ontents Safety Information ............ii Specifications ..............iv Section 1: About the Machine ............1 Section 2: Preparing for Operation ..........5 Section 3: How to Operate ............15 Section 4: Operational Troubleshooting ........19 Section 5: Inspection and Care ...........21 Section 6: Wedge Applications ...........28 Section 7: Mechanical Components ...........31 Section 8: Electrical Components ..........67 Section 9: Technical Troubleshooting ........75 3700 M elaint...
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efore egin Message Conventions DANGER signifies an action or specific equipment area that can result in serious injury or death if proper precautions are not taken. WARNING signifies an action or specific equipment area that can result in personal injury if proper precautions are not taken. CAUTION signifies an action or specific equipment area that can result in equipment damage if proper precautions are not taken.
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efore egin Message Conventions Avoid injury. Do not reach around guards. Hazardous voltage. Contact will cause electric shock or burn. Turn off and lock out power before servicing. Moving parts can crush and cut. Keep guards in place. Lock out power before servicing.
peCifiCations Maximum Product Size: ....11.75 W x 14 L in (298.5 x 355.6 mm) Minimum Product Size: ....3.75 W x 3.75 L in (95.3 x 95.3 mm) Optional: ........... 2 W x 2.5 L in (50.8 x 63.5 mm) Min/Max Product Thickness: ......
About the Machine Features The Reliant 3700 is designed for reliability, flexibility, and ease of use. All parts required for setup, loading, feeding, and easy operator con- trol are combined into one compact unit. • Feeders can be configured two ways: one-shot Review the diagram below to become familiar with names and loca- mode or batch count mode.
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Main Assemblies Feature Descriptions Feature Description Gate assembly Mounted on a gate plate directly above the feed belts, this device provides a curvature to help preshingle stacked product. Adjustment knob allows you to set downward pressure. When properly adjusted, a one-thickness gap is created to help singulate and eject product.
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Control Panel Components 3700 M eliant anual...
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Control Panel Feature Descriptions Feature Description AC power cordset connector Cordset plugs into this IEC320 connector to provide feeder with power from a grounded/fused outlet. Switchable for either 115- or 230-VAC. Feed/flight trigger connector The remote flight-detect sensor plugs into this 4-pin connector to provide the “start”...
Preparing for Operation Once the feeder is installed, you are ready to prepare the machine for operation. You must perform several adjustments with the prod- uct you are going to be feeding and do a test run with this product When performing initial adjustments prior to verify that it is set correctly before going on-line.
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STEP 1: Procedure To adjust the gate assembly for proper gap: Gate Assembly Adjustment 1. Slide a single sheet of test product under the gate assembly. (continued) It may be necessary to pull up on the adjustment knob to allow the piece to be inserted.
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STEP 1: To adjust the gate for effective product skew control, follow these steps: Gate Assembly Adjustment 1. Repeat drag test detailed on previous page. (continued) 2. Test the piece for uneven side-to-side drag. Grasp with two hands and slide it front-to-back under the gate assembly. A proper adjustment allows for equal drag on the left and right sides of the piece of product.
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Changing From Review The feeder is shipped to you with a high-tension spring in the gate Factory Set assembly. Certain types of product may demand that you change the High-Tension to gate assembly from a high-tension setting to a low-tension setting (for example, irregular shaped product).
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STEP 2: Review The side guides hold the stack of product being fed and guide the Side Guides Setting product through the feeder in a straight line of movement. You can adjust the side guides to accommodate different sizes of product. Objective Adjust the side guides so the product stack maintains uniformity from A good “rule-of-thumb” measurement to use is...
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STEP 3: Review The back wedge provides proper lift to the product to help keep it off Back Wedge the table top and feed belts, and it creates the force necessary to push Adjustment product against the gate assembly. By adjusting it back and forth from the gate assembly or pivoting side to side, you can create the lift and force necessary to preshingle product against the curvature of the gate assembly.
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STEP 3: Back Wedge Adjustment (continued) Objective Adjust the back wedge for proper support of the product off the table top, without creating any pinch or stress points. Procedure To adjust the back wedge for initial proper positioning, follow these steps: 1.
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STEP 3: Back Wedge Adjustment (continued) 4. Move the back wedge forward and backward until the bottom sheet is not touching the table top. A good starting point is to Moving the back wedge too far forward to the measure about 5/8 in. (16 mm) from the bottom sheet to front gate assembly can create a pinch point between edge of table top.
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STEP 4: Review The Sheet-Detect photo sensor is mounted on the flexible arrm ex- Photo Sensor tension assembly to detect the leading edge of a product about to be Adjustment ejected so as to turn the feeder Off. The Flight-Detect photo sensor is mounted on the line to detect a target (for example, a conveyor lug) so as to eject a product.
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STEP 5: Now that you have made all the necessary adjustments for operation, it is recommended that you verify product singulation and separation Manual Test at the feeder for your particular application. Before you power-up and to Verify run your machine with a full hopper, manually feed several sheets of product through the gate assembly area.
How to Operate Sequence of Successful power-up and operation is assured if you apply the follow- ing sequence of steps: Operation 1: Loading product in the hopper 2: Determining stack height 3: Powering On feeder 4: Setting/adjusting speed 5: Running test cycles 6: Final check STEP 1: 1.
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STEP 2: 1. Gradually add more product to the hopper after the initial stack is formed around the gate assembly. As stack height will Determining Stack have a preferred minimum and maximum, you will have to experiment to determine effective range of height. 2.
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STEP 4: 1. Set the variable speed control to the lowest speed (counter- clockwise). Setting/Adjusting Speed 2. Start by slowly turning the control clockwise to gradually in- crease feeder speed to coincide with the production line speed of your particular application. STEP 5: •...
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Clearing a Jam If a jam occurs during operation, follow these steps: 1. Open the discharge safety shield (interlock switch prevents feeder from starting while shield is in the “open” position). 2. Remove jammed product from feeder. While doing so, try to determine the cause of the jam (see Section 4, Operational Troubleshooting).
Operational Troubleshooting This table is intended to provide you with quick solutions to the more common day-to-day problems you may encounter. For additional troubleshooting information, refer to the Technical Troubleshooting section. Problem Cause Solution On/Off switch in "Off" (or "O" position). 1.
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Operational Troubleshooting (continued) Problem Cause Solution Feed belts not 1. Check if reset button/fault indicator is Feeder operation was stopped due to operating; continuous illuminated. Press Reset button. a "time-out" fault (i.e., miss, jam, no alarm sound product in hopper). Feed belts not Discharge safety shield not closed 1.
Inspection and Care Please read this Section to learn how to: When performing initial adjustments prior to operation, always make sure you turn Off • Visually inspect your machine to detect part prob- the main power switch, open the discharge lems which may require adjustment or replacement.
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Visual Inspection Ensuring Proper Feed and Discharge Belt Tracking (continued) Check for visual signs of: • Stretching. • Improper roller adjustment. Ensuring Proper Feed Belt Tracking Ensuring Proper Timing and Drive Belt Tracking Check for visual signs of: • Misaligned timing pulleys. Ensuring Proper Drive Belt Tracking 3700 M eliant...
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Visual Inspection (continued) Checking for Gate Assembly Wear Check for visual signs of wear: • Advancing O-ring or Standard O-ring (if applicable): Flat areas along the O-rings. • Bar gate: Bar material begins to flatten excessively. See “Preventive Care” to follow. Advancing O-Ring Gate Optional Bar Gate II Optional Standard O-Ring Gate...
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Visual Inspection (continued) Advancing O-Ring Gate: Adjusting Worn Advancing O-Rings O-Ring Gate To adjust worn O-rings on advancing O-ring gate: 1. Turn Off feeder and remove power cord from outlet. Gate Adjustment 2. Remove gate assembly from gate plate. Knob 3.
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Preventive Care Cleaning Feed and Discharge Belts To clean feed belts: 1. Turn Off feeder and remove power cord from outlet. 2. Open discharge safety shield. 3. Remove gate assembly from gate plate for easier access to belts. Use only isopropyl alcohol (98% concentration). Other solvents will cause belts to wear 4.
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Preventive Care (continued) Cleaning Gate Assembly Use only isopropyl alcohol (98% concentration). Do not use any other types of solvents. They will cause premature wear of the belts, or even total breakdown of the product. Depending on the application, it may be To clean gate assemblies: necessary to move the feeder from original 1.
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Preventive Care (continued) Cleaning Photo Sensors To clean the photo sensor lenses: 1. Turn Off feeder and remove power cord from outlet. 2. Open the discharge safety shield (to access sheet-detect sen- sor). Do not use any solvents or cleaning agents 3. Using a soft, dry cloth, wipe across the face of each lens. when cleaning the photo sensor lenses. This can result in surface damage and eventual faulty 4.
Wedge Applications There is a variety of wedges that may be utilized for feeding various products of differing properties. A wedge may be used either alone or in combination with another wedge depending upon the size and/or properties of the product that is being fed. The following will help to identify which wedge to use for a specific product.
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Wedge Applications (continued) Part Number Description/Setup Example Product Usage 63311017 (Optional) Small Triangle (4 inches wide) Light to medium weight prod- ucts from 3 to 6 inches in length such as Z-fold and C-fold letters, business reply cards, and small booklets.
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Wedge Applications (continued) Part Number Description/Setup Example Product Usage 63311350 (Optional) Large Articulating Roller Light to heavy weight products from 6 to 14 inches in length such as large envelopes, flat sheets, card stock, and corrugated. 63311026 (Optional) Single "S" Light to heavy weight products from 4 to 14 inches in length such as envelopes, card stock, and...
Mechanical Components BASE FEATURES 3700 M eliant anual...
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BASE FEATURES ITEM QTY. PART NUMBER DESCRIPTION 44675003 Mount Front Base Plate 44675004 Mount Back Base Plate 44675022 cover BottoM Protective 44640009 Bracket ruBBer sPacer 43555068 suPPort o ring cover 64911011 sensor st sheet asseMBly 64911009 switch saFety interlock asseMBly 44640011 shaFt toP cover hinge Mount 44909023...
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BASE FEATURES ITEM QTY. PART NUMBER DESCRIPTION 44649034 Module ac Power entry (w/o Fuse) 53500006 Fuse 3a 250v slo-Blo gMd 5 X 20MM 67511034 harness Fault/reset switch asseMBly 44699017 graPhic standard lower 64911005 harness Flight trigger 44699016 cover Plate 69911066 Miss detect asseMBly 44699010 graPhic standard uPPer...
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SOLID GATE PLATE ASSEMBLY Assembly # : 64011004 ITEM QTY. PART NUMBER DESCRIPTION 44640004 Plate, solid gate 44646002 Block, side guide 44646001 Block, side guide adjusting 44646004 Block, adjustMent reFerence 44646010 rack 44646005 shaFt, Pinion adjustMent 44646006 guide, rail side suPPort 44646015 sPacer, lower 44646016...
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6” ADJUSTABLE TRANSPORT HOLD DOWN ASSEMBLY Assembly # : 13301102 3700 M eliant anual...
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6” ADJUSTABLE TRANSPORT HOLD DOWN ASSEMBLY Assembly # : 13301102 ITEM QTY. PART NUMBER DESCRIPTION 51330006 Block, hold down 51385032 Bar, hold down 51277052 shaFt, hold dow 51312003 Pin, sPring 1/8 in 51328001 sPring, hold down 23500095 Bearing, Ball 51277087 collar, disch roller 102688B05 shcs #10-32 X .75...
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HOLD DOWN ASSEMBLY Assembly # : 67511024 3700 M eliant anual...
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HOLD DOWN ASSEMBLY Assembly # : 67511024 ITEM QTY. PART NUMBER DESCRIPTION 51328002 Block, hold down 51277052 shaFt, hold down 51277087 collar, disch roller 51312001 Mount, hold down 51312003 Pin, sPring 1/8 in 51328001 sPring, hold down 23500095 Bearing, Ball 102637B02 Fhcs #10-32 X 3/8 102937B05...
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STANDARD O-RING GATE ASSEMBLY Assembly # : 67511020 3700 M eliant anual...
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STANDARD O-RING GATE ASSEMBLY Assembly # : 67511020 ITEM QTY. PART NUMBER DESCRIPTION 44675013 cover, toP Protect 44649010 key, saFety interlock 13511872 assy, standrad o-ring 102706B03 Bhcs #8-32 X 1/2 103333B07 keP nut #8-32 53500609 laBel, warn injury 2.7 X 1.4 3700 M eliant anual...
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DOUBLE S WEDGE ASSEMBLY Assembly # : 63311025 3700 M eliant anual...
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DOUBLE S WEDGE ASSEMBLY Assembly # : 63311025 ITEM QTY. PART NUMBER DESCRIPTION 44633014 wedge Block 44633010 roller wedge shaFt 44633016 round t-nut 44633033 knoB, 3 arM 44633024 roller wedge 43555098 handle 10-32 X .75 44633026 Block Mounting 23560147 shaFt, idler 44633025 s wedge 44633027...
Electrical Components Reliant 3700 Electrical Wiring Transformer Low Voltage AC In High Voltage AC In Kick Current Adjust % Stepper Motor Drive Board 3700 M eliant anual...
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CPU Board Expansion Board Reliant 3700 Series Electrical Wiring Diagram Controlled Document No. 44-699-100 3700 M eliant anual...
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Reliant 3700 Miss Detect Detail 3700 M eliant anual...
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Power Entry Module Part Number 44649034 3700 M eliant anual...
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Reliant Series DC Stepping Motor Part Number 53511390 3700 M eliant anual...
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Unipolar DC Stepping Motor Drive Boards Part Number 44649030 3700 M eliant anual...
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Reliant Series CPU Board Part Number 44675057 3700 M eliant anual...
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When replacing the EPROM on the CPU board, please EPROM Replacement take the following precautions: 1. Always discharge yourself when handling any electronic component (CPU board or EPROM). 2. When removing the EPROM from the socket, be very careful A qualified service technician should perform the changes listed in this document.
Technical Troubleshooting General Troubleshooting The “drive” consists of the AC power supply (transformer), the step- per motor drive board, and the motor. The “controls” consist of the Terms DC power supply and the control assembly. This control assembly consists of the CPU board, the I/O expansion board, and any ribbon cables and wiring harnesses.
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Problem Solution No power to feeder when 1. Make sure there is power present at the AC main where the feeder is plugged in. power switch is turned on 2. Check three-wire AC power cord for integrity at all three points. 3.
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Problem Solution Decreased power experi- If the input power module fuse holder is installed in the 230V position, and the line enced after fuse is replaced power is at 115V, the feeder will have noticeably decreased power. Never apply more than 125V when the fuse holder is in the 115V position.
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Problem Solution Check integrity of both ends of drive wiring harness between the CPU board Motor does not run, is noisy, connector J8 and the 13-terminal connector to the drive board. makes a “growling” sound, Using a digital multimeter or an oscilloscope, measure the amplitude of the or runs in reverse (contin- pulse train and verify that it is at least 2.3VDC.
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Problem Solution 1. Refer to the DC power supply board diagram. Remove 6-pin DC wiring harness Fan does not operate/Test- connector from output of DC supply. Measure the supply’s output pins for the pres- ing DC power supply ence of DC power. If voltages are not present, verify AC power is being applied to AC input.
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Problem Solution 1. Remove reset button harness from Expansion Board connector J6. On/Off beeping sound is heard, reset button blinks, 2. Using a small metal blade screwdriver, short pins 3 and 4 together on Expansion and pressing button does Board connector J6. not reset fault 3.
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Problem Solution Steady beep is heard, reset 4. Verify the sheet sensor’s power-on green LED is illuminated. Is the green LED button is illuminated, and illuminated? pressing button does not reset fault (continued) Yes: Go to step 5. No: Go to step 7. 5.
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Problem Solution Feeder Will Not Cycle: Test- The Trigger Input ing the Trigger and/or Cycle Button Inputs 1. Verify the flight or trigger sensor’s power-on green LED is illuminated. Is the green LED illuminated? Yes: Go to step 2. No: Go to step 3. The terms “flight sensor”...
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Problem Solution 1. Remove fuse F1 from the Expansion Board and measure across its pins for conti- Testing the Fault Output nuity. If continuity is not measured, replace the fuse. Connector 2. Fuse F1 is connected in series with a set of contacts inside the mini relay located on the Expansion Board.
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