FACTORY
SETTING
7
8
9
4
5
6
Del
1
2
3
+ /-
0
AC
Enter
Press the “Servo
Set Up” button to
open the Servo
Set Up menu
Press the number value in the
“VAC ON REF.” column next to
the feeder number of the feeder
you wish to adjust, a numeric
touch pad will appear. Enter a
negative (-) number value if you
want to trigger the vacuum cups
sooner that the Factory Settings
provided for, enter a positive (+)
number value, if you want to
trigger the vacuum later than the
factory settings provided for.
(Fig. 13-66)
140
In the event the vacuum turns “Off” too soon resulting in the mechanical separator feet catching or preventing the material
from being captured by the gripper jaws, set the timing for the vacuum to stay on longer by performing the following:
A.
B.
appear.
C.
D.
enter message. The “Factor Settings” button should now be visible in the lower left corner of the Timing
Menu.
E.
Press the “Factory Settings” button to bring up the factory settings menu, see figure 13-67.
F.
Settings menu.
G.
change to, press the “0” in the “VAC OFF REF. column for that feeder. A numeric touchpad will appear.
H.
Enter a positive number such as [1] and press the enter button on the numeric touch pad. It is not necessary
to enter a + symbol to indicate a positive number. The new number value will now appear in the VAC OFF
REF. column, see figure 13-67. (Note: If you the vacuum shut off sooner, enter a negative number [- 1].)
I.
J.
to the Timing menu.
K.
141
Press the Timing
button to open the
timing Menu
Button will become
visible
x
150
Setting menu
FACTORY
SETTING
7
8
9
4
5
6
Del
1
2
3
+ /-
0
AC
Enter
Press the “Servo
Set Up” button to
open the Servo
Set Up menu
“VAC OFF REF.” column next to
the feeder number of the feeder
you wish to adjust, a numeric
touch pad will appear. Enter a
negative (-) number value if you
want to trigger the vacuum cups
trigger the vacuum later than the
factory settings provided for.
(Fig. 13-67)
142
In the event the mechanical separator feet are set to a height which is not conducive to smooth operation due to the
relative to the height of the vacuum cup, adjust the height of the mechanical separator feet by performing the following:
1.
Pivot the rotary feeder up until the gravity latch catches and holds the feeder in the up position, see
figure 13-68.
( ! Warning: To avoid damage to the machine and possible minor injury, Do Not release the feeder until
the latch is securely in place to support the feeder.)
The latch is gravity operated and
should fall into place. To lower the
feeder lift “Up” on the feeder, then lift
“Up” on the latch, hold the latch out
of the way while lower the feeder to
the operating position.
!
Warning: !
Make sure the latch is
securely in place before
releasing the feeder
Pivot the feeder
up to the right
(Fig. 13-68)
143
2.
Using a 4mm Allen wrench loosen the retaining screw on both mechanical kicker feet, then slide each
mechanical kicker foot to the height you desire. Tighten the retaining screws to secure the adjustment, see
figure 13-69.
(Fig. 13-69)
Using a 4mm Allen wrench, loosen the
mechanical kicker foot by turning the screw
counter clockwise, tighten by turning clockwise
Adjust the mechanical
kicker foot by sliding it up
or down to the desired
height
!
Caution
!
Make sure you adjust “Both” mechanical
kicker feet to the same height. Failure to
do so may result in paper jams
144
Once the feeder is separating and pulling material correctly, set the double detector by performing the following:
1a.
Set the “Double Detector” by: Method One, Presence of a Double
A.
is displayed.)
B.
Lift the feeder to the “Up and Latched” position, see figure 13-70.
C.
Manually place two (2) pieces of material under the double detector roller. (See figure 13-70) if the double
indicator icon is lit, turn the detector adjustment knob in a clockwise direction until this icon is no longer lit.
(Note: Just because you may find the double detector icon lit, it can not be assumed that it is set properly
for the material you are about to run)
D.
Manually remove one (1) of the two (2) pieces of material from under the double detector. The double
detect icon light should go off.
E.
F.
When the set up is complete, exit the set up menu simply by pressing the upper left-hand corner of the
Turn the adjustment knob
clockwise to raise the detector,
counter clockwise to lower the
detector
Place sample pieces under the
double detector roller bearing
(Fig. 13-70)
145
1b.
Set the “Double Detector” by: Method Two, Absence of a Double
A.
is displayed.)
B.
Lift the feeder to the “Up and Latched” position, see figure 13-70.
C.
Manually place two (2) pieces of material under the double detector roller. (See figure 13-70) Turn the
detector adjustment knob in a counter clock wise direction until the double detector icon light comes on.
(Note: Just because you may find the double detector icon lit, it can not be
assumed that it is set properly for the material you are about to run)
D.
Very slowly turn the adjustment knob in a clock wise direction until the double detector icon light goes off.
Continue to turn the adjustment knob another quarter turn when setting up a tri-fold letter. (Helpful Tip:
Turn the adjustment knob more than a quarter turn when setting up thicker material and less than a
quarter turn when setting up single sheet material)
E.
F.
When the set up is complete, exit the set up menu simply by pressing the upper left-hand corner of the
The Rotary Feeder also has a product sensor that functions similarly to the product sensor on the friction feeder with one
major exception both the double detector and the product detector time of engagement can be set in the “Servo Menu” of
the Factory Settings. Depending on the type of product you are running, you may wish to advance the timing of the
detection. To adjust the settings perform the following:
A.
B.
appear.
C.
D.
enter message. The red “Factor Settings” button should now be visible in the lower left corner of the Timing
Menu.
E.
Press the “Factory Settings” button to bring up the factory settings menu, see figure 13-71.
F.
Press the “Servo Setup” button located in the lower left corner of the Factory Setting menu to open the Servo
Settings menu.
146
G.
change to, press the “0” in the “MISS CHK SETTINGS. column for that feeder. A numeric touchpad will
appear.
H.
Enter a negative number such as [- 1] and press the enter button on the numeric touch pad. The new number
value will now appear in the “MISS CHK SETTINGS”. Column see figure 13-71. (Note: If you want to delay
when the vacuum comes on, enter a positive number [1]. It is not necessary to enter a + symbol to indicate a
positive number.)
I.
J.
to the Timing menu.
K.
Depending on the type of product you are running, you may wish to retard the timing of the detection, to do this perform
the following:
A.
Open the timing menu by pressing the “Timing” button on the operator’s run screen.
B.
appear.
C.
D.
Menu.
E.
Press the “Factory Settings” button to bring up the factory settings menu.
F.
Settings menu.
G.
change to, press the “0” in the “MISS CHK SETTINGS”. column for that feeder. A numeric touchpad will
appear.
H.
Enter a positive number such as [1] and press the enter button on the numeric touch pad. It is not necessary
to enter a + symbol to indicate a positive number. The new number value will now appear in the “MISS CHK
SETTINGS”. column. (Note: If you the vacuum shut off sooner, enter a negative number [- 1].)
I.
J.
to the Timing menu.
147
K.
Press the Timing
button to open the
timing Menu
Button will become
visible
x
150
Setting menu
FACTORY
SETTING
7
8
9
4
5
6
Del
1
2
3
+ /-
0
AC
Enter
Press the “Servo
Set Up” button to
open the Servo
Set Up menu
“Miss CHK Settings” column next
to the feeder number of the
feeder you wish to adjust, a
numeric touch pad will appear.
Enter a negative (-) number
value if you want to trigger the
miss sensor and double detector
trigger the detection later than
the factory settings provided for.
(Fig. 13-71)
148
Envelope Turnover Set Up
149
Set up the Envelope Turnover
The turnover has an adjustable take up roller, (ie: The front top crown roller of the top gum belt), that can be set to
accommodate the thickness of the inserted envelope you are running, To make this adjustment, perform the following:
1. Jog the machine forward until an inserted envelope approaches the exit end of the front table.
2. Manually slide the inserted envelope under the take up roller of the turnover.
3. Hold the end of the inserted envelope with your left hand and slowly adjust the pressure adjustment knob with
your right hand until moderate to firm pressure is felt on the end of the envelope under the take up roller, see
figure 13-72.
Manually place the lead edge of an
inserted envelope under the take
up roller
Turn the adjustment knob,
clockwise to raise, counter
clockwise to lower, until
moderate to firm pressure
is detected.
(Fig. 13-72)
150
Shingle Conveyor Set Up
151
Set Up of the Shingle Conveyor
Set up the Shingle Conveyor by performing the following:
1. Position the edge of the shingle conveyor approximately three (*3) inches from exit end of the turnover also aligning
the center of the envelope knock down assembly with the center of the red gum belts. (Note: (*3) inches stated in this
step is a starting reference point for the approximate distance when running a I-ounce, #10 envelope. The size and
weight of the material as well as the selected running speed of the FlowMaster RS inserter has a direct bearing on the
distance between the shingle conveyor and the exit end of the turnover. Increasing or decreasing this distance may
be required to accommodate the material your running.)
2. Remove both the envelope knock downs by turning the retaining lock knob, located on the envelope knock down
mounting clamp, in a counter clock-wise direction, then lift each mounting clamp free from the stop plate, see
figure 13-73.
3. Cycle the FlowMaster RS inserter at regular running speed.
4. Observe the material at the exit end of the turnover as it lands on the shingle conveyor, the material should lightly
strike the stop plate of the envelope knock down assembly near the surface of the conveyor bed, see figure 13-74.
(Note: If the material is landing on the conveyor bed or striking the stop plate too high above the conveyor bed, you
may need to adjust the position of the stop plate or the position of the conveyor as described in step #1 or position
and adjust the envelope knock downs previously removed in step #2.)
5. Return both of the envelope knock downs (removed in step #2), to the stop plate. Position each envelope knock
down approximately 1/4 “ from the top and bottom edge of the material, and tighten the retaining lock knob by turning
it in a clock-wise direction, see figure 13-74.
6. Adjust the knock down straps. Once the job has been started and running speed has been established, watch the
finished product as it lands on the shingle conveyor and look for these occurrences:
A. The material strikes the stop plate so hard that it bounces back before landing on the conveyor. Adjust the knock
down straps to apply greater resistance to the material, (slowing it down) before it strikes the stop plate. Do this
by turning the adjustment knobs, on both envelope knock downs, in a clock-wise direction.
B. The material lands on the conveyor before reaching the stop plate. Adjust the knock down straps to apply less
resistance to the material, (allowing it to maintain speed) to reach the strikes the stop plate. Do this by turning the
adjustment knobs; on both envelopes knock downs, in a counter clock-wise direction.
152
(Fig. 13-73)
Top View – Shingle Conveyor
Loosen these Retaining Lock Knobs to adjust the
position of the Envelope Knock Down Assembly
Envelope Knock
Down Assembly
Position Knock Downs
approximately ¼” from the edges
of the material
Loosen this retaining lock knob
to adjust the height of the
Envelop Knock Down
Adjustment knob
to increase or
decrease pressure
of the envelope
knock down guide
Loosen this retaining lock
knob to adjust the position of
the Envelope Knock Down
on the Stop Plate
(Fig. 13-74)
153
Envelope In-Feed Conveyor Set Up
154
The FlowMaster RS insert is designed with an envelope in-feed conveyor for continuous filling envelope hopper. This
conveyor is activated by a Banner AN-7 sensor. Setting up the envelope in-feed conveyor is typically the last step in a
normal job set up. To set up the envelope in-feed conveyor perform the following:
1.
Loosen all three (3) of the retaining lock knobs found on the back edge of the envelope guide rail.
2.
Using one the envelopes of the job as a straight edge, lay it flat on the conveyor bed with one edge against the
back guide rail overhanging the end of the conveyor into the envelope hopper, see figure 13-75.
Adjust envelope back guide by sliding back and forth
Sample envelope must have just
enough clearance to pass
Separator Gate
Slide sample envelope
along envelope back guide
(Fig. 13-75)
3.
While holding the sample envelope against the back guide rail, slide the guide rail back until the sample envelope
makes light contact with the inside surface of the envelope hopper separator gate, see figure 13-75.
155
4.
Tighten the retaining lock knob located on the back of the envelope guide rail, close to the envelope hopper, see
figure 13-76.
5.
Using the same sample envelope, lay it flat on the conveyor with one end against the back edge of the envelope
guide rail. Fold the sample envelope over the edge of the conveyor bed and crease the firmly to create a 90
degree angle in the envelope sample, see figure 13-76.
(Fig. 13-76)
Fold the sample envelope over the
conveyor bed to create a gauge to
set the other lock knobs by
Turn Retaining
Lock Knob
counter
clockwise to
loosen,
clockwise to
tighten
6.
Using the folded envelope as a gauge, lay it on the conveyor with the folded end against the back edge of the
envelope guide rail, adjust the envelope guide rail to match the folded envelope end dimension then tighten the
center retaining lock knob. Repeat this step at the far end of the envelope guide rail. This will ensure that the
envelopes will travel the length of the conveyor without skewing before entering the envelope hopper.
156
7.
Over-fill the envelope hopper with a stack of envelopes a 3” to 4” higher than the envelope in-feed conveyor bed,
see figure 13-80. (Note: The envelope must be placed in the envelope hopper with the flap side face up and the
flap edge facing the envelope in-feed conveyor.)
Over-fill envelope hopper
3” to 4”
(Fig. 13-77)
8.
Place your hand flat along the outer edge of the envelope stack and pull the top portion of the stack back onto the
conveyor bed, see figure 13-78.
(Fig. 13-78)
Pull the top portion of the envelope stack
back onto the envelope in-feed conveyor
157
9.
Fill the remaining length of the conveyor with envelopes. Fan them out and keep the height equal to the height of
the envelope guide rail, see figure 13-79
Keep the height of
the envelopes equal
to or less than the
height of the
envelope guide rail
(Fig. 13-79)
158
Changing the
Pusher Finger Configuration
159
Pusher Finger Configuration for the 16-K FlowMaster
In order to run the FlowMaster at speeds over 12000 per hour, it will be necessary to change the pusher finger
configuration depending on the model FlowMaster you are running and / or the pin spacing you’re running in. To change
the pusher finger configuration, perform the following:
1. Jog the machine forward until three (3) pusher lugs appear on the top surface of the box cam and one (1) pusher
lug is positioned at 3-o’clock on the pusher drive sprocket and one (1) pusher lug is positioned at 9-o’clock on the
idler sprocket, see figure 13-75. (Note: The pushers can also be positioned manually. Open the clear pusher
finger cover, the servo drive will automatically disengage, move the pusher finger lungs into the reference position
by hand.)
Reference position for pusher
finger configuration
Top View
(Set with 2 pushers)
C
B
D
E
A
Side View
(Set with 2 pushers)
F
(Fig. 13-75)
160
2. Set up the pusher finger configuration to match the pusher requirements of the Servo Homing menu you wish to
use. See reference charts on this page.
Pusher Configuration for the FlowMaster RS 16000 (16K - 6 X 9)
16K
Servo Homing
Use Pusher
Machine Type
Selection
Chain Lugs
4 Pushers
FlowMaster 16000
7" Pin Spacing
A, C, E, F
3 Pushers
FlowMaster 16000
7" Pin Spacing
B, D, F
Maximum
Speed
16,000
12,000
Pusher Configuration for the FlowMaster RS 16000 XL (16K - 10 X 13)
16K
Servo Homing
Use Pusher
Maximum
Machine Type
Selection
Chain Lugs
Speed
4 Pushers
FlowMaster 16000 XL
7" Pin Spacing
A, C, E, F
16,000
3 Pushers
FlowMaster 16000 XL
7" Pin Spacing
B, D, F
12,000
2 Pushers
FlowMaster 16000 XL
14" Pin Spacing
C, F
12,000
161
To remove a pusher finger shaft assembly, perform the following:
1. Remove the pusher finger shaft lug caps from each end of the pusher finger shaft of the selected assembly using
a 3/32 allen wrench. (Note: The cap and base of each pusher finger lug were machine milled as a set. Each cap
and base has been stamped with matching identification numbers. These identification numbers must be
matched when re-assembling the caps back to their original position on the bases. If the caps are not properly
matched to the bases, it may cause an uneven wear pattern on the pusher finger shaft, see figure 13-76.)
Socket Head
Allen Screws
Lug Cap
L4
Matching identification
Numbers
L4
Lug Base
(Fig. 13-76)
2. Manually position the pusher shaft to the bottom side of the box cam assembly approximately one (1) inch to the
right of the idler sprockets.
3. Lift the box cam assembly, from the operator’s side, and retrieve the pusher shaft. (Note: If these steps have
been performed correctly, the pusher shaft should be found laying freely on the insert deck.)
4. Return the pusher chain to the original position, where step #1 was performed and return the lug caps to their
prospective bases. (Note: Be sure to line up the matching identifying numbers.)
162
To add a pusher finger shaft to a selected chain lug, perform the following:
1. Remove the lug caps from the lug bases on both pusher chains at the selected position. (Note: The cap and
base of each pusher finger lug were machine milled as a set. Each cap and base has been stamped with
matching identification numbers. These identification numbers must be matched when re-assembling the caps
back to their original position on the bases. If the caps are not properly matched to the bases, it may cause an
uneven wear pattern on the pusher finger shaft, see figure 13-76.)
2. Manually position the un-capped lug bases to 4-o’clock on the pusher assembly drive sprocket, located at the
right end of box cams.
3. Position the pusher shaft assembly on the lug bases, (be sure that the white nylon spacers at both ends of the
pusher shaft are arranged between the lug bases and the inside surface of the box cams, see figure 19.). (Note:
It may be necessary to move the entry fingers out of the way to gain extra room for this step.)
4. While holding the pusher shaft to the lug bases, manually pull the pusher shaft assembly into the top track of the
box cam, see figure 13-77.
Shown with entry fingers moved out of normal
operating position
(Fig. 13-77)
5. Secure the pusher shaft to the lug bases with the prospective caps. (Note: Be sure to line up the matching identifying
numbers.)
163
Section - XIV
Optional
Over Head Vacuum Assist
Envelope Opener
164
The Optional Over Head Vacuum Assist Envelope Opener has been found to be a useful device in running flat size end
seam envelopes that have been packaged and stored on end causing a sever curl at one end of the envelope. It has also
been found useful in running some custom style envelopes. To set up and run the Over Head Vacuum Assist Envelope
Opener, perform the following:
1. Open the envelope menu by pressing the “ENV MENU” button located in the upper right hand corner on the
2. Press the “Envelope Assist Timing Menu” Button located in the upper right corner of the Envelope Menu, see
figure 14-1.
3. Press the “Opener ON / OFF” button located in the upper left hand corner of the Envelope Assist Timing Menu
until it reads “Opener ON”.
4. Jog the machine forward until an envelope comes to the “Full Stop” mark and the chain stops moving. (Helpful
Tip: Take note of the “Encoder Position” reference located in the bottom center of the Envelope Assist Timing
Menu. You will need to use this reference in Step 5.)
5. Press the number value under the heading “Plunger Down Vac On”. A numeric touch pad will appear. Enter the
number currently appearing in the “Encoder Position” previously referenced in Step 4 then press the “Enter” key
on the numeric touch pad, see figure 14-1. The number you entered on the touchpad should now appear as the
setting for the “Opener On” value.
6. Press the number value under the heading “Plunger Up”. A numeric touch pad will appear. Enter a number ten
(10) degrees higher than the “Plunger Down Vac On” value then press the “Enter” key on the numeric touch pad.
The number you entered on the touch pad should now appear as the setting for the “Opener On” value.
7. Open the “Timing Menu” by pressing the Timing Menu button located on the left side of the operator’s run screen.
8. Check the number value under the heading “Insert Air OFF”. Go back to the operator’s run screen, re-open the
Envelope Menu, then re-open the “Envelope Assist Timing Menu”
9. Press the number value under the heading “Plunger Vac Off”. A numeric touch pad will appear, see figure 14-1.
Enter the number value found in the “Insert Air Off” section of the Timing Menu then press the “Enter” key on the
numeric touch pad. The number you entered on the touch pad should now appear as the setting for the “Plunger
Vac Off” value.
165
Env Assist
Timing
Menu
WATER
TIME
Auto
Mode
ENV
OFF
02
Continue
Trying
Miss
Stop
320
Missed Flap
Position
ENV ASSIST MENU
Opener
Off
Plunger
Down
Vac On
025
Divert
Flap
Plunger
220
Divert Miss & Doubles
Plunger
Vac
Off
Up
230
# Of Diverts
For Stop
285
Encoder Position
Press the number value under the
headings, a numeric touch pad will
appear, enter the new number and
press the enter key. The new number
should appear under the heading
220
“Encoder Position” is for
reference only. Do not attempt
to change the number value.
x
150
7
8
9
AC
4
5
6
Del
1
2
3
+ /-
0
Enter
(Fig. 14-1)
166
To position the vacuum cups of the Over Head Vacuum Assist Opener, perform the following:
1. Jog the machine forward until an envelopes comes to the “Full Stop” mark and the envelope gripper chain stops
moving.
2. Position the vacuum cups towards the outer edges of the envelope near the throat in the following manner:
a. Using a 3/16” Allen wrench, loosen the socket head retaining screws located at each end of the sliding
mount plate to adjust the side to side location of the vacuum cups. The screws are accessible from each
side of the vacuum solenoid, see figure 14-2. ( ! Caution: Do Not block the operating path of the Insert
Entry Fingers with the vacuum cup assemblies.)
Adjust the side to side
location of the vacuum cups
Using a 3/16 Allen wrench, turn both of
the retaining screw counter clockwise to
loosen, clockwise to tighten.
(Fig. 14-2)
167
b. Using a 3/16” Allen wrench, loosen the socket head retaining screw located on the top of each solenoid at
the slide bar to adjust the forward or backward position of the vacuum cups, see figure 14-3.
( ! Caution: Do Not block the operating path of the Envelope Gripper Chain with the vacuum cup
assemblies.)
Adjust the forward and
backward position of the
vacuum cups
Using a 3/16” Allen
Loosen the retaining
screw by turning it
counter clockwise, turn
clockwise to tighten
(Fig. 14-3)
168
c.
Adjust the height of the vacuum cup solenoid inside the housing so that it assist in opening the envelope
with minimal distortion to the throat of the envelope, see figure 14-4. ( ! Caution: Some distortion may
occur using the Optional Overhead Vacuum Assist Envelope Opener, use care to keep it to a minimum,
see figure 14-5 and 14-6.)
Adjust the height of
the vacuum cup
solenoid inside the
housing
Using a 2.5 mm Allen wrench loosen the
retaining screws by turning them counter
clockwise, turn clockwise to tighten
(Fig. 14-4)
169
The symbol indicates the ideal placement
for the vacuum cups of the Over Head
Vacuum Assist Opener
(Fig. 14-5)
Minimal height
Maximum end clearance
Maximum height
Minimal end clearance
(Fig. 14-6)
170
Section - XV
Remote Control
171
The FlowMaster RS is equipped with a remote control for basic run functions. The remote can be carried by an operator
or mechanic and used to “Stop”, “Jog” or “Run” the machine from several feet away. For remote control operations, see
figure 15-1.
START button will run the
machine providing there are
no errors displayed on the
run screen and there are no
open safety interlocks
STOP button will stop the
machine under any condition
or cycle state the machine
is in
START
STOP
CYCLE
ALT
ALT button has no function
on the FlowMaster RS
inserter
CYCLE button will run the
machine at jog speed only
while the button is pressed
providing there are no errors
displayed on the run screen
and there are no open safety
interlocks
(Fig. 15-1)
172
The Remote Control of the FlowMaster RS inserter is powered by two (2) RENATA 3 volt batteries, model CR2450N.
RENATA lithium batteries offer excellent storage characteristics. The loss of capacity due to self discharge is less
than 1% per year at room temperature (23°C). Thanks to the high stability of their chemical system, MnO2/Li
batteries have a shelf life of up to 10 years, at room temperature.
The internal chemical reactions of a battery are accelerated by high temperatures and slowed by low
temperatures. In other words, the loss of capacity during storage depends largely on storage temperature. Higher
temperatures result in increased self discharge rates, while lower temperatures reduce self discharge. Storage at
low temperatures bears the risk, however, that batteries are short circuited by moisture condensation when
transferred into a warmer environment.
The actual life expectancy of the batteries is undetermined due the variance of operating temperature and frequency
of use.
In the event you remote control fails due to weak batteries, the batteries can be easily be changed, see figure 15-2.
Remove the two
screws from the
battery cover
Remove the battery
cover from the back of
the remote
Remove the old
batteries and
replace them with
new batteries
(Fig. 15-2)
173
Section - XVI
Touch Screen Menus
&
Factory Settings
174
Operator’s Run Screen
B
A
C
R
D
E
Operators Run Screen
F
Q
G
H
P
I
16000
(Fig. 16-1)
O
N
M
175
L
K
J
Reference
Letter
A
Feature
Input Menu
B
C
D
E
Feeder Menu
Envelope Menu
Servo Menu
Maintenance Menu
F
G
Timing
Report Screen
H
Front Table
I
Conveyor Menu
J
Sequential Start / Stop
K
End
L
Arrow UP
M
Speed Input
N
Arrow DOWN
O
New Job
P
Job #
Q
Piece Count
R
Input Double Detect
Function
Access input menu to enable
optional input
See Fig Schedule 16-2 and 16-3
See Fig Schedule 16-4
See Fig Schedule 16-8 thru 16-11
Access Maintenance Menu
to manually engage all
air and vacuum solenoids
See Fig Schedule
Review all machine activity
for the most current job run
Note: This information is not
stored to memory but may be
hard wired to a printer.
Access Front Table Menu
to re-position front table for
job set up
Access Conveyor Menu
for optional sort conveyor
"Start" Begins job run by
engaging all feeders in
sequential order
"Stop" Ends job run by
disengaging all feeders in
sequential order
Signals PLC that the job being
run is finished, also stops
the clock in the Report feature
Increases machine speed
in increments of 1000 or 500
Changes speed increments from
1000 to 500 also displays
current running speed
Decreases machine speed
in increments of 1000 or 500
Prompts PLC to receive
new feeder selection and
feature selection
Displays job number on screen
and in report menu
Displays quantity of envelopes
inserted. Resets when
"New Job" button is depressed
Set up tool for optional input
176
Setting
Type
Touch Screen Button
Touch Screen Button
Touch Screen Button
Touch Screen Button
Touch Screen Button
Touch Screen Button
Touch Screen Button
Touch Screen Button
Touch Screen Button
Touch Screen Button
Touch Screen Button
Touch Screen Button
Touch Screen Button
&
Visual indicator
Touch Screen Button
Touch Screen Button
Numeric Touch Screen
Visual indicator
Visual indicator
A
B
C
D
E
F
Q
G
P
O
H
265
200
318
09
(Fig. 16-2)
N
M
L
K
J
I
Feeder One
Item
Description
On / Off button
A
One Shot button
B
Batch On / Off button
C
Batch Count Number
D
Friction / Shuttle button
E
F Outer VAC On / Off button
Air Jet On / Off button
G
H Slow Cycle On / Off button
Placement In Track
I
Feed Time
J
K
L
M
N
O
P
Cascade button
Encoder Position
Double Latch Icon
Double / Jam Detect
Double Detect Icon
Reset button
Q
Count. Cycle
Function
Engages and disengages feeder
Manuals triggers feeder to cycle one time only
Engages and disengages Batch Counting function
Point of entry for amount of pieces to be batched
Press to identify feeder type, Friction or Rotary
Engages and disengages outer vacuum cup in Rotary Feeder Only
Engages and disengages "Air" separation in Rotary Feeder Only
Press to reduce feeder cycle speed of "One Shot" function in Rotary Feeder Only
Point of entry to determine where Rotary Feeder places piece in track
Point of entry to determine when a Friction Feeder begins to cycle
Engage and disengages Cascade feature. In the event feeder #1 miss feeds or runs out
of paper, the machine will not stop, no other feeders will feed into a belt placement
missed by feeder #1 including the envelope
View field to display current encoder position (This is not an active button)
Illuminates to show double is detected in test cycle during set-up
Point of entry to determine when product sensor becomes active for this feature
Illuminates to show double is manually detected during set-up
Press to reset "Double Latch" icon after test cycle
Press to continually cycle feeder during set up
(Must be press a second time to stop feeder)
177
A
B
C
D
E
F
Q
G
P
O
H
265
200
318
09
(Fig. 16-3)
N
M
L
K
J
I
Item
Description
Function
On / Off button
Engages and disengages feeder
A
One Shot button
Manuals triggers feeder to cycle one time only
B
Batch On / Off button
Engages and disengages Batch Counting function
C
Batch Count Number
Point of entry for amount of pieces to be batched
D
Friction / Shuttle button
Press to identify feeder type, Friction or Rotary
E
Engages and disengages outer vacuum cup in Rotary Feeder Only
F Outer VAC On / Off button
Air Jet On / Off button
Engages and disengages "Air" separation in Rotary Feeder Only
G
H Slow Cycle On / Off button Press to reduce feeder cycle speed of "One Shot" function in Rotary Feeder Only
Placement In Track
Point of entry to determine where Rotary Feeder places piece in track
I
Feed Time
Point of entry to determine when a Friction Feeder begins to cycle
J
Backup Feeder button
Engage and disengages Backup feature (See page for details)
K
Encoder Position
View field to display current encoder position (This is not an active button)
L
Double Latch Icon
Illuminates to show double is detected in test cycle during set-up
M
Double / Jam Detect
Point of entry to determine when product sensor becomes active for this feature
N
Double Detect Icon
Illuminates to show double is manually detected during set-up
O
Reset button
Press to reset "Double Latch" icon after test cycle
P
Press to continually cycle feeder during set up
Count. Cycle
(Must be press a second time to stop feeder)
Q
178
The following pages depict menu and feature changes found only on the Servo drive FlowMaster RS inserters.
Envelope Menu
B
A
Env Assist
Timing
Menu
WATER
TIME
Auto
Mode
ENV
OFF
D
C
02
K
Miss
Stop
320
Missed Flap
Position
J
E
Continue
Trying
Divert
Flap
Divert Jam
Time
# Of Diverts
For Stop
015
025
Divert Miss & Doubles
(Fig. 16-4)
I
H
G
179
F
Envelope Menu Legend
Reference
Letter
A
B
b
C
D
E
F
G
G2
G3
H
I
J
K
K2
Setting
Function
Type
Engage envelope feeder
Touch Screen Button
Auto Mode to run live jobs
Touch Screen Button
Set Up Mode to run
Touch Screen Button
envelopes only. Used
during machine set up
Water Time
Determine how long water
Real time / Milli-seconds
solenoid stays on
Envelope Assist
Opens menu for the Overhead
Touch Screen Button
Vacuum Assist Opener
Determine how long sensor is blocked
Divert Jam Time
Real time / Milli-seconds
To signal jam at diverter
Determines amount of diverts occur
# of Diverts for Stop
Number Value
Before stopping machine
Divert On Miss Only
Diverts inserted envelope
Touch Screen Button
if one or more pieces that
Are detected as missing
Divert On Double Only Diverts inserted envelope
Touch Screen Button
if one or more pieces
are detected as doubled
Divert On Miss and Double Diverts inserted envelope
Touch Screen Button
in the event of a miss feed
or double feed
Continue Trying
Suspends Collator and
Touch Screen Button
Pusher activity while
(Note: “Cascade” in Feeder
envelope attempt to feed
#1 Must be turned OFF)
Divert Flap
Suspends Collator and Pusher
Touch Screen Button
activity while front table runs out
(Note: “Continue Trying”
Unopened envelope to diverter
Must be turned ON)
Missed Flap Position
Determines what point in the
Encoder reference
machine cycle the machine
will stop in for a missed
envelope. Works in conjunction
"Jog Miss" feature
Miss Stop
Stops machine if envelope
Touch Screen Button
flap is not detected
Jog Miss
Reduces machine to jog speed
Touch Screen Button
then advances to "Missed
Flap Position" before stopping
Feature
Envelope On / Off
Auto Mode /
Set Up Mode
180
Envelope Assist Opener Menu
ENV ASSIST MENU
A
Opener
Off
Plunger
Down
Vac On
Plunger
Up
220
225
Plunger
Vac
Off
220
B
Encoder Position
135
E
Item
A
B
C
D
E
D
C
(Fig. 16-5)
Setting I.D.
Setting Type
Factory Setting
Function
Opener
Enables & Disables
On / Off
Button
None
Overhead Vac. Assist Opener
Plunger
Encoder
Turns Vacuum
Vac. Off
Reference
285
Solenoid Off
Plunger
Encoder
Activates Plunger
Up
Reference
225
to lift up
Encoder
Encoder
Displays current
Position
Reference
None
Encoder position
Plunger Down
Encoder
Activates Plunger, down
Vac. On
Reference
220
Turns Vac. Solenoid On
* Functional only after adding other devices to the FlowMaster RS & LS Inserters
181
Timing Menu
A
B
C
D
E
265
225
F
R
G
135
330
H
318
Q
I
P
O
285
140
14795
Factory
Setting
(Fig 16-7)
N
M
L
K
J
(Note: Figure 16-7 shows the timing menu as it would appear after the password is entered to make the “Factor Settings”
button visible)
See Factory Settings chart on page 188 for an explanation of settings (A) through (R) as shown in figure 16-13.
182
Timing Menu Settings for FlowMaster RS (In 4 Pusher Configuration)
Item
Setting I.D.
Setting Type
Factory Setting
A
* Match Times
Button
Varies
B
Feed Times
Button
200
C
* Input Times
Varies
D
Batch Interrupt
Envelope
Detect
Envelope
Vacuum On
Envelope
Vacuum Off
Insert
Air On
Insert
Air Off
Run
Screen
* Print
Screen
Job
Number
Button
Encoder
Reference
Encoder
Reference
Encoder
Reference
Encoder
Reference
Encoder
Reference
Encoder
Reference
Button
None
Button
Informational
Display
None
None
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
Note:
265
225
135
330
140
285
Password
Factory
Settings
Time &
Date
Button
None
Button
Informational
Display
None
Enter
Encoder
Display
Button
Informational
Display
None
None
None
Function
Factory Control for Camera
Matching System
Encoder reference
for Feeder Start times
Factory Control for Input
Devices to be Added
Position to hold Collator
for a Feeder to Batch Count
Position to activate
Sensor to detect an envelope
Vacuum Solenoid
Position to deactivate
Vacuum Solenoid
Air & Vacuum Solenoid
Returns user to
Operator Run Screen
Activates Printer
Displays Job
Number
Opens Numeric touch pad
to enter password
Accesses Factory Settings
menu after password is entered
Displays
Date & Time
Press button to enter
number displayed on Encoder
to a selected timing reference
Displays current
Encoder position
Encoder
Visual
Displays current
Dial
Display
None
Encoder position
These are standard factory timing settings and do not reflect accommodations or concessions for
variables in paper stock, which may differ regionally. If by some unknown circumstance any or all timing
settings are rendered to a 0 value, these settings are useful only as a starting point. Further adjustment
may be necessary dependent on paper characteristics and conditions in your region.
183
Timing Menu Settings for FlowMaster RS & LS (In 2 Pusher Configuration)
Item
Setting I.D.
Setting Type
Factory Setting
A
* Match Times
Button
Varies
B
Feed Times
Button
100
C
* Input Times
Varies
D
Batch Interrupt
Envelope
Detect
Envelope
Vacuum On
Envelope
Vacuum Off
Insert
Air On
Insert
Air Off
Run
Screen
* Print
Screen
Job
Number
Button
Encoder
Reference
Encoder
Reference
Encoder
Reference
Encoder
Reference
Encoder
Reference
Encoder
Reference
Button
None
Button
Informational
Display
None
None
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
Note:
265
225
135
330
140
285
Password
Factory
Settings
Time &
Date
Button
None
Button
Informational
Display
None
Enter
Encoder
Display
Button
Informational
Display
None
None
None
Function
Matching System
Encoder reference
Devices to be Added
Vacuum Solenoid
Vacuum Solenoid
Returns user to
Operator Run Screen
Activates Printer
Displays Job
Number
to enter password
Displays
Date & Time
Displays current
Encoder position
Encoder
Visual
Displays current
Dial
Display
None
Encoder position
184
Timing Menu Settings for FlowMaster RS & LS (In 3 Pusher Configuration)
Item
Setting I.D.
Setting Type
Factory Setting
A
* Match Times
Button
Varies
B
Feed Times
Button
75
C
* Input Times
Varies
D
Batch Interrupt
Envelope
Detect
Envelope
Vacuum On
Envelope
Vacuum Off
Insert
Air On
Insert
Air Off
Run
Screen
* Print
Screen
Job
Number
Button
Encoder
Reference
Encoder
Reference
Encoder
Reference
Encoder
Reference
Encoder
Reference
Encoder
Reference
Button
None
Button
Informational
Display
None
None
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
Note:
265
225
135
330
140
285
Password
Factory
Settings
Time &
Date
Button
None
Button
Informational
Display
None
Enter
Encoder
Display
Button
Informational
Display
None
None
None
Function
Matching System
Encoder reference
Devices to be Added
Vacuum Solenoid
Vacuum Solenoid
Returns user to
Operator Run Screen
Activates Printer
Displays Job
Number
to enter password
Displays
Date & Time
Displays current
Encoder position
Encoder
Visual
Displays current
Dial
Display
None
Encoder position
185
FlowMaster LS
A
B
150
(Fig. 16-8)
Reference
Letter
A
B
Feature
Home Servo's
spacing
Homing Position
Function
Setting
Type
Touch Screen Button
timing position
Encoder Setting
homing position
186
FlowMaster LS 12000 XL
A
B
150
(Fig. 16-9)
Reference
Letter
A
B
Feature
Home Servo's
spacing
Homing Position
Function
Setting
Type
Touch Screen Button
timing position
Encoder Setting
homing position
187
Servo Menu for the
FlowMaster RS 6X9
A
B
150
(Fig. 16-10)
Reference
Letter
A
B
Feature
Home Servo's
spacing
Homing Position
Function
Setting
Type
Touch Screen Button
timing position
Encoder Setting
homing position
188
Servo Menu for the
FlowMaster RS XL
A
B
150
(Fig. 16-11)
Reference
Letter
A
B
Feature
Home Servo's
spacing
Homing Position
Function
Setting
Type
Touch Screen Button
timing position
Encoder Setting
homing position
189
Factory Settings
190
Factory Settings for the Q Series PLC
FlowMaster RS inserters come with preset factory settings in the Programmable Logic Controller, (PLC). These settings
control the frequency for the feeder drives as well as the front table drive motor for the FlowMaster. There are also
encoder and time settings used for some machine functions such as batch feed, speed up after stop, jog speed and
standard delay start. These settings were derived by running the FlowMaster inserter with 220 volts, single phase, with a
30 amp breaker, set up with 50# offset or 20# bond paper inserting into a 24# white wove standard #10, 6X9 and 9X12
booklet envelopes.
In order to gain access to the factory default settings screen, perform the following:
(1)
Press the Timing button located on the upper right side of the Operator’s Touch Screen, the Timing menu
will appear on the screen, see item F, figure 16-1.
(2)
Press the Password button located on the lower left side of the Timing menu. A security password window
will appear along with a numeric touch pad, see figure 16-12.
(3)
Enter “12006” on the numeric touch pad and press the return arrow located in the bottom right corner of the
touch pad. The Security Password window will now read, (If this was done correctly a message will appear
indicating successful password entry, if this message does not appear you will have to enter the password
again).
(4)
Menu.
(5)
A factory Setting button will now be visible in the lower left corner of the Timing menu. Press the Factory
Setting button to gain access to the factory setting menu, see figure 16-1. The standard factory default
settings can be found on page .
(Note: The factory setting button is a secure button and will only remain visible on the timing menu for five
(5) minutes. If after five (5) minutes you wish to re-enter the factory settings menu, you will have to re-enter
the password in order to gain access
191
Timing Menu
(Fig. 16-12)
225
265
135
330
140
295
318
Factory
Setting
Security Password
Pressing the “Password” button
will bring up the window as
shown at the right. The “Factory
Settings” button will not be
visible until the password
“12006” has been entered
correctly
COMPLETED
x
150
7
8
9
4
5
6
1
2
3
+
0
Note: The Security Password screen shown in this
view has been reduced to fit the illustration.
192
Factory Settings Menu
A
B
C
D
0015760951
0014650025
218
285
Diverter
Connected
S
E
80
R
F
Q
112607
P
150
G
200
H
140
I
10
2000
120
2500
J
(Fig. 16-13)
O
N
M
L
K
Note: The number values shown in this diagram are for illustration only and may not accurately
represent the real factory settings for all Servo Drive FlowMaster RS Models.
See Factory Settings chart on pages 189 for an explanation of settings (A) through (S) as shown in figure 16-13.
(Note: Some settings are different depending on Servo Drive Model, Pin configuration and Pusher configuration.)
193
Factory Settings for FlowMaster RS
Item
Setting I.D.
A
Total
Envelopes
B
Total Cycles
Select #
C
of Feeders
Current
Encoder
Position
Diverter
Connected
Turnover
Type
Feeder Fault
Position 7"
Servo
Setup
Feeder
Speeds
Timing
Screen
D
E
F
G
H
I
J
L
M
N
O
P
Q
Factory Setting
Function
Displays total
Display
Informational
Display
None
envelopes run
Displays total
machine cycles
Selects
Button
Informational
Display
Button
Button
Encoder
Reference
None
Set to Number of
Feeders on
machine
None
Active if
Diverter is present
Set to motor
style in Turnover
140
Button
None
Button
None
Button
None
Jam Time
Real Time In
1/10 of
second
10
Speed Up
After Stop
Feeder Fault
Position 14"
Jog Speed
(Feeder Drive)
Jog Speed
(Main Drive)
Encoder
Setting
Encoder
Reference
Piece
Per/ Hour
Piece
Per/ Hour
Pump Motor
Real Time In
1/10 of
second
Informational
Display
Feeder
K
Setting Type
Informational
Time Out
Software
Revision
Delay
R
Start
Real Time In
1/10 of
second
S
Batch
Speed
Hertz
Setting
120
140
2500
2000
150
Parameters in PLC
Displays current
encoder position
Enables /
Disables Diverter
Not Active
in all Models
Position in cycle to
stop for feeder error
Opens
Servo Menu
Opens Feeder
Speeds Menu (See Fig. 16-6)
Returns to
Timing Menu
Actual time the material
obstructs the miss sensor
when it is interpreted as a jam
Encoder position the machine
must
pass before ramping up to the
selected run speed after stopping
Position in cycle to
stop for feeder error
Actual speed feeders
run while jogging machine
Actual speed machine
runs while jogging
Actual time the pump
motor runs after machine
None
stops before timing out
Identifies Software
installed in machine
Delays machine motion
when started to allow
01
80
Warning:
Never set over 90
time for air to engage
Accelerates
feeder speed
when batch counting
194
In the event you wish to change the factory settings perform the following:
(1)
Open the factory settings menu as described on page 186, remember, the password to enter is, 12006.
(2)
Press the number of the function you wish to change. A numeric touch pad will appear.
(3)
Enter the new setting on the numeric touch pad and press the return arrow located in the lower right hand
corner. The new number you entered on the touch pad will now appear as the new setting.
In most applications the FlowMaster RS will run exceptionally well with the factory settings. However, paper
characteristics can vary dramatically in different regions. In some cases altering some of the factory settings may improve
the efficiency of the FlowMaster RS.
(Caution: Many of the factory settings reference the encoder position or time. Before altering the factory settings, make
sure the FlowMaster RS is properly timed and the encoder is set correctly as stated on pages 75 through 76 of the
Operator’s Manual.)
The following are some examples of conditions that warrant changing the factory settings.
Example (A)
Issue:
After a feeder miss or double, some of the feeders feed the first piece onto the
Pusher pins of the collator material belts instead of between them, often times
causing a “Collator Track Jam” error. This only happens while the machine is
ramping up to run speed. It doesn’t happen while jogging the machine.
Cause:
The collator track belts startup too fast or too slow to accommodate the feeders.
Solution:
Alter the Speed Up After Start setting in order to accommodate the feeders first
cycle while ramping up to run speed. (Helpful Tip: If the leading edge of the
material is landing on top of the pusher pins, lower the setting of the “Speed Up After
Stop” function. If the trailing edge of the material is landing on top of the pusher
pins, raise the setting of “Speed Up After Stop” function.)
Example (B)
A feeder errors occurs but when the “Fill Track” button is pressed the material feeds
Issue:
into the back of the pusher pins of the collator material belts and wrinkles up.
Cause:
The collator material belts have stopped too close to the feeder when the error
occurred.
Solution:
Jog the machine forward until the pusher pins of the collator material belts are far
enough ahead of the feeder to allow the material land flat into the material pathway.
Review the “Current Encoder Position” displayed in the upper right hand corner of
the Factory Setting menu, enter that number as the “Feeder Fault Stop Position”.
(Note: On FlowMaster RS model XL, be sure to enter the new setting in the
correct pin spacing menu that the machine is currently running. ie: 14” or 7”. )
195
Example (C)
Issue:
When jogging the machine a “Collator Track Jam” error appears
Cause:
At jog speed the material is landing on top of the pusher pins of the collator material belts.
Solution:
Increase or decrease the “Jog Speed Feeder Drive” so the material will land
Between the pusher pins of the collator material belts. (Note: The jog speed of
the feeder drive is normally 50 to 60 percent faster than the jog speed for the
main drive.)
If the FlowMaster is set up to run non-uniform size or some other paper medium that varies significantly from the normal, it
may again become necessary to alter some of the factory settings.
The following is an example of when changing the hertz settings of the feeder drive may be appropriate.
Example (D)
Size issue:
While running a standard letter folded to 3-5/8” X 8-1/2” in some of the feeders and a coupon measuring
2-1/2” X 6” in one of the other feeders at 10,000 per hour, the FlowMaster gives a false feeder miss error
only in the feeder running the smaller coupon size piece on the operators run screen, at 8,000 per hour
the false miss still occurs but not as often, at 6,000 per hour the false miss still occurs but less often than
it did at 8,000 per hour. The lower the speed the machine is set at the less frequent the false miss
occurs.
Cause:
The smaller size piece is passing under the miss sensor, faster than the miss
sensor can register or the space between pieces shingling from the separator wheels is greater than ½”.
Solution:
Check the set up of the feeder, make sure that a ½” space is being created between pieces as they pass
under the miss sensor. Lower the hertz settings at each speed level the problem is occurring. Typically
the problem is more pronounced at higher running speeds. Start at the lower speeds first then work your
way up, see page .
(Note: Adjustment of the hertz settings is not a solution for a poor set-up, always check the feeder set-up before
adjusting the hertz settings.)
196
To Change the hertz setting, perform the following:
(1)
Open the factory settings menu as described on page 175, remember, the password to enter is, 12006.
(2)
Press the Feeder Speeds button located in the lower right corner of the factory settings menu. A window will appear
over the factory settings menu, see figure 16-5, item (I) page 179.
(3)
Press the number of the hertz setting located below the speed range that you wish to change. A numeric touch pad
will appear, see figure 16-6.
(4)
Enter the new hertz setting on the touch pad and press the return arrow located in the bottom left corner of the
touch pad. The new number you entered will now appear as the hertz settings for the speed range you chose to
alter.
(Note: The FlowMaster RS & LS models has two different hertz setting charts that appear in the same window. The top
chart reads “FEEDER SPEEDS IN HZ @ 14” SPACING” the bottom chart reads
“FEEDER SPEEDS IN HZ @ 7” SPACING”. This refers to the spacing of the collator material belt pin configuration. Be
careful to adjust the hertz in the spacing chart the machine is currently set up for.)
11
MAIN
2500 or
LESS
2501 to
3500
3501 to
4500
4501 to
5500
30
35
40
25
6501 to
7500
7501 to
8500
50
8501 to
9500
55
5501 to
6500
15
Feeder
45
9501 to
10500
10501 to
11500
GREATER
THEN 11500
65
70
75
60
FEEDER SPEEDS IN HZ @ 14 “ SPACING
11
MAIN
2500 or
LESS
15
6501 to
7500
2501 to
3500
3501 to
4500
4501 to
5500
5501 to
6500
20
25
30
35
40
7501 to
8500
15
Feeder
45
8501 to
9500
9501 to
10500
10501 to
11500
11501 to
12500
12501 to
13500
13501 to
14500
14501 to
15500
GREATER
THEN 15500
50
55
60
65
70
75
80
80
x
FEEDER SPEEDS IN HZ @
7 “ SPACING
150
7
8
9
AC
4
5
6
Del
1
2
3
+ /-
0
Note: The number values shown in this
diagram are for the FlowMaster RS Model only
and may not accurately represent the real
factory settings for all Servo Drive FlowMaster
Models. For Servo Drive Models see charts on
pages 188 and 189.
Enter
(Fig 16-14)
197
FlowMaster RS Servo Drive - 16K / 4 Pusher Configuration
Pin Spacing
Speed Range
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
2500 or Less
2501 to 3500
3501 to 4500
4501 to 5500
5501 to 6500
6501 to 7500
7501 to 8500
8501 to 9500
9501 to 10500
10501 to 11500
11501 to 12500
12501 to 13500
13501 to 14500
14501 to 15500
Greater Than 15500
Hertz Setting
15
20
25
30
35
40
45
50
55
60
65
70
75
80
80
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
FlowMaster RS & LS Servo Drive - 16K & 12K / 3 Pusher Configuration
Pin Spacing
Speed Range
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
7 - Inch
2500 or Less
2501 to 3500
3501 to 4500
4501 to 5500
5501 to 6500
6501 to 7500
7501 to 8500
8501 to 9500
9501 to 10500
10501 to 11500
11501 to 12500
12501 to 13500
13501 to 14500
14501 to 15500
Greater Than 15500
198
Hertz Setting
35
40
45
50
55
60
65
70
75
80
85
0
0
0
0
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
FlowMaster RS & LS - XL Servo Drive - 12 K / 2 Pusher Configuration
Pin Spacing
Speed Range
14 - Inch
14 - Inch
14 - Inch
14 - Inch
14 - Inch
14 - Inch
14 - Inch
14 - Inch
14 - Inch
14 - Inch
14 - Inch
14 - Inch
14 - Inch
14 - Inch
14 - Inch
2500 or Less
2501 to 3500
3501 to 4500
4501 to 5500
5501 to 6500
6501 to 7500
7501 to 8500
8501 to 9500
9501 to 10500
10501 to 11500
11501 to 12500
12501 to 13500
13501 to 14500
14501 to 15500
Greater Than 15500
Hertz Setting
25
30
35
40
45
50
55
60
65
70
75
0
0
0
0
199
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Hertz
Servo Drive Menu
A
B
C
D
N
E
F
G
H
(Fig. 16-15)
M
L
K
J
I
Special Note:
Feeder reference designation in figure 16-15 is for Rotary Feeder placement in any of the 6 standard feeder locations.
200
Item
Setting I.D.
Feeder Home
Setting Type
Program
Factory Setting
A
Offset Column
Miss Check
Setting
Vac. On
Reference
Vac. Off
Reference
Servo Fault
Display
Pusher
Servo Fault
Display
Collator
Servo Fault
Feeder
Major Column
Servo Fault
Feeder
Minor Column
Value
Program
Value
Program
Value
Program
Value
0
B
C
D
E
F
G
H
I
J
K
L
M
N
Informational
Display
Informational
Display
Informational
Display
Informational
Display
Informational
Display
Program
Value
0
Function
Feeder Default for Homing
Also effects material release in
track
Determines when Product Sensor
& miss detect activate
Determines when Vacuum
Solenoid turns ON
Determines when Vacuum
Solenoid turns OFF
None
Shows Servo Faults
That Occur with Pusher Motor
None
Shows Servo Faults
That Occur with Collator Motor
None
Shows Servo Faults in
Feeders Major Column
0
0
Shows Servo Faults in
Feeders Minor Column
Identifies program segment
Program #
None
that faulted
Program Error
Identifies the type of error
Code
None
that occurred by code
Feeder Cams
Turns on / Off
On / Off
Button
None
Cam Profile
Feeder Air Jet
Program
Determines when feeder
Duration Column
Value
0
air jets turn OFF
Feeder Air Jet
Program
Determines when feeder
On Column
Value
0
air jets turn ON
Feeder #
Informational
Identifies feeder location
I.D. Columns
Display
None
in program
None
201
Section - XVII
Electrical Timing Settings
202
Electrical Timing Settings
The FlowMaster RS and LS inserters have several electrical timing settings that can be adjusted to accommodate
different paper characteristics and envelope sizes. To determine what timing settings are right for the job you’re running,
Perform the following:
Check and Set the “Envelope Vacuum On / Off” in accordance to the size of the envelope you’re setting up by performing
the following:
1.
Press the Timing Screen button on the Operator’s Run Screen to open the timing menu, see figure 17-1
Press the Timing
button to open the
timing Menu
(Fig. 17-1)
2.
Place a sample of the envelope you’re setting up on the envelope track rail, slide it towards the envelope hopper
until the back edge of the envelope touches the envelope stack in the hopper, see figure 17-2.
(Fig. 17-2)
Place a sample envelope on guide rail
Slide the sample envelope back until it
touches the envelopes in the hopper
203
3. Jog the machine forward until a gripper jaw is positioned at the opposite end of the sample envelope,
see figure 17-3.
Special Note: The envelope vacuum On / Off timing as stated will accommodate any size envelope from 6” linear running
length to 13” linear running length providing the Model FlowMaster is designed to run flat size envelopes. In the event the
envelope you are setting up measures less than 6” linear running length, make sure the envelope shuttle plate is
completely under the envelope stack in the hopper before setting the “ENV. VAC. ON”.
Jog the machine
forward to position a
gripper jaw at the
opposite end of the
envelope
Note: The gripper jaw should be positioned
so the inside of the grip surface of the jaw is
even with the end of the sample envelope
(Fig. 17-3)
5. Read the number value located under the encoder dial on the Timing menu previously opened in step 1 and
compare it the number under the “ENV. VAC. ON” button. If the number value under the “Env. Vac. ON” button is
within a 5 degree range, (+) plus or (-) minus, make no change and move on the next step. If the number value
range is greater than 5 degrees, change the number under the “Env. Vac. ON”. This can be accomplished in one
of two ways:
(A) Press the actual button marked “ENV. VAC. ON”. The button will now read “Press Enter”. Press the
“Yellow” Enter button located under the encoder dial. The number value shown under the encoder dial
will now appear as the new setting for the “ENV. VAC. ON”, see item (A), figure 17-4.
(B) Press the number value under the “ENV. VAC. ON” button, a numeric touch pad will appear. Manually
enter the number value shown under the encoder dial, then press the “Enter” key on the touch pad. The
number you entered will now appear as the new setting for the “ENV. VAC. ON”, see item (B), figure17-4.
204
(A)
Press the “ENV. VAC.
ON. Button then press
the “Yellow” Enter
button
135
135
(B)
Press the number
value under the
“ENV. VAC, ON.”
Button, a numeric
touch pad will
appear
135
(B)
Enter the number
value shown under
the encoder on the
touch pad then
press the enter key
135
x
150
7
8
9
4
5
6
Del
1
2
3
+ /-
0
AC
Enter
(Fig. 17-4)
205
5. Jog the machine forward until a gripper jaw comes under the “Front Table Jam Sensor”, mounted to the envelope
hopper, continue jagging the machine until the gripper jaw opens, and continue jogging the machine until the
gripper jaw JUST starts to close. STOP jogging the machine at this point, see figure 17-5.
(Fig. 17-5)
Jog the machine forward
until a gripper jaw appears
under the Front Table Jam
sensor
Continue jogging until the gripper jaw has
opened and JUST starts to close, then STOP
jogging the machine
compare it the number under the “ENV. VAC. OFF” button. If the number value under the “Env. Vac. Off” button is
range is greater than 5 degrees, change the number under the “Env. Vac. Off”. This can be accomplished in one
of two ways:
(A) Press the actual button marked “ENV. VAC. OFF”. The button will now read “Press Enter”. Press the
will now appear as the new setting for the “ENV. VAC. OFF”, see item (A), figure 17-6.
(B) Press the number value under the “ENV. VAC. OFF” button, a numeric touch pad will appear. Manually
number you entered will now appear as the new setting for the “ENV. VAC. OFF”, see item (B), see
figure 17-6.
206
(A)
Press the “ENV. VAC.
OFF. Button then
press the “Yellow”
Enter button
330
330
330
(B)
Enter the number
value shown under
the encoder on the
touch pad then
press the enter key
330
(B)
Press the number
value under the
“ENV. VAC, OFF.”
Button, a numeric
touch pad will
appear
x
150
7
8
9
4
5
6
Del
1
2
3
+ /-
0
AC
Enter
(Fig. 17-6)
207
Setting the “Insert Air On / Off”
The Insert Air feature is a dual function feature. It activates the insert air blowing into the envelope to form the envelope
to an open posture following the natural contour of the envelope throat and it activates the insert vacuum dishes located
on the front table in front of the insert air plate which anchor the envelope, holding it securely in place to be inserted. To
setup the Insert Air On / Off, perform the following:
Insert Air On:
(A). Open the envelope menu, and press the “Auto Mode / Setup Mode” button until it reads “Setup Mode”.
(B). Return to the Timing Menu following the procedure stated in step (1) figure 17-7.
(C). Jog the machine forward until it acquires an envelope, continue jogging the machine forward until the lead edge of
the envelope is even with the center groove of the insert air plate then stop jogging, see figure . (Note: Since the
insert vacuum dishes and the insert air are activated from the same timing feature, ”Insert Air On” turning the
insert air on at this position ensures that the vacuum dishes will be at maximum potential when the envelope
comes to the “Full Stop Mark”.)
Jog an envelope forward
until the lead edge is even
with the center groove of
(Fig. 17-7)
(D). Read the number value located under the encoder dial on the Timing menu previously opened in step 2 and
compare it the number under the “Insert Air On” button. If the number value under the “Insert Air On” button is
range is greater than 5 degrees, change the number under the “Insert Air On”. This can be accomplished in one
of two ways:
(A) Press the actual button marked “Insert Air On”. The button will now read “Press Enter”. Press the
will now appear as the new setting for the “Insert Air On”, see item (A), figure 17-8.
(B) Press the number value under the “Insert Air On” button, a numeric touch pad will appear. Manually enter
the number value shown under the encoder dial, then press the “Enter” key on the touch pad. The
number you entered will now appear as the new setting for the “Insert Air On”, see item (B),
see figure 17-8.
208
(A)
Press the “Insert Air
On”. Button then press
button
135
135
(B)
Enter the number
value shown under
the encoder on the
touch pad then
press the enter key
135
135
(B)
Press the number
value under the
“Insert Air On”
Button, a numeric
touch pad will
appear
x
150
7
8
9
4
5
6
Del
1
2
3
+ /-
0
AC
Enter
(Fig. 17-8)
209
Insert Air Off:
1. Acquire a sample of the “Top” piece of the collated set and place it on the insert deck in front of one set of pusher
fingers.
2. Jog the machine forward until the sample piece enters the envelope and travels ¼” to ½” past the lowest point of
the envelope throat, then STOP jogging the machine, see figure 17-9.
(Fig. 17-9)
Note: Envelope was cut
away for visual reference
Jog the machine forward until the
sample piece is ¼” to ½” past the
lowest point of the envelope throat
¼” to ½”
compare it the number under the “Insert Air Off” button. If the number value under the “Insert Air Off” button is
range is greater than 5 degrees, change the number under the “Insert Air Off”. This can be accomplished in one
of two ways:
(A) Press the actual button marked “Insert Air Off”. The button will now read “Press Enter”. Press the
will now appear as the new setting for the “Insert Air Off”, see item (A), figure 17-10.
(B) Press the number value under the “Insert Air Off” button, a numeric touch pad will appear. Manually enter
the number value shown under the encoder dial, then press the “Enter” key on the touch pad. The
number you entered will now appear as the new setting for the “Insert Air Off”, see item (B),
see figure 17-10.
210
(A)
Press the “Insert Air
On”. Button then press
button
295
295
(B)
Enter the number
value shown under
the encoder on the
touch pad then
press the enter key
295
295
(B)
Press the number
value under the
“Insert Air Off”
Button, a numeric
touch pad will
appear
x
150
7
8
9
4
5
6
Del
1
2
3
+ /-
0
AC
Enter
(Fig. 17-10)
211
The Envelope Detect feature is comprised of a Banner AN-7 sensor that emits a short range inferred light, positioned to
reflect off an open envelope flap, back to the sensor. This detector can be positioned anywhere along a 180 degree arc.
The operator has control over when this sensor becomes activated. Once activated the sensor has pulse length of
approximately 2 milliseconds. (In effect, operates much like the shutter on a camera.) In the event the flap of the
envelope you are setting up has any bold lettering or logo art printed in Purple, Red, Orange, Pink or Black ink, reposition
the sensor to read on a non-printed surface of the flap. (i.e.; In-between the printed lettering or logo art.) (Special Note:
Purple, Red, Orange and Pink ink all contain a red pigment that will absorb inferred light to the degree that it will not
reflect back to the sensor causing a “False” detect. Black Ink absorbs all color bands of light.)
To find the number value for the Flap Detect feature, perform the following:
1. Jog the machine forward until the envelope gripper chain stops. A gripper jaw should be a the full stop mark with
the gripper jaw unopened, see figure 17-11.
Inside of the Gripper
jaw aligned with the
full stop mark
Full Stop Mark
(This is a factory applied machine index mark)
(Fig. 17-11)
compare it the number under the “Envelope Detect” button. If the number value under the “Envelope Detect”
button is within a 5 degree range, (+) plus or (-) minus, make no change and move on the next step. If the
number value range is greater than 5 degrees, change the number under the “Envelope Detect”. This can be
accomplished in one of two ways:
(A)
Press the actual button marked “Envelope Detect”. The button will now read “Press Enter”. Press the
will now appear as the new setting for the “Insert Air Off”, see item (A), figure 17-12.
(B)
Press the number value under the “Envelope Detect” button, a numeric touch pad will appear. Manually
number you entered will now appear as the new setting for the “Envelope Detect”, see item (B), see
figure 17-12.
212
(A)
Press the “ENV
DETECT”. Button then
press the “Yellow”
Enter button
125
125
125
(B)
Enter the number
value shown under
the encoder on the
touch pad then
press the enter key
(B)
Press the number
value under the
“ENV DETECT”
Button, a numeric
touch pad will
appear
125
x
150
7
8
9
4
5
6
Del
1
2
3
+ /-
0
AC
Enter
(Fig. 17-12)
213
The “Feeder Start Time” can be altered at any time during a job setup or job run in order to accommodate any type of
paper or any change in paper characteristic. Ideally the paper should feed from the feeder at a 22 degree down angle
plane and strike the back of a set of collator pusher pins near the track rails, see figure 17-13.
Time the feeder to feed the paper so that it
strikes the back of the collator pusher pins near
the track rails
(Fig. 17-13)
Typical factory set feeder start times are as follows:
4 Pusher Configuration – 200
3 Pusher Configuration – 75
2 Pusher Configuration - 100
In the event you observe the material lead edge landing on the top of the collator pusher pins, manually put in a HIGHER
number value for that feeder start time. In the event you observe the material trailing edge landing on the top of the
collator pusher pins, manually put in a LOWER number value for that feeder start time.
214
215

Flowmaster RS Manual

Transcription

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