Thiele Streamfeeder Reliant 3700 Manual
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Reliant 3700
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  • Page 1 Reliant 3700 Manual...
  • Page 2 Part Number: 00900383 © 2010 Thiele Technologies, Inc. - Streamfeeder. All rights reserved. No part of this publication may be reproduced, photocopied, stored on a retrieval system, or transmitted without the express written consent of Thiele Technologies, Inc. - Streamfeeder.
  • Page 3: Table Of Contents

    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...
  • Page 4 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.
  • Page 5 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.
  • Page 6: Specifications

    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: ......
  • Page 7 3700 M elaint anual...
  • Page 8: About The Machine

    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.
  • Page 9 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.
  • Page 10 Control Panel Components 3700 M eliant anual...
  • Page 11 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”...
  • Page 12: Preparing For Operation

    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.
  • Page 13 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.
  • Page 14 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.
  • Page 15 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).
  • Page 16 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...
  • Page 17 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.
  • Page 18 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.
  • Page 19 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.
  • Page 20 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.
  • Page 21 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.
  • Page 22: How To Operate

    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.
  • Page 23 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.
  • Page 24 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: •...
  • Page 25 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).
  • Page 26: 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.
  • Page 27 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.
  • Page 28: Inspection And Care

    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.
  • Page 29 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...
  • Page 30 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...
  • Page 31 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.
  • Page 32 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.
  • Page 33 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.
  • Page 34 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.
  • Page 35: Wedge Applications

    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.
  • Page 36 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.
  • Page 37 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...
  • Page 38: Mechanical Components

    Mechanical Components BASE FEATURES 3700 M eliant anual...
  • Page 39 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...
  • Page 40 BASE FEATURES 3700 M eliant anual...
  • Page 41 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...
  • Page 42 CARRIAGE ASSEMBLY Assembly # : 67511162 3700 M eliant anual...
  • Page 43 CARRIAGE ASSEMBLY Assembly # : 67511162 ITEM QTY. PART NUMBER DESCRIPTION 311-0234 assy, Front discharge shaFt 44675012 shaFt Front discharge 23560121 douBle detect Bearing cuP holder 23500095 Bearing Ball r6 311-0235 assy, rear discharge shaFt 44675046 shaFt rear discharge 43560097 Pulley 16t 1/2 Bore w/Flange 23500032 holder outBoard Bearing cuP...
  • Page 44 ADJUSTABLE TRANSPORT ASSEMBLY Assembly # : 37001101 3700 M eliant anual...
  • Page 45 ADJUSTABLE TRANSPORT ASSEMBLY Assembly # : 37001101 ITEM QTY. PART NO. DESCRIPTION ITEM QTY. PART NO. DESCRIPTION 44675112 ExtEnsion, sidE PlatE 103296B18 1/8 x 3/8 woodruff kEy 44846050 HoldEr, r4 BEaring CuP 103274B04 snaP ring 3/8 44582021 r4 BEaring 102688B02 sHCs #10-32 x 3/8 51330010 sHaft, lowEr disCHargE...
  • Page 46 ADVANCING O-RING GATE ASSEMBLY Assembly # : 67511028 3700 M eliant anual...
  • Page 47 ADVANCING O-RING GATE ASSEMBLY Assembly # : 67511028 ITEM QTY. PART NUMBER DESCRIPTION 44657007 handle studded 10-32 X 1/2” 00002302 Bhcs 8-32 X 1/2” lg 44657010 sPacer Belt indeXer .312 X .375 00003320 screw shoulder 8-32 slotted 00003321 screw shoulder 8-32 X 1/8 44657005 Belt indeXer Bracket 44657003...
  • Page 48 SOLID GATE PLATE ASSEMBLY Assembly # : 64011004 3700 M eliant anual...
  • Page 49 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...
  • Page 50 6” ADJUSTABLE TRANSPORT HOLD DOWN ASSEMBLY Assembly # : 13301102 3700 M eliant anual...
  • Page 51 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...
  • Page 52 HOLD DOWN ASSEMBLY Assembly # : 67511024 3700 M eliant anual...
  • Page 53 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...
  • Page 54 STANDARD O-RING GATE ASSEMBLY Assembly # : 67511020 3700 M eliant anual...
  • Page 55 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...
  • Page 56 DOUBLE S WEDGE ASSEMBLY Assembly # : 63311025 3700 M eliant anual...
  • Page 57 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...
  • Page 58 TRIANGLE WEDGE ASSEMBLY Assembly # : 63311214 3700 M eliant anual...
  • Page 59 TRIANGLE WEDGE ASSEMBLY Assembly # : 63311214 ITEM QTY. PART NUMBER DESCRIPTION 44633014 wedge Block 44633017 shaFt, wedge guide 44633018 wedge guide shaFt 43560212 wedge, Material suPPort 44633033 knoB, 3 arM 44633016 round t-nut 103274B04 snaP ring 3/8 102688B04 shcs #10-32 X 5/8 3700 M eliant anual...
  • Page 60 LOW PROFILE WEDGE ASSEMBLY Assembly # : 63311050 3700 M eliant anual...
  • Page 61 LOW PROFILE WEDGE ASSEMBLY Assembly # : 63311050 ITEM QTY. PART NUMBER DESCRIPTION 44633014 wedge Block 44633016 round t-nut 44633033 knoB, 3 arM 44633018 wedge guide shaFt 43560050 narrow roller 33500020 Belt tension 23500095 Bearing, Ball 103240B04 Fw #10 102708B02 Bhcs #10-32 X 3/8 102688B04 shcs #10-32 X 5/8...
  • Page 62 FLIGHT SENSOR ASSEMBLY Assembly # : 63011038 12 13 3700 M eliant anual...
  • Page 63 FLIGHT SENSOR ASSEMBLY Assembly # : 63011038 ITEM QTY. PART NUMBER DESCRIPTION 00002216 screw, ssscPPt 10-32 X 1/4 00002614 screw shcs 6-32 X 3/4 435so263 tie, caBle Black 44608041 locline adjustaBle 44608042 Bracket sensor Mounting 44640016 collar, locline 1/4 Mounting 44681020 screw sssnyltiP 10-32 X 3/4 44681021...
  • Page 64 SHEET SENSOR ASSEMBLY Assembly # : 13301101 (for Adjustable Transport only) 3700 M eliant anual...
  • Page 65 SHEET SENSOR ASSEMBLY Assembly # : 13301101 (for Adjustable Transport only) ITEM QTY. PART NUMBER DESCRIPTION 44640014 Bracket, sensor staBilizer 44649011 sensor, PnP diFFus 44640015 Mounting Bracket 44640016 collar, locline 1/4 Mounting 44608041 locline adjustaBle 1/4 44608046 nut, heX 1/8 nPt 44608042 lockline nPt connector 1/4 X 1/8 102760B09...
  • Page 66 SHEET SENSOR ASSEMBLY Assembly # : 64911011 (for Reliant 3700 without Adjustable Transport) 3700 M eliant anual...
  • Page 67 SHEET SENSOR ASSEMBLY Assembly # : 64911011 (for Reliant 3700 without Adjustable Transport) ITEM QTY. PART NUMBER DESCRIPTION 44640014 sensor Bracket 44640016 locline 1/4 Mounting collar sensor PnP diFFuse reFlective right 44649011 angle 44640015 sensor Mounting Bracket 44608042 solid locline nPt connector 1/4 X 1/8 44608046 solid nut heX 1/8 nPt 44608041...
  • Page 68 ELECTRICAL COMPONENTS Assembly # : 67511002 3700 M eliant anual...
  • Page 69 ELECTRICAL COMPONENTS Assembly # : 67511002 ITEM QTY. PART NO. DESCRIPTION 44630002 BasE PlatE 44649030 Board stEPPEr driVE Bld72-5 44649054 groMMEt 3/4 x 3/8 x1/2 44649033 Board PowEr dC 5V & 12V 2.5 x 4.25 44649036 BraCkEt PowEr suPPly Mounting 53511390 Motor stEPPEr assy 44630011...
  • Page 70 Optional Components QUICKSET DOUBLE DETECT ASSEMBLY Assembly # : 63011097 3700 M eliant anual...
  • Page 71 QUICKSET DOUBLE DETECT ASSEMBLY Assembly # : 63011097 ITEM QTY. PART NUMBER DESCRIPTION 14380008 assy, hold down dd 14380009 assy, Quickset dd 51438016 Bar, cross eXt discharge 14380005 assy, harness Quickset dd 14380006 assy, cBleXtenQckst dd 900459 Manual, Quickset dBldetect 102688B07 shcs #10-32 X 1 102937B02...
  • Page 72 SINGLE S WEDGE ASSEMBLY Assembly # : 63311026 3700 M eliant anual...
  • Page 73 SINGLE S WEDGE ASSEMBLY Assembly # : 63311026 ITEM QTY. PART NUMBER DESCRIPTION 44633014 wedge Block 44633032 shaFt, wedge guide 44633026 Block Mounting 44633028 shaFt Pivot Block 44340013 Bracket, roller 44633025 s wedge 44633027 sPacer 44633016 round t-nut 44633033 knoB, 3 arM 44340015 ratchet handle, 1/4 23500076...
  • Page 74: Electrical Components

    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...
  • Page 75 CPU Board Expansion Board Reliant 3700 Series Electrical Wiring Diagram Controlled Document No. 44-699-100 3700 M eliant anual...
  • Page 76 Reliant 3700 Miss Detect Detail 3700 M eliant anual...
  • Page 77 Power Entry Module Part Number 44649034 3700 M eliant anual...
  • Page 78 Reliant Series DC Stepping Motor Part Number 53511390 3700 M eliant anual...
  • Page 79 Unipolar DC Stepping Motor Drive Boards Part Number 44649030 3700 M eliant anual...
  • Page 80 Reliant Series CPU Board Part Number 44675057 3700 M eliant anual...
  • Page 81 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.
  • Page 82: Technical Troubleshooting

    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.
  • Page 83 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.
  • Page 84 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.
  • Page 85 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.
  • Page 86 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.
  • Page 87 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.
  • Page 88 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.
  • Page 89 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”...
  • Page 90 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.
  • Page 92 315 27th Avenue NE · Minneapolis, MN 55418 · USA : (763) 502-0000 · F : (763) 502-0100 : service@streamfeeder.com Mail : www.streamfeeder.com © 2010 Thiele Technologies, Inc. - Streamfeeder Printed in the USA.

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