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FlowMaster 12000

Operator’s Manual Copyright Sure-Feed Engineering, Inc. 2000. All rights reserved.

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FlowMaster 12000 Operator’s Manual

(Version 4.2) 2

Notice This manual is updated frequently to accommodate changes, modifications and updates made to the FlowMaster inserter software and / or machine. As these changes are made the version number of the manual will also change. Please check our web site, www.Sure-Feed.com


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Table of Contents Section I Power up the FlowMaster 12000 …………………………….……… 8 Cycling the FlowMaster ……………………………….……………… 8 Safety Features ……………………………………………………….. 8 Section II Insert Air Plate Set Up …………………………………………..…… 9 Setting the Insert Air Pressure ……………………………………… 11 Section III Material Track Set Up …………………………………………..……. 12 Setting the Material Pusher Pins ………………………………….… 13 Setting the Material Drag Straps ……………………………………. 14 Section IV Material Feeder Station Set Up ……………………………..……… 15 Material Feeder Options: Batch Count ………………………………………….. 21 Feeder Back Up Feature …………………...………. 22 Multiple Feeder Back Up Feature ………………..... 23 Cascade Feature …………………………..……...… 23 Section V Envelope Settings ………………………………………………...…. 24 Envelope Options:

Jog Miss Feature …………………………..……….. 26 Miss Stop Feature …...……………………….…….. 26 Immediate Miss Feature ………….…..…….……… 26 Multi Try Feature ………………………………….… 27 Divert Feature ……………………………………….. 28 Set Air Pressure for Divert ……………………….… 29


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Section VI Envelope Feed Hopper Set Up …………………………………..…. 30 Section VII Settings to Open Envelope Flap ………………………………….…. 32 Section VIII Setting the Front Table Position …………………………………..… 35

Setting the Envelope Vacuum Plate ……………………………...… 36 Aligning the Insert Entry Fingers …………………………...……….. 37 Entry Finger Safety Bulletin …………………………………………. 39

Section IX Continuous Envelope Feed Conveyor Set Up …………………….. 40 Setting the Envelope Height Sensor ………………………….....…. 41 Section X Envelope Turnover ……………………………………………………. 42 Section XI Water System …………………………………………………………. 45 Section XII Starting the Job ……………………………………………………….. 47 Section XIII Ending the Job ………………………………………………….…….. 49 Section XIV Front Table: Mechanical Timing Settings Timing and Height Settings for the Right Gripper Jaw ...…………. 52 Timing the Envelope Shuttle Cam ………………………………….. 54 Timing and Height Setting for the Center Gripper Jaw …………… 55 Collator: Mechanical Timing Settings Timing the Insert Pusher Fingers

……………………………….…... 57 Timing the Material Belts

………………………………………….…. 58 Timing the Encoder …………………………………………………... 60 Timing the Insert Entry Fingers ……………………………………... 63


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Section XV Electronic Timing Settings ……………………………………..……. 64 Envelope Vacuum Timing “ON” …………………………….………. 65 Envelope Vacuum Timing “OFF” …………………………………… 66 Setting the Material Feeder Start Time ………………………...….. 68 (Machines manufactured after June 1, 2000) Setting the Material Feeder Start Time …………………...…..…… 70 (Machines manufactured before June 1, 2000) Timing the Insert Air “ON” …………………………………………… 72 Timing the Insert Air “OFF” ………………………..………………… 73

Batch Interrupt Setting ……………………………………………….. 74 Envelope Flap Detector Setting ………………………...……...…… 76 Setting the Missed Flap Position ……………………………………. 78 Setting the Collator Track Jam Detector ……………………...……. 79

(Machines manufactured after June 1, 2000) Section XVI Front Table Lubrication …………………..………………………….. 81

Center Envelope Gripper Jaw Opener Assembly ……………….... 82 Right Envelope Gripper Jaw Cam Follower …………………….…. 82 Front and Back Envelope Feed Shuttle Control Shafts ……..…… 83 Envelope Feed Shuttle Cam Follower ………………………..……. 83 Envelope Gripper Jaw Chain ………………………………..……… 84 Index Drive Cam Box ……………………………………………...… 85 Left Bearing, Left Section, Main Drive Shaft …………...…………. 86 Square Slid Drive Shaft, Main Drive Pulley to Collator ……………86 3-Way Crown Gear Drive …………………………………...….…… 87 Right Bearing, Right Section, main Drive Shaft ………...………… 88 Front and Back Bearings, Envelope Feed Shuttle ………...……... 88 Miter Gears ……………………………………………………………. 88

Collator Lubrication ……………………..…………………………… 89 Pusher Chain Assembly …………………………………………….. 90 Envelope Entry Finger Control Shaft Bushings ………………...… 90 Envelope Entry Finger Cam Follower ……………………………... 91 Front and Back Bearings, Collator, Main Drive Shaft ……………. 92 Front and Back Bearings, Material Belt, Main Drive Shaft …….... 92 Pusher Finger Chain Maintenance ……………………………….... 93


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Section XVII Optics Mark Reader Installation …………………………………… 96 Items Needed ……………………………………………………...… 96 LED Installation …………………………………………………...…. 97 LED Electrical Wiring ………………………………..………………. 100 Installation of the OMR Sensor …………………………………….. 102 Operate the Vertical Sort Conveyor by Sort Mark …….………….. 105 Operate the Vertical Sort Conveyor by Batch Count …………….. 105 Operate as a Shingle Conveyor ……………………………………. 106

Section XVII Trouble Shooting the FlowMaster 12000 ………………...…………108


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FlowMaster Orientation

Material Feeders

Continuous Envelope Feed Conveyor

Insert Deck and Pusher Finger Assembly

Front Table

Envelope Turnover Envelope Shingle Conveyor

Envelope Feed Hopper

Collator

Interface Run Screen


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Section-I Turning the Machine on and Cycling the Machine Power Up the FlowMaster: 1. Turn on the power supply switch located at the back of the collator below feeder station number 1.

Turn this switch in a clockwise direction until it engages. 2. Go to the digital “Operator Interface Screen” located over the feeder stations near the inserter

pusher assembly. The operator interface screen will automatically come up on the “Run Menu” window when the machine is powered up. This is a sensor touch screen. Any function you may wish to change or set can be accessed simply by touching the button style icon displayed on the screen. The operator interface screen has been mounted on a swivel and can be pivoted 180 degrees to face either end on the machine.

3. Press the “Motor Power” button located in the lower right hand corner of the Run Menu screen,

which will engage the drive motors in the machine. (Note: If the machine is left inactive for a period of fifteen (15) minutes, the drive motors will go into a dormant or sleep state. An alert, “Turn Motor Power On” will appear on the operator interface screen and it will be necessary to press the “Motor Power” button again.)

4. To jog the machine, the blue safety button and the yellow jog button must be pressed at the same

time. To run the machine, the blue safety button and the green run button must be pressed at the same time. The safety buttons are spaced apart from the main buttons so that the operator must use both hands to engage movement of the machine, this ensures that the operator’s hands are in a safe position when the machine starts. The red reset, yellow jog and green run buttons are located on top of the collator cabinet near feeder #6. There are two (2) blue safety buttons on the machine, both are on top of the collator cabinet, one is located near the exit end of the insert pusher finger assembly, the other is located near feeder #3.

Safety Features: All FlowMaster inserters come equipped with the following safety features: Electronic Safety Barriers – Two sensors form an inferred beam that runs the length of the collator from

feeder number one (1) to the insert pusher finger cover. Any disruption of this beam that occurs between any of the feeders over the material path will cause the machine to stop. Any time the insert pusher finger cover is opened will also cause a disruption of the beam. When this safety barrier has been breached, a massage reading “Safety Barrier Broken” will appear on the operator’s interface run screen. There are two more sensors forming a barrier over the envelope chain of the front table, this barrier is also integrated with the machine’s jam detector system. When this barrier is breached, the machine will stop and a message reading “Front Table Jam” will appear on the operator’s interface run screen.

Interrupt Switches – Both cabinet doors of the front table are equipped with an interrupt switch. Once the

door has been opened, the machine stops, the compressed air flow is stopped, allowing the pressure in the system to dissipate and a message reading “Front Table Open” will appear on the operator’s interface run screen.

Safety Stop Buttons - There are two (2) red safety stop or emergency stop buttons on the collator section

of the machine. One is locate near feeder #2 the other is located near the insert pusher finger assembly. Another safety stop is located at the center of the side cover on the shingle conveyor or sort conveyor.

(Warning: Machine warranty will void if safety devices are altered, removed or tampered with!)


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Section-II Insert Air Plate Set Up The FlowMaster 12000 comes equipped with four (4) standard size Insert Air Plates. (Other sizes can be purchased) The insert air plate works with compressed air in synchronized time with two vacuum plates to form and open an envelope with very little distortion, allowing for smooth insertion at any speed. The correct size to use should measure 1” less in width at the front edge of the plate, than the inside width of the envelope. This rule should be observed at all times for optimal inserting at any speed. 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. 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”) 4. Remove the four (4) phillips head screws from the base of the insert air plate that was previously

used. 5. Lift up the front edge closest to the envelope chain, then pull the plate towards the envelope chain

to remove it. 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. (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 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)

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.)


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(Fig. 1)

Top view of Insert Air Plate (Staged)

Front view of Insert Air Plate Showing air orifice

(Staged)

Insert Air Plate Orifices

Phillips head screw locations


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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 XIV page 672.) To adjust the air pressure setting:

1. Gently pull up on the control knob located on the collator cabinet between the insert box cam and the envelope feed conveyor.

(Fig. 2)

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

(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 26, page 38, showing the direction and path the air follows from the insert air plate.)

Air Pressure Gauge

Insert Air Pressure Control Knob


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Section-III Setting Up the Material Track 1. Loosen the button head allen screws at the end of the machine, near feeder #1, that secure both material side rails to the material pathway. 2. Using the widest piece of material being used in the job, fold it in half to create a center crease,

then unfold the 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.

(Fig. 3)

Material Side Rails

Align center crease in setup piece with phillips head screw in center track section

Button head screw


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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 3, page 12) 5. Tighten the button head allen screw to secure the side rail to the material path. 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. (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. Setting Material Pusher Pins The FlowMaster 12000 is equipped with four (4) material belts, outer left, center left, center right and outer right. Each belt has thirty (30) removable material pusher pins that are aligned to form rows of pusher pins in groups of four (4) to transport material in the pathway. These pins are snap 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 remove some of the material pusher pins from the material belts in the pathway, in order to narrow the material pathway. Keep in mind that the FlowMaster 12000 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 removing 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 near feeder number one (1), as shown in figure 4.

(Fig. 4) Material Pusher Pins

Phillips head screws

Material Track Sections


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B. Use pliers to firmly grasp each pusher pin at the middle, twist and pull in a straight upward motion.

(Note: To prevent scarring the pusher pins, wrap the jaws of the pliers liberally with electricians’ tape. ) C. Repeat steps one (1) and two (2) until all of the pusher pins from both outside material belts are

removed. D. Once all of the material pusher pins are removed, jog the machine forward for thirty (30) to thirty-five

(35) cycles while watching the material pathway, to ensure that none of the outside belt pins were overlooked.

E. Continue the setup by positioning the material side rails as stated in steps one(1) through nine(9) of

this section. (Note: The position in which you remove 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.) To return to a standard size setup, return the material pusher pins to their belt blocks by: A. Spread the material side rails so they are not over slots the material pusher pins travel in. B. Jog the machine forward until the two (2) center pusher pins are even with the phillips head screws,

that secure the material track sections to the material bed, near feeder number one (1)as shown in figure 4, page 13.

C. The nylon pin blocks should be clearly visible through the slots between the track sections. D. Hold one end of a pusher pin over the hole in pin block, using a nylon or rubber mallet, tap the pin into

the block until it bottoms out. (Note: Use only light to moderate force when setting pusher pins into pin blocks)

E. Repeat steps C and D until all of the material pusher pins have been set back into the pin blocks. F. Once all of the material pusher pins have been reseated, jog the machine forward for thirty (30) to

thirty-five (35) cycles while watching the material pathway, to ensure that all pusher pins have been restored to their proper position.

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)


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Section-IV Setting Up the Material Feeder Stations: 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 5. (Note: It is important to select feeders in chronological order, starting from the lowest number feeder) (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. See figure 13, page 23)

(Fig. 5) 2. Press the On / Off button to engage the feeder. 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 6, page 16.)

C. Place the creased piece on the feeder friction belts D. Align the crease with the phillips head screws located on the metal shroud, on the

separator wheels. (See figure 7, page 17.) 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)

Feeder Select Buttons


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(Fig. 6)

Staged view of feeder side guide, off the feeder

Lever style knob, locks the side guide vertically

Round style knob, locks the side guide horizontally


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(Fig. 7) 5. Set the “Wedge” under the material to obtain the proper stack angle for feeding, see figure 8, page 18. 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)

Phillips head screws

Top view of feeder showing separator wheels centered on material

Separator Wheel Shroud


(Version 4.2) 18

6. 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 8. (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) 7. Set the gap or nip of the “Ejector Rollers”. Turning the adjustment knob (See figure 8 and figure 9

page 19) 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)

8. Fill the feeder with material. The feeders are designed to hold a stack of material up to twenty

inches, depending on the characteristics of the material. 9. Test this part of the set up by pressing the “One Shot” button, found on the feeder menu, see

figure 5, page 15 to advance one piece at a time. Check the pieces as they feed to ensure proper separation.

(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. 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 and hold down the red reset button located on the collator cabinet for two (2) seconds)

(Fig. 8)

Separator Wheel Adjustment Knob

Ejector Roller Adjustment Knob

Material Wedge

Separator Wheel


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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 5, page,15.)

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. (See figure 9) 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. (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 “Latch” light comes on under double detector icon. (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))

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 every feeder)

(Fig. 9)

Double Detector Adjustment Knob

Top Ejector Roller

Top Ejector Roller Adjustment Knob

Miss Sensor

FRONT VIEW

Double Detector Roller


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10b. Set the “Double Detector” by: Method Two, Absence 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 5, page,15.)

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 (See figure 9, page 19) in a counter clock wise direction until the “Latch” light under the double detector icon

comes on. (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 “Latch” 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. 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 left-hand corner of the set up menu window. This will automatically return you to the “Run Menu”.


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Material Feeder Setting Options: Optional Batch Count Any feeder can be independently set to cycle a predetermined number of times more than the machine. To engage this feature: A. Press the “Batch Count” button found in the feeder menu until it reads “Batch On”. B. Press the “Number” space, located to the right of the batch count button, to bring up a numeric touch pad. . Enter the number of pieces you wish to count per batch. C. Press the return arrow found at the bottom right hand corner of the touch pad to return to the feeder menu. (Note: The word “Batch” will appear on the main Run Screen below each feeder icon that has this option engaged)

(Special Note: It will be necessary to set an interrupt stop for the material belt when using the batch option. See “Batch Interrupt” of Section XV, Timing Settings, pages 74 and 75)

(Fig. 10)

1 2 3

4 5 6

7 8 9 0

-

. DEL

Batch Count Button


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Optional Feeder Backup Feature The backup feature makes it possible for an operator to run thick or hard to handle material without constant intervention. When the primary feeder runs out of material, the backup feeder takes over allowing the operator to re-supply the feeder when they choose to instead of when they have to.

Any material feeder can be backed up with another feeder. The back up feeder selected must be the next feeder up from the primary feeder, in numeric order. To engage this feature: A. Press the feeder number button of the selected backup feeder to bring up the setup menu window. B. Press the “#0” at the bottom of this window, a numeric touch pad will come up. C. Enter the number of the primary feeder being backed up, then press the return arrow to return the feeder menu window. (This will notify the backup feeder to engage only when the primary feeder misses, when the primary feeder resumes feeding, the backup feeder will stop) D. Set up the other backup feeders following steps #2 through #8 of this section. (Note: a <<< symbol will appear on the main Run Screen below each feeder icon that has this option engaged) (Fig. 11)

1 2 3

4 5 6

7 8 9 0

-

. DEL


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Optional Multiple Feeder Backup Feature Any material feeder can be backed up with several other feeders in numerical order. All of the back up feeders selected, must be selected in ascending numeric order from the previous backup feeder To engage this feature: A. Press the #1 feeder to bring up the feeder menu window. B. Press the “Multiple Backups On / Off” button until it reads “Multiple Backups On”. (Note: Feeder #1 does not have to be part of the feeder group to use the Multiple Backup feature. The menu window must be brought up only to engage this feature) C. Follow steps A through D of the “Optional Feeder Backup Feature” section. (Fig. 12)

Optional Cascade Feature This feature can only be used in feeder #1 and only when feeder #1 has no designated backup feeder. This feature will stop each feeder sequentially, in ascending order, including the envelope feeder, in the event feeder #1 has a skip-feed, allowing that space on the material belt where the skip-feed occurred, to travel through the entire collator and insert deck without creating an incomplete collated insert set. (This feature can be used in feeder #1 in conjunction with other feeders using other options) To engage this feature: A. Press the “Cascade” button found only in the setup menu window for feeder #1. (Fig. 13)

Multiple Backups Button

Cascade Button


(Version 4.2) 24

Section-V 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. (Fig. 14)

Envelope On Button

1 2 3

4 5 6

7 8 9 0

-

. DEL


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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 14, page 24. (Helpful Tip: Most envelopes manufactured in the United States, seal well with the water time set at “01”) (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. Select the correct envelope size by pressing the “Envelope Size” button located at the bottom of the envelope menu. (A size reading of “#10 or 6X9 will appear below this button) (Note: The FlowMaster is programmed to equate envelope size to the size of the material being inserted. If you have selected a 6X9 envelope, the FlowMaster will presume that the material being inserted measures approximately 51/2 “ X 81/2” and will automatically advance or retard the speed of the material feeders accordingly. If a smaller size piece is actually being inserted into a 6 X9 envelope, the material feeder may run the piece at an accelerated speed and detect a “False” miss. If this occurs, it may be necessary to select the envelope size based on the smallest size piece being inserted, instead of the actual size of the envelope being used) 5. To set the envelope detector see (Section XV, Electronic Timing Settings, figure 66, page 76) 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, page 29. 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 33, page 46, to limit the water flow in the line.


(Version 4.2) 26

Setting Options in the Envelope Menu Window: The FlowMaster 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 “Immediate Miss / Multi Try” 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.

(To set the position that the machine stops in, see Section-XV, Electronic Timing Settings, figure 71, page 78)

(Fig. 15) “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. Immediate Miss / Multi Try Button “Immediate Miss” This will stop the machine without any continuation in the event of a missfed envelope. This will require the operator to manually correct the problem.

Jog Miss / Miss Stop Button Press this button to display the desired feature


(Version 4.2) 27

“Multi Try” This will allow all material feeders and the material track belts to continue running and “Divert” the collated material while the machine attempts to feed envelopes for a predetermined number of cycles. (Note: The Divert Air option will

automatically engage when the “Multi Try” option is turned on) The operator can set the number of attempts the machine tries to feed before stopping, by pressing the “Number Area” located under the “Immediate Miss / Multi Try” button. This will bring up a numeric touch pad, enter the number of times you want the machine to try to feed an envelope before stopping and press the return arrow to close the touch pad window. The number of tries will now be displayed in the envelope menu. With this option engaged, the machine will feed material and divert it until an envelope successfully feeds or the predetermined number of cycles has lapsed. (Note: It is not recommended setting this option at more than two (2) attempts) (Warning, materials may be damaged or spoiled

using this option) (Fig. 16)

Immediate Miss / MultiTry Button Press this button to display the desired feature

1 2 3

4 5 6

7 8 9 0

-

. DEL


(Version 4.2) 28

Divert On/Off Button “Divert On” This allows the machine to continue to run the material group containing an

incomplete collated set without disrupting the integrity of the other material groups in the material track or stopping the machine. When the missfeed 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 miss

occurred. A signal is also sent to the envelope feed hopper disabling the impulse to feed an envelope for the particular material group containing the missfeed. The machine then allows the incomplete collated set to be pushed over the envelope chain by the insert pusher fingers, then engages the two air jets located below the envelope chain and blows it clear from the machine. This will occur in the event of miss fed material. The amount of air pressure for this option can be regulated. The control knob for this setting is located under the insert deck and can be accessed through the side cover of the collator. (See figure 18, page 29)

(Note: The words ”Divert Mode Is Active” will appear on the main Run Screen when this option is engaged. (Warning, materials may be damaged or spoiled using this option) (Fig. 17)

Divert On/Off Button


(Version 4.2) 29

(Fig. 18) To set the divert air pressure:

4. Gently pull up on the control knob to unlock it.

5. To increase the air pressure, turn the knob clockwise. 6. To decrease the air pressure, turn the knob counter clockwise. 7. Once the air pressure has been set, push the control knob back down to lock it.

Divert Air Pressure Control KnobAir Line leading to Pressure

Gauge, Controlling Insert Air Pressure

Air Line leading to the Manifold of the Insert Air Plate

Air Line leading to Water Tank

Air Line leading to Divert Air Manifold

Air Hose leading to Solenoid for Venture Vacuum for Envelope Vacuum Shuttle

Air Hose leading to Solenoid for Venture Vacuum for Envelope Vacuum Ports

Water Tank Air Pressure Control Knob


(Version 4.2) 30

Section-VI Envelope Feed Hopper Set Up: 1. Press the “Auto Mode / Setup Mode” button on the main run menu, allowing the

envelopes to run without the material feeders engaged. When the set up mode is on the words “Setup Mode” will appear in the button and on the main run screen and the Blue Safety Buttons will begin flashing.(Note: The Auto Mode / Setup Mode button may appear in the envelope menu)

(Fig. 19) 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”. 3. Place an envelope into the envelope feed hopper, holding the flap edge of the envelope flush against the inside surface of the stationary guide of the envelope feed hopper 4. Adjust the side rail until the inside surface almost touches the bottom edge of the envelope and secure the rail lock knob in this position. 5. Go to the exit end of the front table and place an envelope in the envelope track with flap edge flush against the inside surface of the stationary exit. front table. 6. Adjust the side rail until the inside surface almost touches the bottom edge of the envelope and secure the rail lock knob in this position. 7. Place a moderate stack of envelopes into the envelope feed hopper. 8. Set the trailing end guide of the envelope feed hopper to a position approximately 1/16” greater that the length of the envelope, then tighten the lock knob to secure this setting.

Auto Mode/ Setup Mode

Set Up Mode


(Version 4.2) 31

9. Jog the machine to the position where the envelope feed shuttle has retracted completely into the envelope feed hopper. Set the envelope jog wedge, located on the trailing end of the envelope feed shuttle so that the thinnest edge rest approximately 1/4” under the envelope stack. 10. Jog the machine forward until the lead edge of the envelope feed shuttle is just under the feed gate. 11. 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 20.)

(Fig. 20) Section-VII

Envelope Feed Gate

Height Adjustment Knob Envelope

Height Sensor


(Version 4.2) 32

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. (Note: Machines manufactured after August 1, 2000 may come equipped with a flap opener that requires less adjustments.) 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 pre-open flex guide, as shown in figure 21.

(Fig. 21)

Pre-open Flex Guide Adjustment Knob

Pre-open Flex Guide

Top of Envelope Wheel Opener (Most of the wheel is below the surface of the envelope track)

Envelope Wheel Opener Assembly

Envelope Feed Gate Adjustment Knob


(Version 4.2) 33

2. Turn the adjustment knob on the Pre-Open Flex Guide, until the flap edge is slightly bent just below the surface of the envelope track. (Turn the adjustment knob clock wise will lower the guide and increase the amount of bend to the envelope flap edge, counter clockwise will raise the guide and decrease the amount of the bend. When this is properly set, the flap edge of the envelope should feed smoothly over the wheel of the “Envelope Wheel Opener Assembly” See figure 21, page 32)

3. Slowly jog the machine forward and observe the lead edge of the envelope, if the envelope

appears to skew or twist from the gripper jaw, the flex guide is set too low. If the lead edge of the envelope appears to strike the opener wheel instead of ride over it smoothly, then the flex guide is not set low enough.

4. 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. Adjust the position of the plow by: A. Loosen the socket head allen screws holding the clamp on the mounting bar for the plow.

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 4, tighten the socket head allen screws. (Caution: When positioning the plow, be sure to leave

enough clearance for the envelope gripper jaw to pass) (Fig.22)

Staged view of Plow showing flap guide rod

Plow Adjustment Socket head allen screws and clamp.

Flap Guide Rod


(Version 4.2) 34

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. Loosen the socket head allen screws holding the rod clamp on the trailing end of plow.

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)

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 22, page 33.)


(Version 4.2) 35

Section-VIII 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 envelope is in front of the insert deck. (Note: The envelope chain should be stopped when forward movement has ceased and the gripper jaw is still closed.) 3. 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. 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) C. Press the right or left direction arrow buttons to move the Insert Table and position the center of the envelope throat to the center of the insert air plate. (Fig. 23)

Front Table Button


(Version 4.2) 36

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 port, which is always open. This plate is positioned so that the leading edge of an envelope will be over the vacuum port when the envelope chain stops. The other vacuum plate contains three (3) vacuum ports 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.

(Fig. 24) 5. Set the “Envelope Insert Vacuum Plate” by: A. Jog the machine forward until an envelope stops in front of the insert air plate.

B. Observe the location of the vacuum ports in relationship to the trailing edge of the envelope. One of these three ports needs be under the envelope approximately 1/4” from the trailing edge. If this is already the case, skip to step “D” and proceed, if this is not the case, proceed with step “C”)

C. Loosen the two (2) philips head screws, closest to the envelope chain, then slide the vacuum plate into position so that one (1) of the vacuum ports is situated 1/4” under the envelope from the trailing edge. (Warning: Only loosen, removal these two (2) philips 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) philips head screws. (Caution: Do not over tighten) 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. (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)

Vacuum Plate Adjustment Screws

Vacuum Ports


(Version 4.2) 37

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 26, page 38, 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 four (4) 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 lock knobs, located at the top of each entry finger arm.

3. Position the side entry fingers to enter the envelope just inside each end of the

envelope. 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. (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. 25)

Entry Finger Lock Knobs

Envelope Entry Fingers Note: The two outside entry fingers are inside the throat of the envelope. The two center entry fingers are not due to a deep “V” cut into the throat by the envelope manufacture.


(Version 4.2) 38

5. Check the insert material with the entry fingers

6. Place a complete set of collated material to be inserted into the envelope in the material track in front

of feeder number 6. 7. Jog the machine forward until the material until is ½” to ¾” from the throat of the envelope. In this

position you should see the corners of the insert material leading into the envelope about to pass directly under the outer entry fingers. If not, further adjustments must be made as stated above in steps 2 through 4. (Note: The tips of the envelope entry fingers should be just entering the envelope ahead of the insert material. (See item #1, figure 26.) If they are not entering the envelope ahead of the material, the timing must be re-set, proceed to page 63 of Section XIV, Mechanical Timing Settings)

(Fig. 26)

1

9

4 3

8

7

2

6

5

1 - Insert Entry Finger Assembly 6 – Insert Air Plate 2 – Direction of Air Flow 7 – Static Flap Brush 3 – Cut Away Side View of Envelope 8 – Cut Away Side View of Envelope 4 – Insert Material Chain Track 5 – Insert Pusher Finger 9 – Stationary Vacuum Port

2

2


(Version 4.2) 39

Safety Tip The FlowMaster 12000 is equipped with 4 entry finger arms. During certain setups you may elect not to use all of the entry fingers. In the event you wish to disengage some of the entry finger arms, it is necessary to completely remove them from the machine. It has recently been brought to our attention that some machine operators have been moving the entry finger arms up, off of the insert air plate instead of removing them. When the entry finger arms are repositioned to allow free movement away from the surface of the insert air plate, it creates a potential machine problem and a safety concern as well. To remove the entry finger arm from the machine:

1. Hold the entry finger arm and remove the ratchet knob and the socket head allen screw located at the top of this assembly. (See the figure below)

2. Once the ratchet knob and socket head allen has been removed, the entire assembly can be

removed and safely stored until required on a different set-up.

(Helpful Tip: To prevent the loss of small parts, return the ratchet knob and socket head allen screw to their original position on the entry finger arm assembly before storing.)

[Safety Illustration]

Remove these items to remove entry finger assembly

Comment [BS1]:


(Version 4.2) 40

Section-IX Continuos Envelope Feed Conveyor Set Up: The continuos envelope feed conveyor was designed to limit operator intervention to load envelopes. This will allow the operator more time to perform quality checks, sort, tray, sleeve and tag completed mail. This conveyor is bolted to the base of the front table. When the front table is moved to align an envelope for inserting, as shown in “Section VIII”, page 35, it may become necessary to make some adjustments on the continuos feed conveyor. 1. Loosen all three (3) lock knobs on the long envelope guide rail. 2. Adjust the feed end of the guide rail so the inside surface is in line with the inside surface of the feed gate. (The straight edge of an envelope can be used to assist you with this adjustment, see figure 27) Tighten the lock knob to hold the feed end of the rail in that position. (Fig. 27) 3. It is important that the envelopes track straight on the conveyor. To ensure straight tracking, the

long envelope guide rail must be parallel to the edge of the conveyor cabinet. Measure the distance between the back surface of the feed end of the rail to the back edge of the conveyor cabinet. Set the trailing end of the back rail to match the measurement taken at the feed end, then secure the rail lock. (Again, this can be done using an envelope. Simply hold one end of an envelope against the outside edge of the back rail and crease it at the point where it bends over the back edge of the conveyor cabinet) Once the rail is in position, tighten the trailing end lock knob, then tighten the center lock knob.

(Note: It may be necessary to repeat the steps in this section, if further adjustments are

made to the front table position as shown in “Section VIII”, page 35.)

Envelope Guide Rail

Inside surface of the envelope feed gate

One of three Lock Knobs


(Version 4.2) 41

(Fig 28) Setting the Envelope Height Sensor The envelope height sensor is located on the same mounting bracket as the trailing end guide of the envelope feed hopper. (See figure 28) This sensor governs the amount of envelopes fed into the envelope hopper by the continuos feed conveyor. The sensor recognizes the presence of the envelopes in the feed hopper, as the envelopes are fed out of the hopper, the height of the envelope stack drops below the level of the sensor, the sensor then sends a signal to the Programmable Logic Controller, (PLC). The PLC sends a signal to activate the drive motor of the envelope feed conveyor, the conveyor then refills the envelope hopper to the height the sensor has been set to. The height of the envelope stack is important. If the stack is too high, it may cause too much resistance for the envelope shuttle to feed properly. To adjust the height of this sensor: 1. Loosen the lock knob located of the back of the sensor mount by turning it in a counter clock-wise

direction. 2. The sensor can be slid up or down in the bracket slot. Position the sensor so that the center of the

eye is approximately 3” off the surface of the envelope feed shuttle. 3. Tighten the lock knob of the sensor. (Note: The position of the envelope height sensor as described above is intended as a reference point to start from. The sensor may need to be raised or lowered to accommodate the specific characteristics of the envelopes you wish to run.)

Envelope Feed Conveyor

One of Three Lock Knobs Envelope

Height Sensor


(Version 4.2) 42

Section-X Envelope Turnover When an envelope has been inserted, the envelope gripper jaw closes on it again and feeds it under the flap moistener brush then to the end of the front table. At this point the envelope is still positioned with the flap side facing up. The envelope turnover takes the envelope from the front table and turns the envelope over so the front or address side is face up. The envelope then exits the envelope turnover onto the shingle conveyor for sorting. (Note: Ink Jets, postage meters and stampheads can also be installed inline between the envelope turnover and shingle conveyor.) 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 29, page 43. 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 30, page 43.)

3. Set the tension roller of the envelope turnover to it’s 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 31, page 44.

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 a fully inserted 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.

Helpful Tip: Jamming or flap wrinkling may occur if the flap closure guide rod is up too high over the inserted envelope. This guide can be re-shaped by hand using little to moderate force, see figure 31, page 37.


(Version 4.2) 43

(Fig. 29)

(Fig. 30)

Envelope Turnover Leveler Foot

5/8” Lock Nut

Note: The space between the surfaces of the Front Table and the Envelope Turnover must be maintained.


(Version 4.2) 44

(Fig. 31)

Envelope Turnover

Front Table

Top Tension Roller of Envelope Turnover

Exit Idler Roller of Front Table

Tension Roller Adjustment Knob

Retaining Nut


(Version 4.2) 45

Section-XI Water System: The FlowMaster has a pressurized water system that distributes water to the flap moistener brush in consistent increments. The water tank is pressurized with air at 3 to 4 psi. Water is fed from the water tank through a solenoid to the flow valve then to the flap moistener brush. In order to monitor how much water gets to the moistener brush, the solenoid can be programmed, as described in “Section V”, page 24 to open in increments of ten (10) milliseconds per machine cycle. Water volume can also be regulated manually at the flow valve. (Note: The factory setting is, solenoid timing set at 1, with the flow valve opened all the way. This setting works well in most applications.) The moistener brush is mounted in a fixed position over a conical shaped idler roller. The idler roller brings the flap of the envelope to bear on the moistener brush. An overflow tray is mounted below the idler roller to collect any excess water that may roll off the idler roller. A drain hose runs from the overflow tray to the bottom frame of the collator. A receptacle (not supplied) needs to be placed here, such as an empty milk jug or something similar Filling the Water Tank 1. Open the left cabinet door of the “Front Table”. (You’ll find the water tank located on the inside left front leg) 2. Open the filler valve located at the top of the tank. 3. Fill the tank using only clean water. To know when the tank is full, check the water level tube located on the side of the tank. (Tip: You may wish to use a funnel to avoid spillage) 4. Close the filler valve on the top of the water tank. (Note: The water tank will not become pressurized unless this valve is closed) 5. Go the “Run Menu” A. Press the Maintenance button located in the upper right hand corner of the screen. This will bring up the maintenance window. B. Press the “Water On” button a few times to prime the flap moistener brush. Water will be visible in the hose when the brush is fully primed. C. Return to the run screen by pressing the “Run Screen” button located at the bottom right hand corner of this window. (Fig. 32)

Maintenance Button Water On Button


(Version 4.2) 46

(Fig. 33) (Note: Use only clean water to fill the water tank, do not use water from the over flow receptacle.)

Fill Valve

Water Level View Tube

Water Solenoid and Flow Valve

Water Tank

Air Hose and Fitting (Used to pressurize the tank)


(Version 4.2) 47

Section-XII Starting the Job: Go the operator interface screen: 1. Turn off the “Setup Mode” by pressing the setup mode button. The button will now read ”Auto Mode” and the words “Setup Mode” will no longer appear on the main run menu. 2. Press ”Job#” found in the lower left hand corner of the run screen. This will bring up a numeric touch pad. Enter the job number, then press the return arrow found in the lower right hand corner of the touch pad to return to the run menu. 3. Press the “Sequential Start”. (Note: When pressing the Sequential Start button, the button will read “Seq. Stop” in preparation for the end of the job) 4. Select the speed you wish to run the job, by pressing one of the cycle speed indicators shown at

the bottom of the run menu. 5. Press the “New Job” button, this will clear the amount shown in the “Piece Count” section of the run screen and record the date and time the job was started in the report section of the controller. 6. Look over the material path, the envelope chain and insert deck to be sure no tools or setup materials were left in the path of any moving parts. 7. Press the blue safety switch and the green start switch at the same time. (Fig. 34)

1

2

3

5

4


(Version 4.2) 48

The FlowMaster will start collating the job in the sequence order employing all of the features and options the operator selected in the setup. Stop the machine after it has inserted two or three envelopes. Open one of these and check to see that the correct materials were used in the set up, the correct collation order was setup and the envelopes are sealing properly. If window envelopes are being used, check to see that all address information appears in the window.


(Version 4.2) 49

Section-XIII Ending a Job: To end a job, go to the interface run screen: 1. Press the “Sequential Stop” button on the run menu.

(Note: When pressing the Sequential Stop button, the button will read “Seq. Start” in preparation for the beginning of the next job)

The FlowMaster will stop each of the selected feeders in the same order it was setup in and shut off the envelope feeder when the last collated set exits the collator. 2. Press the “End Job” button, this will record the date and time the job ended and complete

all computations in the reports section of the database. 3. Remove any excess material that may be remaining in the material feeders, envelope feeder and feed conveyor. The FlowMaster is programmed to provide you with report information. To acquire this information: 1. Press the “Trend” button on the run menu. This will display a graph

screen showing:

The “Current Rate” of pieces per/hour (shown as a red line)

The “Average Rate” of pieces per/hour over an 2 hour period (shown as a blue line)

The “Start” date and time

(Fig. 35)

(Note: The 2-hour trend report is typically used to show how well a single job ran.)


(Version 4.2) 50

2. Press the words “2 HOUR TREND” on the trend report screen to change to an 8-hour trend report. This will display a graph screen showing:

The “Current Rate” of pieces per/hour (shown as a red line)

The “Average Rate” of pieces per/hour over an 8 hour period (shown as a blue line)


(Fig. 36)

(Note: The 8-hour trend report is typically used to show how efficiently the shift ran.)


(Version 4.2) 51

3. Pressing the “Report” button shown on the “Trend” graph screen or the “Report” button shown on

the run screen will bring up a “Production Report. This report will show:

The number of “Misses” that occurred at each feeder

The number of “Doubles” that occurred at each feeder

The number of “Jams” that occurred at each feeder

The number of times each feeder ran out of material

The number of “Envelope Misses” that occurred

The number of “Jams” that occurred at the front table

The number of “Jams” that occurred at the turnover outfeed

The number of times the operator stopped the machine

The number of times a “Safety Barrier” was broken


The “Ending” date and time

The “Job Production Rate”

The “Total Piece Count”

(Fig. 37)


(Version 4.2) 52

Section-XIV Mechanical Timing Settings:

Front Table: Timing and Height Setting of the Right Gripper Jaw Timing the Right Envelope Gripper Jaw:

1. Jog the machine forward until the envelope chain comes to the full stop position.

2. Look at the “Right Envelope Jaw”, the cam that operates the opener, should be starting to go up on the high lobe. At this point the “Envelope Shuttle” should be in the back position with the cam follower at top center of the high lobe of the cam. The envelope chain will remain stopped while the operating cams for the right jaw opener and the envelope shuttle continue to cycle. If these cams are not in this position, when forward movement of the chain first stops, make the following adjustments:

To position the Right Envelope Jaw Opener Cam:

A. Loosen the 9/16” bolt on the cam clamp

B. Turn the cam, clockwise to advance the cam, counter clockwise to retard the cam.

C. Hold the cam in place and make sure the cam follower is contacting the cam, while tightening the 9/16” clamp bolt. (Caution: Do not over tighten the bolt)

(Fig. 38)

Right Gripper Jaw Opening Cam

9/16” Bolt

Cam Follower

Gripper Jaw Opening Fork

Advance


(Version 4.2) 53

Setting the Height of the Right Envelope Gripper Jaw: There is a direct relationship to how much the gripper jaw opens and the timing of the operating cam. The gripper jaw should be set to open between two-thirds and three-fourths of its maximum height. To set this, perform the following:

1. Jog the machine forward until the cam follower is on the high dwell of the operating cam. 2. Loosen the 9/16” bolt that clamps the cam follower to the gripper jaw shaft. 3. Push the jaw opener fork up until it opens the gripper jaw to its maximum height, get a

visual bearing on this position. 4. Lower the jaw opener fork until the gripper jaw appears to be open two-thirds to three-

fourths of its maximum height, as observed in step 3.

5. Hold the opener fork in this position and tighten the 9/16” bolt on the cam follower. (Make sure the cam follower maintains contact with the cam)

(Fig. 39)

Cam Follower

9/16” Bolt


(Version 4.2) 54

Envelope Shuttle Timing Timing the Envelope Shuttle Cam:

A. Remove the end cover from the front table B. Loosen the two (2) 1/8” set screws in the side collar of the cam

(Helpful Tip: It may be necessary to jog the machine forward to gain access to both set screws. This is best accomplished indexing the machine by hand, see figure 40. If someone is assisting you, make sure you hands are clear from the front table before the machine is jogged forward)

C. From the shuttle end of the front table, turn the cam, clockwise (down) to advance the cam, counter clockwise (up) to retard the cam.

D. Hold the cam in place while tightening the two (2) 1/8” set screws. (Caution: Do not over tighten the set screws)

(Fig. 40)

Envelope Shuttle Cam and Cam Follower, as viewed from end of front table

Envelope Shuttle Cam and Cam Follower, as viewed from the front of front table

Envelope Shuttle Envelope Shuttle Cam and Cam Follower

Advance

Advance


(Version 4.2) 55

Timing and Height Setting of the Center Gripper Jaw Timing the Center Envelope Gripper Jaw: 1. Jog the envelope chain forward to the stop position.

2. Look at the “Center Envelope Jaw”, the cam that operates the opener, should be starting to go up on the high dwell. If these cams are not in this position, when forward movement of the chain first stops, make the following adjustments:

To position the Center Envelope Jaw Opener Cam:

A. Loosen the two (2) 1/8” set screws in the side collar of the cam (Helpful Tip: It may be necessary to jog the machine forward to gain access to both set screws. This is best accomplished indexing the machine by hand, see figure 41. If someone is assisting you, make sure you hands are clear from the front table before the machine is jogged forward)

B. Turn the cam, clockwise (down) to advance the cam, counter clockwise (up) to

retard the cam. (Caution: There will be noticeable spring tension on this am caused by the cam opener)

C. Hold the cam in place and tighten the set screws.

(Caution: Do not over tighten the set screws)

(Fig. 41)

Center Jaw Opener Cam

Advance

Cam Follower, Slotted Stud

Cam Follower ½” Lock Nut


(Version 4.2) 56

Setting the Height of the Center Envelope Gripper Jaw: There is a direct relationship to how much the gripper jaw opens and the timing of the operating cam. The gripper jaw should be set to open between two-thirds and three-fourths of its maximum height. To set this, perform the following:

1. Jog the machine forward until the cam follower is on the high lobe of the operating cam.

2. Loosen the 1/2” nut that holds the cam follower stud to the center jaw opener, see

figure 41, page 55. 3. Insert a flat screwdriver into the slot found in the cam follower stud at the roller

end and turn it counter clockwise (up) until the gripper jaw is opened to its maximum height, get a visual bearing on this position. (Note: the cam follower stud has been milled for eccentric adjustment)

4. Turn the cam follower stud clockwise until the gripper jaw appears to be open two-

thirds to three-fourths of its maximum height, as observed in step 3. 5. Hold the Cam follower stud in this position with the screwdriver and tighten the

1/2” nut.


(Version 4.2) 57

Timing the Insert Pusher Fingers: The insert pusher fingers must be timed with the opening and closing of the envelope chain gripper jaw. To set the timing, perform the following: 1. Jog the machine until the envelope jaw is in the stop position. Continue to jog the machine until the

envelope gripper jaw just begins to close. 2. Observe the position of the insert pusher fingers. They should be fully extended to their forward most

position. If the pusher fingers are not in this position, an adjustment must be made. To adjust the position of the insert pusher fingers:

A. Loosen the “Trantorque” nut on the drive pulley for the insert pusher fingers, with a 5/8”

open end or box wrench. It will be necessary to hold the pusher fingers in place to do this. (Place a screwdriver or an allen wrench between one of the flat center bars of the insert pusher finger assembly and the pusher finger shaft for leverage. The pusher fingers will want to travel in a forward direction, hold them in place) (Special Note: the trantorque nut will loosen in two [2] stages. First it will appear tight when you start to loosen it, then it will move easily for approximately half a turn, then it will appear tight again. You must loosen the trantorque nut beyond both tight spots)

(Fig. 42)

B. When the trantorque nut is loose, move the pusher fingers into position as stated in step 2. (Reference the insert pusher finger chain, on the sprocket closest to the trantorque nut. The center of the pusher finger shaft lug on the chain should be positioned at approximately “4 O’clock” on the sprocket)

C. Hold the pusher fingers in this position with a leverage tool and tighten the trantorque nut.

(Note the pusher fingers will want to travel in a backwards direction) (Special Note: The trantorque nut will tighten as any other nut. You may not notice two [2] different stages of tightness as was previously noticed)

Staged view of Trantorque Nut

Location of Trantorque Nut


(Version 4.2) 58

Timing the Material Belts of the Collator: The material belts of the collator must be timed with the insert pusher fingers, after the pusher fingers have been timed with the envelope chain. When the collator material belts are correctly timed, the material pusher pins will advance the material ahead of the insert pusher fingers before dropping below the insert deck. To set the timing, perform the following: 1. Jog the machine until the trailing end of the insert pusher fingers, are precisely 2 and 7/8” from the

back edge of the insert deck. (Fig. 43) 2. Remove the side section of cabinet cover, below the insert deck. 3. Insert a screwdriver or large allen wrench into the hole at the end of the driveshaft of the material belts

of the collator. (Note: You will need a leverage tool to loosen the trantorque nut) 4. Loosen the trantorque nut with a 1 and ¼” open end or box wrench by turning the nut in a counter

clockwise direction. (Note: The collator material belts will want to travel in a backward direction. Use the leverage tool to prevent this movement. This movement can also be prevented, by having someone hold the mail drive pulley of the motor and cam box under the front table) (Special Note: the trantorque nut will loosen in two [2] stages. First it will appear tight when you start to loosen it, then it will move easily for approximately half a turn, then it will appear tight again. You must loosen the trantorque nut beyond both tight spots)

5. Grasp one of the material belt pulleys, under the insert deck and turn it counter clockwise to position

one set of material pusher pins even with the leading end of the pusher fingers. Material belts and driveshaft will move freely. (Note: Remove the leverage tool from the hole in the material belt drive shaft, before positioning the material belts)

6. When the material belts are in the proper position, reinsert the leverage tool into the hole at the end of

the material belt drive shaft. (Note: Use care not to disturb the material belt position) 7. Tighten the trantorque nut by turning it in a clockwise direction. (Special Note: The trantorque nut will

tighten as any other nut. You may not notice two [2] different stages of tightness as was previously noticed)

2 and 7/8 Inches

Back edge of Insert Deck Trailing end of Insert Pusher Fingers

Position Pusher Pins with the leading edge of Pusher Fingers


(Version 4.2) 59

(Fig. 44)

Trantorque Nut

Hole in Driveshaft for leverage tool

Material Belts


(Version 4.2) 60

Timing the “Encoder” The encoder monitors the position of the collator drive shaft, for the duration of each cycle and sends the information to the “Operators Run Screen” computer. Electronic timing, for “Envelope Vacuum, Insert Air and Feeder Start” functions, are set in the machine’s computer through the operators run screen. It is important to position the encoder pulley properly on the drive shaft so that the electronic timing settings are accurate. To set the encoder, perform the following: 1. Press the “Timing” button on the run menu to bring up the timing menu (Fig. 45) 2. Jog the machine forward until the envelope gripper jaw comes parallel to the end of the stationary

envelope vacuum plate, chain side, in front of the insert air plate. (Note: The encoder, when properly set will read 90 degrees on the reference dial)

(Fig. 46)

Encoder Dial


(Version 4.2) 61

3. Remove the side section of cabinet cover, below the insert deck. 4. Check the current reading of the encoder dial showing on the timing menu. If it is past the 90 degree

mark then subtract 90 from the current setting, add that amount to the current setting to determine what the display will read when the pulley is retarded. Retard the pulley until the new setting is displayed on the dial. (Note: The encoder dial only displays readings in an ascending manner regardless of which direction the pulley is turned)

Example:

The machine is jogged into position and 140 degrees is displayed on the dial 140 minus 90 equals 50 50 added to 140 equals 190 – this is what should be displayed when the pulley is retarded 50 degrees. (Reminder: The encoder dial only reads in an ascending manner) If the reading is less than 90, then advance the pulley until 90 degrees is displayed on the dial.

5. Using a 3/32” allen wrench, loosen the two (2) set screws located in the side collar of the encoder

timing pulley, on the material belt driveshaft and adjust the pulley as needed to obtain a 90 degree setting.

(Fig. 47)

Encoder Timing Belt (Staged view from top of machine, also showing encoder box)

Set screw location Encoder Box


(Version 4.2) 62

(Fig. 48) 6. Advance or retard the encoder timing pulley as needed and tighten the tow (2) set screws. 7. Jog the machine forward through one complete cycle, stopping at the position described in step 2 and

check the reading on the encoder dial to ensure a 90-degree setting. (Note: Once the encoder has been properly set, the electronic timing setting can be set)

Encoder Timing Belt (Actual view from below machine)


(Version 4.2) 63

Timing the “Insert Entry Fingers” 1. Engage the “Set Up Mode” as described in Section VI on page 30. 2. Place a complete set of collated material to be inserted into the envelope in the material track in-

between feeder number 6 and the insert pusher finger deck. 3. Jog the machine forward until the material until is ½” to ¾” from the throat of the envelope. In this

position the tips of the envelope entry fingers should be just entering the envelope ahead of the insert material. If the entry fingers are entering the envelope at the same time or behind the insert material then a timing adjustment must be made. To accomplish this perform the following:

A. Standing in the operator’s position, open the hinged black cover located between the insert

pusher finger assembly and the envelope continuos feed conveyor, by lifting the edge closest to the insert pusher finger assembly to access the timing cam for the envelope entry fingers.

B. Using an 1/8” T-Handle allen wrench, loosen the two (2) set screws, located on the cam collar,

by turning them in a counter clock-wise direction. (Note: It may be necessary to jog the machine forward to gain access to both of the set screws)

C. Using the T-Handle allen still in the second set screw loosened move the cam to the right to

advance the cam or to the left to retard the cam. D. Tighten one set screw only, then check the new timing setting by repeating steps 2 and 3.

(Note: It may be necessary to repeat steps B through D until the desired timing setting has been obtained)

E. Once the desired timing setting as been established, tighten the second set screw and lower the black cover.

(Fig. 49)

Open black cover

One of Two Set Screws

Timing Cam for Envelope Entry Fingers


(Version 4.2) 64

Section-XV Electronic Timing Settings FlowMaster Inserters manufactured after June 1, 2000 will be programmed with the ability to set each material feeders start time independently. The collator track jam sensor can also be set to read at a predetermined time in the machine’s cycle. Typically these settings are used for material that is either extremely thin or unusually thick or die-cut to an unusual shape. FlowMaster inserters manufactured before June 1, 2000 do not have the ability to set individual feeder timing, setting or altering the feeder time of these machines will affect all the feeders simultaneously. The settings for the collator track jam sensor can not be altered on the older machines. However, this program upgrade can be acquired and down loaded to the older machines. (Fig. 50)

Electronic Timing Menu (post June 1, 2000) Showing new “Track Jam” Button and “Feeder Times” Button to set each feeder timing independently

Electronic Timing Menu (pre June 1, 2000) Showing “Feeder Start” Button to set the start time of all feeders simultaneously


(Version 4.2) 65

Set the Envelope Vacuum Timing: Envelope Vacuum Timing On:

1. Jog the machine until the envelope feed shuttle is in the back position 2. Press the “Timing” button on the run menu to bring up the timing menu

(Fig. 51) (Note: In the upper left-hand corner of the timing menu there will be a digital display of a dial showing the position of the machine in degrees. Under the dial will be an enlarged reading of the actual dial display; under the reading will be an “Enter” button. You will need to reference these in order to set the vacuum timing)

3. Press the “Env Vac On” button. The button will illuminate and read “Press Enter” 4. Press the “Enter” button located under the encoder dial display. The number shown in the

dial reading will now appear as the setting for the “Envelope Vacuum On” function. (Fig. 52)

PRESS ENTER

Envelope Vacuum On

Press this “Enter” button to set timing


(Version 4.2) 66

All envelopes may not react the same to vacuum. You may wish to advance or retard the vacuum timing setting or set the timing manually. To do this follow steps 1 and 2 as stated above, then proceed with steps “A” and “B”.

A. Press the number setting under the “Env Vac On” button, this will bring up a numeric touch pad.

B. Enter the degree of the cycle, as a number, that you wish to have the vacuum come on,

then press the return arrow found in the lower right hand corner of the touch pad to return to the timing menu.

(Fig. 53) Envelope Vacuum Off: Jog the machine until the envelope feed shuttle is in the forward position, and then perform the following:

1. Press the “Env Vac Off” button. The button will illuminate and read “Press Enter” 2. Press the “Enter” button located under the encoder dial display. The number shown in the

dial reading will now appear as the setting for the “Envelope Vacuum Off” function.

(Fig. 54)

PRESS ENTER

Envelope Vacuum Off



(Version 4.2) 67

To set the vacuum off timing manually:

A. Press the number setting under the “Env Vac Off” button, this will bring up a numeric touch pad.



(Fig. 55)


(Version 4.2) 68

Setting the Material Feeder Start Times The timing of the material feeders to the movement of the collator material belts may be changed to accommodate the material being run. If the leading edge of the material you are setting up is landing on top of the material pusher pins in the collator track, it may be necessary to retard the timing, in which the feeder starts to cycle. If the trailing edge of the material you are setting up lands on the top of the material pusher pins, it may be necessary to advance the timing, in which the feeder starts to cycle. To change the timing setting of machines manufactured after June 1, 2000, perform the following: 1. Jog the machine forward until the pusher pins on the collator material belts have passed under the

feeder you are working with and the material has begun to feed into the material track. (Note: Ideally the leading edge of the material should strike the collator track just after a set of material pusher pins have passed under the feeder. Thereby allowing enough time for the material to settle onto the track in-between two sets of pusher pins.)

2. Press the “Timing” button on the run screen to open the timing menu as shown in figure (Fig. 56)

Timing Button

1 2 3

4 5 6

7 8 9 0

-

. DEL


(Version 4.2) 69

3. Press the “Feed Times” button located on the timing menu to open the sub-menu showing each

feeder. Note the number shown in the “Current Position” block, located at the center bottom of this sub-menu. This is your reference point from which you are about to make a setting change.

4. Select the feeder you are setting up by pressing number block under the feeder designation

number that corresponds to the feeder you are working with. A numeric touch pad window will appear.

5. To advance the feeder start time, enter a number smaller that the number showing in the “Current

Position” block on the numeric touch pad. To retard the feeder start time, enter a number greater than the number showing in the “Current Position” block on the numeric touch pad. (Helpful Tip: This adjustment is being made to accommodate the characteristics of the material you are running, to find the precise setting that the material will feed best may be a trial and error process. Do not become discouraged.)

6. Press the return arrow located in the bottom right hand corner of the numeric touch pad to effect

this change and close the window. 7. Press the small close button located at the upper left-hand corner of the green thatched boarder

on the feeder menu to close the menu. (Fig. 57)

Press here to close Feeder Start Timing Menu


(Version 4.2) 70

To change the timing setting of machines manufactured before June 1, 2000, perform the following: 1. Jog the machine forward until the pusher pins on the collator material belts have passed under the

feeders and the material has begun to feed into the material track. (Note: Ideally the leading edge of the material should strike the collator track just after a set of material pusher pins have passed under the feeder. Thereby allowing enough time for the material to settle onto the track in-between two sets of pusher pins.)

2. Press the “Timing” button on the run screen to open the timing menu as shown in figure (Fig. 58) 2. Press the “Feeder Start” button located on the timing menu. The button will illuminate and read

“Press Enter” 3. Press the “Enter” button located under the encoder dial display. The number shown in the dial

reading will now appear as the setting for the “Track Jam”. 4. Press the “Run Screen” button located at the bottom right-hand corner of the timing menu to return

to the operator run screen.

Timing Button

PRESS ENTER


(Version 4.2) 71

To set the Feeder Start Time manually:

A. Press the number setting under the “Feeder Start” button, this will bring up a numeric touch pad.

B. Enter the degree of the cycle, as a number, that you wish to have the jam sensor come

on, then press the return arrow found in the lower right hand corner of the touch pad to return to the timing menu.

C. To advance the feeder start time, enter a number smaller that the number showing in the

“Encoder Dial”. To retard the feeder start time, enter a number greater than the number showing in the “Encoder Dial”. (Helpful Tip: This adjustment is being made to accommodate the characteristics of the material you are running, to find the precise setting that the material will feed best may be a trial and error process. Do not become discouraged.)

D. Press the return arrow located in the bottom right hand corner of the numeric touch pad to

effect this change and close the window. E. Press the “Run Screen” button located at the bottom right-hand corner of the timing menu

to return to the operator run screen. (Fig. 59)


(Version 4.2) 72

Set the Insert Air Timing: Note: The following section illustrates how to set the timing. The actual timing shown in this section is to be used as a reference point from which to start and is not intended to be the actual setting for the envelope stock you’re using. Also note: This timing setting is common to the vacuum ports located in front of the insert air plate. The timing setting you select for the insert air will become the timing setting for the vacuum ports. Insert Air Timing On: (Fig. 60)

1. Jog the machine forward until the timing display reads “90”

2. Press the “Insert Air On” button. The button will illuminate and read “Press Enter” 3. Press the “Enter” button located under the encoder dial display. The number shown in the

dial reading will now appear as the setting for the “Insert Air On” function. (Fig. 61)

PRESS ENTER

Press this “Enter” button to set timing Insert Air On button


(Version 4.2) 73

All envelopes may not react the same to air pressure. You may wish to advance or retard the air timing setting or set the timing manually. To do this follow step 3 as stated above, then proceed with steps “A” and “B”.

A. Press the number setting under the “Insert Air On” button, this will bring up a numeric touch pad.



(Fig. 62) Insert Air Off: Jog the machine forward until 1/4” to 3/8” of the insert material has entered the throat of the envelope, and then perform the following:

1. Press the “Insert Air Off” button. The button will illuminate and read “Press Enter” 2. Press the “Enter” button located under the encoder dial display. The number shown in the

dial reading will now appear as the setting for the “Insert Air Off” function.

(Fig. 63)

PRESS ENTER

Insert Air Off button



(Version 4.2) 74

To set the insert air off timing manually:

A. Press the number setting under the “Insert Air Off” button, this will bring up a numeric touch pad.



(Fig. 64) Batch Interrupt Setting: The FlowMaster 12000 is designed to feed material, singularly, onto a continuos running material belt. When the batch option is engaged, it becomes necessary to cause the material belt to hesitate or stop, depending on the dimensions of the material being batch fed, the number of pieces being batch fed and the running speed of the machine. To set the batch interrupt:

1. Press the “Timing” button on the run menu to bring up the timing menu

(Fig. 65)

2. Jog the machine until one set of pusher fingers is positioned under the ejector rollers of the feeder with the “Batch” option engaged

3. Press the “Batch Interrupt” button. The button will illuminate and read “Press Enter”


(Version 4.2) 75

4. Press the “Enter” button located under the encoder dial display. The number shown in the

dial reading will now appear as the setting for the “Batch Interrupt” function. 5. Test the batch at full cycle speed; observe where the batch fed material is landing. If

either the leading edge or trailing edge of the material is landing on top of the pusher pins, proceed to the manual setting

(Fig. 66)

Depending on the speed the machine is set to run, it may be necessary to manually adjust the batch interrupt setting after setting it with the encoder dial reading. To manually set the batch interrupt:

A. Press the number setting under the “Batch Interrupt” button, this will bring up a numeric touch pad.

B. Enter the degree of the cycle, as a number, that you wish to have the material belt stop,


(Fig. 67) (Helpful Tip: If after setting the batch interrupt using the encoder dial reading and the material’s leading edge lands on top of the pusher pins, the setting needs to be manually increased to allow the belt to travel farther before stopping. If the trailing edge of the material lands on top of the pusher pins, the setting needs to be manually decreased to make the belt stop sooner.)

PRESS ENTER

Batch Interrupt button



(Version 4.2) 76

Envelope Flap Detector Setting: The FlowMaster 12000 is equipped with an electronic envelope flap sensor that emits an inferred light bream. The beam is reflected off the envelope flap back to the sensor, this sends an intermittent signal to the programmable logic control (i.e. PLC) recognizing the presence of an envelope flap and continues cycling the machine. When the beam is not reflected back to the sensor, the sensor sends no signal to the PLC. The PLC interprets the absence of a signal as the absence of an envelope flap. This triggers, what is commonly referred to as a missed envelope or missed flap detected. The machine then stops and the words “Flap Detect Fault” appears on the run screen along with a picture of an envelope in front of the sensor with the flap down. (Note: The angle of the sensor in relationship to the flap is important. The PLC is programmed to recognize a break in the beam at every cycle and interprets this as the gap between envelopes. If this angle is decreased to the point that the gap is not visible to the sensor, the PLC will interpret that as an envelope feed jam. This will also trigger a missed flap detection)

1. Press the “Timing” button on the run menu to bring up the timing menu

(Fig. 68)

2. Jog the machine forward until the leading edge of an envelope is approximately one to two inches under the envelope flap plow. (Note the envelope flap should be nearly vertical at this point)

3. Press the “Env. Detect” button. The button will illuminate and read “Press Enter”

4. Press the “Enter” button located under the encoder dial display. The number shown in the dial reading will now appear as the setting for the “Envelope Detection” function.

(Fig. 69)

PRESS ENTER

Envelope Detect button



(Version 4.2) 77

In most cases the size of the envelope (i.e. A-7, # 10, # 11, 6X9) and flap style can vary without effecting the envelope detection setting. However if you should encounter an unusual style A-7 size envelope or odd flap configuration, the envelope detection can be manually adjusted. To manually adjust the envelope detection setting:

A. Press the number setting under the “Env. Detection” button, this will bring up a numeric touch pad.

B. Enter the degree of the cycle, as a number, that you wish to have envelope detector

active, then press the return arrow found in the lower right hand corner of the touch pad to return to the timing menu.

(Fig. 70)


(Version 4.2) 78

Setting the Missed Flap Position: When using the “Jog Miss” option, as shown in Section-V, page 26, under “Envelope Options” it will be necessary to set the position for the machine to stop, when a missed envelope has been detected. To set the missed flap position: 1. Jog the machine forward until the leading edge of one complete collated set of material has started to

enter an envelope. (Note: This is the best position for the material to stop in, for manual removal, in the event of a missed envelope)

2. Press the timing button on the run menu, this will bring up the electronic timing menu. 3. Reference the number under the encoder dial. (Note: This indicates the degree of the machine cycle

that the machine is currently in. You will need to remember this number) 4. Press the “Run Screen” button in the lower right-hand corner to return to the run screen menu. Then

press the “Env. Menu” button, to bring up the envelope menu. 5. Press the number area above the words “Missed Flap Position” found in the lower right-hand corner of

the envelope menu to bring up a numeric touch pad. 6. Enter the number that you referenced in step 3, of the position you wish to have the machine stop if a

missed envelope occurs. Press the return arrow found in the lower right hand corner of the touch pad to return to the envelope menu.

(Fig. 71)


(Version 4.2) 79

Setting the Collator Track Jam Detector If you should receive what may appear to be a “False” collator track jam error message on the operator’s run screen, rule out some other possibilities first, before adjusting the collator track jam timing setting. Recheck your basic material feeder setup, look for:

Material side guides of the feeder or the material track miss-aligned causing the material to land off center just enough to be detected by the collator track jam sensor, but then settles into the track when the machine stops.

Feeder Wedge set too far under the material causing the material to skew when feeding into the

material track.

Separator Wheel set to lean causing inconsistent feeding, allowing material to be recognized by the collator track jam detector.

If after rechecking your basic material feeder setup you find it necessary to adjust the timing of the collator track jam sensor, proceed with the following steps, on machines manufactured after June 1, 2000: 1. Jog the machine forward to the point where the material feeders begin to filled the track. 4. Press the “Timing” button on the run screen to open the timing menu. 5. Press the “Track Jam” button. The button will illuminate and read “Press Enter” 6. Press the “Enter” button located under the encoder dial display. The number shown in the dial reading

will now appear as the setting for the “Track Jam”.

(Fig. 72) (Note: The collator track jam sensor should be set the same as the lowest feeder.)


PRESS ENTER

Track Jam button


(Version 4.2) 80

To set the track jam timing manually:

C. Press the number setting under the “Track Jam” button, this will bring up a numeric touch pad.

D. Enter the degree of the cycle, as a number, that you wish to have the jam sensor come

on, then press the return arrow found in the lower right hand corner of the touch pad to return to the timing menu.

(Fig. 73)


(Version 4.2) 81

Section-XVI Lubrication FlowMaster inserters will need to be oiled and lubricated according to the number of cycles run on the machine. An alert will appear on the run screen when lubrication and oiling is needed. (Note: If you have general maintenance performed on all your machines and equipment and wish to include your FlowMaster on a weekly or monthly schedule, is considered to be an acceptable practice.) It is not necessary to stop in the middle of a job to perform this task, but should however be done reasonably soon after the reminder appears on the run screen. (Safety Note: Do not cycle, run or otherwise operate this machine while performing any maintenance task or repairs) The following products are recommended by Sure-Feed Engineering Inc. for use on FlowMaster inserters: Recommended Oil or Equivalent - Any SAE 30 (Non-Detergent) Petroleum Based Oil (Paraffin based oil, multiple viscosity oil or oil containing detergent or cleansing additives is not recommended) Recommended Grease or Equivalent for Bearings - Shell Alvania #2, Texaco Multifak #2, Sun Prestige #41, Humble 100K #2, Sinclair Litholine Multi-Purpose Front Table Lubrication The following items will require oil: 1. Center envelope gripper jaw opener assembly, see figure 75, page 82. 2. Right envelope gripper jaw cam follower, see figure 76, page 82. 3. Front and Back Envelope feed shuttle control shafts, see figure 77, page 83. 4. Envelope feed shuttle cam follower, see figure 78, page 83. 5. Envelope gripper jaw chain, see figure 79, page 84. 6. Index drive cam box, see figure 80, page 85. The following points will require grease: 7. Left bearing, left section, main drive shaft, see figure 81, page 86. 8. Square slid drive shaft, main drive pulley to collator, see figure 82, page 86. 9. 3-Way crown gear drive see figure 83, page 80 (Note: Recommended grease – Beacon 325 –

Exxon Co. or equivalent) 10. Right bearing, right section, main drive shaft, see figure 84, page 88. 11. Front and back bearings, envelope feed shuttle, drive shaft, see figure 84. Page 88. 12. Miter gears located between items # 10 and #11, see figure 84, page 88. (Fig. 74)

11

2 3

10 9

5

6

1 4

5

7 8


(Version 4.2) 82

Item 1. - Center Envelope Gripper Jaw Opener Oil the following: Top Roller, Elevator Assembly – full length (Fig. 75) Item 2. – Right envelope gripper jaw cam follower Oil Roller Bearing

(Fig. 76)


(Version 4.2) 83

Item 3. - Front and Back Envelope feed shuttle control shafts Oil Front control shaft between follower roller bearings and the back spring covered control shaft (Fig. 77) Item 4. – Envelope feed shuttle cam follower Oil Roller Bearing and the Upper and Lower Pivot points

(Fig. 78)

Front view of Envelope feed shuttle cam follower

End view of Envelope feed shuttle cam follower


(Version 4.2) 84

Item #5 - Envelope gripper jaw chain Oil both sides of the envelope gripper jaw chain track and the pivot point of each gripper jaw. (Note: Excess oil should be wiped clean from the inside surface of the gripper jaw.)

(Fig. 79)

O


(Version 4.2) 85

Item #6 - Index drive cam box The oil in the index drive cam box should be changed after 2,000 hours of use or every six (6) months. To perform this, do the following: 1. Drain the old oil from the unit by removing the drain plug located on the left side plate, replace the

plug when unit has drained. 2. Remove the vent plug located at the top of the left side of the unit over the drain plug. 3. Fill the unit with one of the recommended oils until the level becomes visible in the view glass

located on the right side of the unit, replace the vent plug when finished. (Note: Dispose of old oil in accordance with your local city, county and state laws and ordinances governing the disposition and or disposal of petroleum products)

(Fig. 80)

View Glass

Vent Plug


(Version 4.2) 86

Item #7 - Left bearing, left section, main drive shaft Apply grease slowly through the grease fitting located in the top of the mounting block until the grease begins to seep out around the bearing seal.

(Fig. 81) Item #8 - Square slid drive shaft, main drive pulley to collator Apply a light coating of grease to square shaft on both side of the pulley. (Note: Care should be taken to keep grease from getting on the belt)

(Fig. 82)


(Version 4.2) 87

Item #9 - 3-Way crown gear drive Add grease by removing fill plug located at the top, center of the gear box, fill until grease level is even with the bottom threads of the fill plug. (Note: If grease is present at the prescribed level upon inspection, do not add)

(Fig. 83)

Top view of 3-Way Crown Gear Drive

Remove Fill Plug


(Version 4.2) 88

Item #10 - Right bearing, right section, main drive shaft and Item #11 - Front and back bearings, envelope feed shuttle, drive shaft Apply grease slowly through the grease fitting located in the top of the mounting block until the grease begins to seep out around the bearing seal. (Fig. 84)

Apply a moderate amount of grease to each miter gear surface with a small brush.

Note: The grease fitting for item #8 is located on the back side of the mounting block and is not visible in this figure.

Top View of Miter Gears

Item #11 – Miter Gears Apply grease liberally to both gears


(Version 4.2) 89

Collator Lubrication The following items will require oil: 1. Pusher finger chain assembly, see figure 86, page 90. 2. Envelope entry finger control shaft bushings, see figure 86, page 90. 3. Envelope entry finger cam follower, see figure 87, page 91. The following points will require grease: 4. Front and Back Bearings, Collator, main drive shaft, see figure 88, page 92. (Accessible through the

collator side panel under the insert pusher finger assembly.) 5. Front and Back Bearings, Material belt, main drive shaft, see figure 88, page 92. (Accessible through

the collator side panel under the insert pusher finger assembly.)

(Fig. 85)

4

3

1

2

5 4 5

Staged view of Collator section (Note: It is not necessary to disassemble the machine to perform oiling and lubrication)


(Version 4.2) 90

Item #1 - Pusher finger chain assembly and Item #2 - Envelope entry finger control shaft bushings Oil both pusher finger chains liberally and wipe off excess oil Oil both control shaft bushings

(Fig. 86)


(Version 4.2) 91

Item #3 - Envelope entry finger cam follower Oil Bearing, cam follower, inside surface of the cam follower bearing mounting block and cam surface. (Note: Care should be taken to keep belts located near this bearing free of oil.)

(Fig. 87)


(Version 4.2) 92

Item #4 - Front and Back Bearings, Collator, main drive shaft and Item #5 - Front and Back Bearings, Material belt, main drive shaft Apply grease slowly through the grease fitting located in the top of the mounting block until the grease begins to seep out around the bearing seal.

(Fig. 88)


(Version 4.2) 93

Pusher Finger Chain Maintenance During normal use the pusher finger chain will stretch. This is a normal occurrence and is expected to happen. When the pusher finger chain stretches, it may allow the pusher finger control shafts to strike the top of the material side guides when the machine cycles. If this is allowed to persist for a prolonged period of time, the pusher finger control shafts may become scored or cut. This is not harmful or damaging to the pusher finger assembly because it was designed and built far beyond the requirements of it’s intended function. However, this may impact the efficiency of the machine’s ability to perform smoothly and should be corrected. The chain tension should be checked regularly and should have a 1/16” to a 1/8” of play in it. To tighten the pusher finger chains, perform the following: 1. Jog the machine forward until the box cam joint can be easily accessed, then lift the pusher finger

assembly cover. See figure 89, page 94for the correct position of the pusher fingers. 2. Loosen booth of the 1/8” allen screws located under each pusher finger chain. These screws

secure the pusher finger chain track to the top left brace found in the pusher finger assembly, see figure 89, page 94.

3. Loosen the three (3) silver 5/32” socket head allen screws located on the left side of both the box

cam mounting plates, see figure 90, page 94. 4. Lift the left end of the box cam nearest the continuos envelope feed conveyor just enough to slid a

3/16” allen wrench between the bottom of the box cam and the insert deck, see figure 91, page 95. (Note: The allen wrench should be no further than ½” under the end of the left section of the box cam.)

5. Place the tip of a flat blade screwdriver inside the center of the box cam joint, near the left brace of

the pusher finger assembly. Using the screwdriver as a wedge, push firmly into the box cam joint until the chain becomes tight.

6. Place your hand on top of the box cam joint and press firmly downward, hold the box cam in this

position. (Note: This will cause the bottom portion of the box cam joint to spread further than the top portion. This difference may not be noticeable to the human eye. This serves two purposes, it provides a narrower gap for the cam follower roller to travel over at the top of the box cam and allows the pusher finger tip to settle into the insert deck grooves smoothly at the bottom of the box cam.)

7. Tighten both of the 1/8” allen screws located under the pusher finger chain start from the right and

work your way to the left see figure 89, page 94. (Note: Placing an allen wrench in the screw heads under the chain will flex the chain outward, the amount the chain flexes should equal the amount of play the chain should have as stated at the beginning of this section.)

8. Continue to hold the box cam in position as stated in step #6. Tighten the three (3) silver 5/32”

socket head allen screws located on the left side of the box cam mounting plate, starting with the screw closest to the cam box joint and work your way out to the left see figure 90, page 94.

9. Remove the screw driver from the box cam joint, remove the 3/16” allen wrench from under the

left end of the box cam. 10. Repeat steps #4 through #9 to adjust the pusher finger chain on the box cam nearest the

operator’s position.


(Version 4.2) 94

(Fig. 89) (Fig. 90)

Silver socket head screws located on the outside of both box cams

1/8” allen screws located under the pusher finger chain


(Version 4.2) 95

(Fig. 91)

Use the heal of your hand to press down on the top of the box cam joint

3/16” Allen wrench in position under left end of box cam

Enlarged view of screwdriver positioned in the center of the box cam joint


(Version 4.2) 96

Section XVII Optic Mark Reader and Vertical Sort Conveyor The Optic Mark Reader must be installed in order to run the “Vertical Sort Conveyor”. The optic mark reader is designed to read a preprinted mark on an addressed document, relay the reading to the Program Logic Controller, (PLC). The PLC interrupts the reading and signals the sort conveyor when to make the sort break. When the sort conveyor receives the signal, a solenoid is activated to engage the mechanical shift arm creating an offset in the vertical stack, thereby making the sort break visible and easy to bundle and tray. The following items are needed to install the Optic Mark Reader: Drill motor 6/32” drill bit ½” drill bit 6/32” machine thread tap Cutting fluid Phillips head screw driver 9/64” Allen wrench 1/8” Allen wrench ½” open end wrench Wire cutter Wire stripper Small 1/8” flat blade screw driver


(Version 4.2) 97

To install the optic mark reader: LED Installation 1. Turn the main power supply, located at the end of the machine near feeder #1, to the off position 2. Remove the end cover from the collator exposing the material belts and tensioner rollers. 3. Using a 6/32” drill bit, drill a hole into the right end of the back lower cross brace of feeder #1. 4. Tap this hole to accept a 6/32” machine thread, socket head bolt. 5. Mount the LED to the right end of the lower back cross brace of feeder #1 with the electrical cable

facing out towards the operator side, the fiber optics fittings will face the feeder mounting plate, see figure 92.

(Fig. 92)

X

X

LED Mounting position Note holes to drill are marked “X”

Fiber Optics Cable

Electrical Cable


(Version 4.2) 98

6. Using a ½” drill bit, drill a hole through the top cabinet near the feeder mounting plate behind feeder

#1, see figure 93. (Note: Be sure to stay to the left of the material belt housing under the material track)

(Fig. 93)

Position of ½” hole for electrical cable must be as close to the feeder mounting plate as possible

Socket head screw to use for mounting wire tie

Stay to the left side, out of the material belt housing when drilling the ½” hole in the top cabinet

Material Belt Housing


(Version 4.2) 99

7. Install a ½” grommet into the hole in the top cabinet. 8. Remove one of the lower socket head screws from the feeder wedge mounting bracket, see figure 93,

page 98. 9. Insert both fiber optics leads into the fiber optic fitting on the LED. Secure them with the supplied set

screws using the hex-head allen wrench also supplied. 10. Feed the electrical cable and the sensor end of the fiber optics cable through a screw mount wire tie.

Using the screw removed from the wedge bracket in step # 9, mount the wire tie to the wedge bracket. 11. Further secure the electrical cable and the fiber optics cable to the lower back cross brace of the

feeder near the mounting plate using slip lock wire ties. 12. Thread the electrical cable through the grommet in the top of the cabinet, keeping the cable to the left

of the material belt housing, guide it to the electrical panel. 13. Remove the center front strain relief from the electrical panel, see figure 94, page 104. Then remove

the wire clamp from the strain relief. 14. Thread the electrical cable from the LED through the strain relief and wire clamp, into the electrical

panel, gently pull excess wire from the LED into the electrical panel and tighten the strain relief. 15. Remove the solid gray plastic cover from the wire channel over the PLC. 16. Thread the electrical cable from the LED into the wire channel at the left end. 17. Very carefully remove the outer cable cover, starting approximately two inches inside the wire channel

from where the cable entered. This will expose six (6) wires, colors; Red, Blue, Green, Black, White and Silver Sheath wire.


(Version 4.2) 100

LED Electrical Wiring Connect electrical wire in the following manner:

1. Silver Sheath wire connects to top of fuse holder, located in the upper left-hand corner of the electrical panel. (Note: This wire will share a connection port with one of the black wires already there)

2. Black wire connects to the upper left side of the terminal block located at the top center

of the electrical panel. (Note: This wire will share a connection port with one of the black wires already there)

3. Red wire connects to the upper right side of the terminal port located at the top center

of the electrical panel. (Note: This wire will share a connection port with one of the red wires already there)

4. White wire connects to “X5” found on the upper left side of the PLC. (Note: There will

be a group of violet or purple color wires to the right of X5. If you should find one of the violet or purple color wire connected to “X5” of the PLC, remove it and reconnect it to first open connection port to the right of the other violet or purple color wires of this group)

5. Both the Blue and Green wires are not to be used. Cut them back and pull the insulation

over the cut end to prevent them from shorting out. (Note: See figure 94, page 101, regarding wiring)

(Helpful Tip: The connection ports can be easily opened by inserting a small 1/8” blade tip screwdriver into the square shape slot below the connection port and press firmly straight into the slot. It may be necessary to wiggle the screwdriver up and down a little to get the port to open)


(Version 4.2) 101

(Fig. 94) Installation of the OMR Sensor

Strain Relief where cable enters electrical panel Terminal Block for Black and Red wires

Fuse Holder where Sheath wire connects

White wire connects to port “X5”


(Version 4.2) 102

1. The OMR Sensor is connected to the fiber optics cable and is designed to read the preprinted sort break mark as the material passes over it. To install the OMR Sensor perform the following:

2. Thread the 5/16” nut onto the sensor barrel until it reaches the lowest point 3. Insert the sensor up through the bottom of the sensor bracket 4. Thread the brass 5/16” nut onto the sensor until it just touches the top of the sensor bracket

(Note: Do not tighten this nut at this time) 5. Thread the black paper guard onto the top of the sensor and tighten it.

(Fig. 95) 6. Guide the optic cable along the feeder mounting plate then under the lower front feeder brace,

towards the blue feeder side plate, see figure 96.

Threaded Sensor Barrel

5/16” Nut

Fiber Optic Cable Elbow

Fiber Optic Cable

Sensor Bracket

Paper Guide

OMR Eye

5/16” Brass Nut


(Version 4.2) 103

7. Attach the fiber optics cable to the lower front feeder brace with electrical wire ties. (Helpful Tip: Place

one wire tie on the lower feeder brace close to the feeder mounting plate, place another wire tie close to the OMR sensor.) (Note: The electrical wire ties are only in use to prevent the fiber optics from catching or snagging on the material pusher pins. The electrical wire ties should be loose enough to allow the optic fiber cable to slid back and forth so the OMR sensor can be re-positioned for different sizes pieces)

8. Slid the mount block of the sensor bracket onto the back edge of the lower front feeder brace, position

the sensor eye to align with the margin containing the sort mark and tighten the lock knob securing the mount block to the brace, see figure 96. (Note: Care must be taken, when positioning the sensor, to avoid placing it on the electrical cables for the collator track jam of feeder miss detectors)

9. Adjust the height of the sensor by turning the threaded barrel, clockwise to lower, counter-clockwise to

rise, until the bottom surface of the paper being fed will make contact with the paper guard of the sensor and pass over it with little or no restriction. (Note: The final position setting of the sensor must leave the light emitting slot in the sensor eye parallel with the leading edge of the paper)

10. Once the height setting has been established, “finger-tighten” the upper and lower 5/16” nuts on the

sensor barrel to the sensor bracket. Apply a 5/16” open-end wrench to the top 5/16” nut and snug it firmly to the bracket. (Note: Watch that the light-emitting eye of the sensor doesn't move during the tightening process.)

11. Place the light reflector over the sensor eye and secure the reflector bracket block to the top front

feeder brace by tightening the lock knob, see figure 97, page 104. 12. Adjust the height of the reflector to approximately ¼” above the top surface of the paper as it feeds

over the OMR sensor.

(Fig. 96)

Under view of Feeder #1 Showing path of Fiber Optics Cable

Electrical Wire Position


(Version 4.2) 104

(Fig. 97)

Light Reflector

Paper Guard (In this figure, the Light Emitting Slot of the eye is obscured by the paper guard)


(Version 4.2) 105

FlowMaster Sort Mark Specifications Line Size:

Width (thickness) must be a minimum of .020”.

Length must be a minimum of .75” (Note: The wider the sort mark is the more consistent the OMR sensor will read it.) Line Position:

1. The line must run from the left to the right in the same direction as the address.

2. The line must be within the first two inches of the leading edge of the paper as it comes out of the material feeder.

3. The area from the leading edge to the trailing edge of the paper must be free of any other

print where the line is to be placed.

To engage and operate the vertical sort conveyor:

.75”

2”

Direction of Travel

Sort mark may be placed on either side of the paper, left to right or top to bottom


(Version 4.2) 106

Go to the operator’s run screen and press the conveyor menu button marked “CONVY MENU” located on the left side of the menu. This will bring up the conveyor menu To Sort by a Sort Mark: 1. Press the “Shingle /Sort conveyor button located on the left side of the menu, until it reads “SORT

CONVY” 2. Press the MARK / BATCH sort button, located on the right side of the menu, until it reads “MARK

SORT” 3. Next test your setting by running the job until a sort break appears on the conveyor. Check the

accuracy of the sort, the pieces following the marked piece should be off set on the conveyor by approximately one inch. If the break did not come immediately after the mark, the “Sort Mark Output Offset Range must be adjusted, see figure 98, page 99.

To Adjust this range:

A. Press the number area located at the middle of the conveyor menu. A numeric touch pad will appear on the screen.

B. Enter the number of pieces that the actual sort break was off by.

Example: The break took place two pieces before the sort mark, enter 2 The break took place two pieces after the sort mark, enter –2 (Note: To enter a negative number, press the “-“ key on the numeric

touch pad before entering a number)

C. Press the return arrow in the lower right-hand corner of the touch pad to enter the new setting and return to the conveyor menu

To Sort by Batch Count: 1. Press the “Shingle /Sort conveyor button located on the left side of the menu, until it reads “SORT

CONVY” 2. Press the MARK / BATCH sort button, located on the right side of the menu, until it reads “BATCH

SORT” 3. Set the pieces you want to batch by

A. Press the number area located at the lower right-hand corner of the conveyor menu. A numeric touch pad will

appear on the screen. B. Enter the number of pieces you wish to batch by. C. Press the return arrow in the lower right-hand corner of the touch pad to enter the new

setting and return to the conveyor menu

To Engage the Shingle Conveyor:


(Version 4.2) 107

Press the “Shingle /Sort conveyor button located on the left side of the menu, until it reads “SHINGLE CONVY” This will disable al other button features in the conveyor menu. (Note: When running as a shingle conveyor the pieces will still come out to the conveyor in a vertical manner. If you want the material to lay flat on the conveyor, you must turn up the speed control setting located on the front leg of the conveyor next to the vertical sort turn unit) (Fig. 98)

1 2 3

4 5 6

7 8 9 0

-

. DEL


(Version 4.2) 108

Section XVIII Trouble Shooting the FlowMaster 12000 The following section depicts some of the more commonly asked questions concerning machine problems or trouble experienced by operators. This section outlines the most common causes of the problems and gives viable solutions. If you should experience a problem that is not shown in this section or experience trouble implementing the solution shown, please call Sure-Feed Engineering Inc. at (727) 571-3330, FlowMaster Support Service extension 210 and we will be glade to assist you. Trouble Shooting: Problem: The envelopes are not feeding from the envelope feed conveyor into the hopper. Cause: The envelope guide rail is misalign or the envelope hopper is set too small. Solution: Re-align the envelope guide rail, (pg. 40) Re-set the envelope hopper, (pg. 30) Problem: The envelope doesn’t feed into the gripper jaw. Cause: The timing of the envelope shuttle to the gripper jaw chain is incorrect ro the vacuum

timing of the envelope shuttle is incorrect. Solution: Adjust the timing cam for the envelope shuttle, (pg. 54) Adjust the timing for the envelope vacuum, (pg. 65) Problem: The envelope flap does not open properly. Cause: The envelope plow may not set correctly for the envelope you are running. Solution: Re-set the envelope plow, (pg. 33) Problem: The envelope flap is creased or wrinkled under the insert air plate. Cause: The envelope flap plow may be set incorrectly or the curved flap guide from the exit end of

the plow is set incorrectly. Solution: Re-set the envelope flap plow, (pg.33) Re-set the envelope curved flap guide, (pg. 34) Problem: Material is sticking out of the envelope after it has been inserted. Cause: The pusher fingers may be out of time with the closing of the envelope gripper jaw. Solution: Re-set the pusher finger timing, (pg. 57)


(Version 4.2) 109

Problem: The material belts of the collator is moving in a jerky fashion. Cause: The batch count option is turned on at one of the feeder stations. Solution: Check the feeder displays and turn off the batch count option, (pg.21) Problem: The pusher fingers are landing on top of the material to be inserted instead of behind it. Cause: The pusher fingers may be out of time or the material pusher pins my be out of time. Solution: Re-time the pusher fingers, (pg.57) Re-time the material pusher pins, (pg.58) Problem: Jamming occurs at the insert air plate. Cause: The entry fingers my not positioned correctly, the entry fingers may be out of time, the

front table may not positioned correctly or the material side guides are not properly set. Solution: Re-align the entry fingers, (pg.37) Re-set the timing for the entry finger, (pg.63) Re-position the front table, (pg.35) Re-set the material side guides, (pg.12) Problem: The envelopes are jamming at the envelope turn over unit. Cause: The flap closure guide rod is set too high or the tension roller of the turn over is not set

correctly. Solution: Re-set the flap closure guide rod, (pg.42) Re-set the tension roller of the turn over, (pg.42) Problem: The material feeder is skewing material into the material track. Pieces stop in the feeder

in a different position at each cycle. Cause: The feeder ejector roller is set too high Solution: Re-set the feeder ejector roller, (pg.18) Problem: The material is not feeding under the separator wheel properly. Cause: The material is restricted in the feeder before it reaches the separator wheel. Solution: Re-set the separator wheel, (pg18)


(Version 4.2) 110

Problem: The material is unfolding in the feeder. Cause: The separator wheel is set too low. Solution: Re-set the separator wheel, (pg18) Problem: The insert material is jamming on the window of the envelope. Cause: The window material may not be glued evenly at the edge, leaving a loose edge to catch

material as it enters the envelope. Solution: Increase the insert air pressure and adjust the insert air timing to stay on longer, (pg.72). That will allow the material to float over the loose window edge. Problem: The envelope are sticking together on the shingle conveyor and the water time

is set at .01. Cause: There is too much air pressure in the water tank or the water flow valve is open too far. Solution: Decrease the air pressure in the water tank, (pg.29) Partially close the water flow valve, (pg.46) Problem: The FlowMaster speed setting is selected at 12000, but the machine will not run any

faster than 2500. Cause: One of the electrical timing functions in the timing menu has a number setting equal to or

less than 0. Solution: Go to the timing menu and check all the settings, each setting must have a value greater

than 0, (pg. 64 through 77) Problem: The envelope are not sealing. Cause: The water flow valve is closed too far, the air pressure in the water tank is set too low or

the water time setting in the envelope sub menu is set too low. Solution: Open the water flow valve, (pg. 46) Increase the air pressure in the water tank, (pg. 29) Increase the water time in the envelope sub menu of the operator’s run screen, (pg.25)


(Version 4.2) 111

Glossary Envelope Feed Conveyor – one of five components of the FlowMaster inserter, specifically a 9-foot conveyor that automatically feeds envelopes into the envelope feed hopper Front Table – one of five components of the FlowMaster inserter, specifically the part that transports the envelopes up to the insert area to be inserted Collator – one of five components of the FlowMaster inserter, specifically the part containing six or more friction feeders to feed collate and transport paper goods and or printed material up to the insert area in a predetermined or programmed order. Feeder – one of six or more friction feeders mounted to the collator section of the FlowMaster, designed to feed paper goods and or printed material into the collator track Ejection Roller or Nip Roller – last set of rollers located at the feed end of each feeder, designed to feed paper goods or printed material into the collator material path Separator Wheels – 3” diameter, normally gold in color, operating in a set of two, located just after the material guides of each feeder, designed to begin the separation of paper goods or printed material from the stack Drag Strap – a nylon strap of varying length affixed to a mounting block designed to be placed on the lower cross bracket near the ejection roller shaft assembly, i.e. sub assembly of the friction feeder Pusher Pin – one of many pins made of delrin pressed into a nylon mounting block which is affixed to one of four material belts located in the material path way of the collator, designed to transport paper goods or printed material from under the feeders onto the insert deck Pusher Finger – one of several fingers mounted to a shaft normally in groups of three, being chain driven, located over the insert deck, designed to transport paper goods or printed material from the insert deck into an envelope Gripper Jaw – one of eight chain driven cam operated mechanical metal jaws located on the front table designed to transport envelopes from the envelope feed hopper to the insert area and then into the envelope turnover Envelope Shuttle – flat aluminum plate mounted to a mechanical arm, cam operated, located in the envelope feed hopper, designed to separate one envelope from a stack of many then transport it into a gripper jaw Envelope Vacuum Plate or Shuttle Plate – one of three separate designs, standard, shallow channel and flat, mounted to the envelope plate, designed to hold via vacuum one envelope for transportation from the envelope hopper to the gripper jaw. The activity of this device is timed electronically. Full Stop Position – refers to the position of the envelope gripper jaw chain when it has completely stopped at the timing mark scribed in the stationary vacuum plate in front of the insert air plate Full Back Position – refers to the position of the envelope feed shuttle when it has retracted completely back into the envelope feed hopper


(Version 4.2) 112

Jog Wedge or Vibrator Wedge – a small wedge shaped part held to the back part of the envelope shuttle plate by a hex head screw. Designed to jog or bounce the envelopes in the envelope feed hopper, used to assist the feeding of envelopes, can be repositioned on the envelope shuttle to one of several pre-drilled and tapped holes. Feeder Wedge – one of four triangular shaped pieces set on two slide shafts, mounted to an adjustable bracket affixed to each feeder. Designed to increase or decrease the pitch of the paper goods or printed material placed in any given feeder.

Encoder – electronic device mounted to the left material belt housing under the insert deck, designed to monitor machine during each cycle. Encoder Setting – placing the machine in a certain position then setting the encoder to reference that position as a predetermined degree of the machine cycle, ie; 90 degrees, 135 degrees, etc…. “The 90” – phrase, jargon used inquire or confirm encoder setting, ie; What’s the 90 set to? Or I have the 90 set correctly. Entry Finger – one of several mechanical fingers designed to enter the envelope prior to being inserted, mounted to mechanical arm being cam operated. Stroke – phrase, jargon, refers to the movement of the entry fingers. Adjustment designed to limit the length of travel of the entry fingers Box Cam – jointed rectangle box machine milled to provide cam-operating action to the pusher finger. Mounted on all FlowMaster inserters in matched pairs Pusher Chain or Pusher Finger Chain - #25 chain containing mounting blocks for the pusher finger shafts. Envelope Turnover – designed to accept inserted and sealed envelope from the exit end of the front table, turn each envelope face up and deliver it to a postage meter, stamp head, ink jet or conveyor.


(Version 4.2) 113

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