Converge 900

Manual
Part Number: 00900474

© 2009 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.

Thiele Technologies, Inc. - Streamfeeder

103 Osborne Road
Minneapolis, MN 55432-3120 USA

Tel: 763.502.0000
Fax: 763.502.0100
E-Mail: service@[Link]
Web: [Link]

Printed in the USA.

Contents
Safety Information.........................................................ii
Specifications...............................................................iv
Section 1: About the Machine........................................................1
Section 2: Technical Installation and Setup..................................5
Section 3: Preparing for Operation................................................8
Section 4: How to Operate............................................................19
Section 5: Operational Troubleshooting.....................................21
Section 6: Inspection and Care....................................................23
Section 7: Additional Wedges......................................................29
Section 8: Mechanical Components............................................33
Section 9: Electrical Components................................................59
Section 10: Technical Troubleshooting.........................................70

Converge 900 Manual i

Before You Begin

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.

ELECTRICAL DANGER signifies an action or specific equipment

area that can result in personal injury or death from an electrical haz-
ard if proper precautions are not taken.

TIP signifies information that is provided to help minimize problems

in the installation or operation of the feeder.

NOTE provides useful additional information that the installer or

operator should be aware of to perform a certain task.

CHECK signifies an action that should be reviewed by the operator

before proceeding.

IMPORTANT alerts the installer or operator to actions that can poten-

tially lead to problems or equipment damage if instructions are not
followed properly.

WARNING LABELS affixed to this product signify an action or spe-

cific equipment area that can result in serious injury or death if proper
precautions are not taken.

ii Converge 900 Manual

Before You Begin

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.

Pinch point. Keep hands and fingers clear.

Moving parts can crush and cut. Keep guards in place. Lock out power
before servicing.

Converge 900 Manual iii

Specifications
Maximum Product Size: ............................. 7 W x 6 L in (177 x 152 mm)

Minimum Product Size: ............................... 2 W x 2.5 L in (50 x 63 mm)

Min/Max Product Thickness: ................... .003-.250 in (.076 x 6.35 mm)

Belt Speed: ............................................ 24,000 in/min (609,600 mm/min)

Placement Tolerance: .............. Steady speed up to +/- 1/16 in (1.58 mm)

Electrical Requirements: .............................................. 115/230vac, 10A

Air Requirements: ...................................................................... 4-6 CFM

Weight: .......................................................................... 60 lbs. (27.22 kg)

iv Converge 900 Manual

Converge 900 Manual v
1 About the Machine
Main Features The Converge 900 is designed for reliability, flexibility, and ease of
use. All parts required for setup, loading, feeding, sensing and easy
operator control are combined into one compact unit.

Review the main assemblies in Figure 1-1 to become familiar with

names and locations of feeder parts and adjustments. This will help
prepare you for initial setup. Descriptions are found in Table 1-1.

Review the control panel components in Figure 1-2 to become fa-

miliar with names and locations of specific connectors, switches, and
controls. This will help prepare you for installation and operation.
Descriptions are found in Table 1-2.

Side Guides

Wedge and
Side Guide
Wedge Adjustment
Adjustment

Gate and
Gate Adjustment

Discharge
Safety Shield

Trigger Sensor and

Adjusting Arm

Universal Mounting
Assembly

Discharge Guides
and Deflector
Nip Roller
Assembly

Encoder Assembly

Figure 1-1. Main Assemblies of Converge 900

1 Converge 900 Manual

 Product Description Section 1

Table 1-1. Main Assemblies Feature Descriptions

Feature Description

Gate assembly and adjustment Mounted on a gate plate directly above the feed belt, this device provides a
curvature to help preshingle stacked product. Adjustment knob allows you
to set downward pressure. When properly adjusted, a gap the thickness of
one and a half pieces is created to help singulate and eject product.

Side guides and adjustments Holds a stack of product to be fed and helps keep it straight for proper
entry through the gate assembly area. Adjustment knob allows you to move
the side guides equally offset for different size products.

Wedge and adjustments Lifts the product to keep it off the table top, reduces excessive contact with
the feed belts, and helps push the product against the curvature of the gate
assembly. To achieve proper lift, adjustment wing-nuts allow you to adjust
the wedge to various positions and angles.

Hold-down This series of rollers provides a self-adjusting pressure on top of product to

force it down on the discharge belt, helping to eject a single product after it
exits the gate assembly area.

Trigger sensor and adjustments Mounted at a remote location, it “looks” for a target on-line (such as the
carrier piece) to start the feeder.

Feed belt Provides the friction and motion necessary to pull individual product from
the bottom of the stack and through the gate assembly area.

Discharge belt Combined with the hold-down rollers, provides the friction and motion
necessary to pull product away from the gate assembly area. Rotates 50%
faster than feed belts to separate and eject the bottom product away from
next product entering the gate assembly area.

Operator control panel Remote handheld, containing switches for setup and operation.

Discharge safety shield Provides residual risk protection to operator when feeder is running.

Nip roller assembly Adjustable set of wheels to capture product as it is dispensed.

Encoder assembly Provides RPM data to feeder controls for timing and placement.

Discharge guides and deflector Provides control of product to minimize skew.

Universal mounting assembly Consists of shaft and plate mounting for most vacuum bases.

Converge 900 Manual 2

Figure 1-2. Operator Control Panel Components

Table 1-2. Operator Control Panel Feature Descriptions

Feature Description
Offset Speed Adjustment to increase feeder speed above the transport speed for added
placement control.

Offset Position Increases delay to the trigger signal for added placement control.

Ready / Jog Illuminated lamp indicates the feeder is ready to dispense product when
triggered. Also acts as a jog button for setup.

Fault / Reset Illuminated lamp to indicate a fault. Pressing it resets the fault and brings
feeder to ready mode.

Cycle Provides a manual cycle of the feeder. Typically used during setup.

Stop Immediately stops the feeder and puts the feeder into fault mode.

3 Converge 900 Manual

Control Interface

SYSTEM I/O TRIGGER INPUT

OPERATOR INTERFACE ENCODER

3
1

5
2

Figure 1-3. Control Interface Features

Table 1-3. Control Interface Feature Descriptions

Feature Description
1 - System I/O Provides the interface connection for integration into other equipment.
Interface signals include; miss/double output, done output, ready output,
and external trigger input.

2 - Trigger Input Provides the connection of the trigger sensor, which triggers a feed cycle
when it senses a passing target (typically the carrier piece).

3 - Operator Interface Provides connection for the remote operator station. See Figure and
Table 1-2 for further information regarding the operator station.

4 - Encoder Provides the connection for the encoder, which provides RPM info of the
base system for operation of the feeder.

5 - AC Inlet Module Provides connection point for incoming power (115VAC or 230VAC).

Converge 900 Manual 4

2 Technical Installation and Setup
! ! !
When performing initial installation and
adjustments prior to operation, always make
sure you turn Off the main power switch, open
the discharge safety shield (to disengage the
interlock), and disconnect feeder from the
electrical power source. Failure to do so can
expose you to a potential start-up and moving
parts which can cause serious injury.
Do not attempt to make any adjustments while
the machine is running. Failure to do so can
expose you to moving parts which can cause
serious injury. Do not wear loose clothing
when operating the feeder. Avoid making
adjustments with loose or unsecured parts.
This can potentially damage parts.
Installation and setup should be performed by
a qualified technician.

Feeder Mounting Using the included mounting brackets and shafts, mount the feeder
no more than ¾” above the transport belts of the host transport you
are integrating it to. Although the mounting brackets and shafts
have been designed to be universal, they may need to be modified to
accommodate your transport.

At the end of the adjustable positioning arm of the fiber optic flight
Flight Sensor sensor is a clamp block designed to mount at several positions within
Mounting the feeder and mounting brackets. Positioning of this component is
crucial to the size of the carrier piece that the Converge 900 will be
tipping on to.

If the carrier piece is narrower than the feeder width, the most suitable
mounting position would be directly over the discharge assembly of
the feeder and can be mounted to the cross bar of the hold down. If
wider than the feeder width, it can be mounted to either of the feeder
mounting brackets.

The focal distance of this sensor is variable from 10-240mm. Position

the sensor approximately 1-2 inches (25.4 – 50.8mm) above the target
and angle the sensor slightly.

5 Converge 900 Manual

Flight Sensor It is important that the sensor only triggers off the carrier piece passing
by. To increase the (GAIN) focal length, turn the adjustment dial
Mounting clockwise (CW). Counterclockwise (CCW) to decrease the “GAIN”
(continued) focal length.

Using the included mounting brackets and shaft, mount the Nip Roller
Wheel Assembly so they are adjustable toward and away from the
Nip Roller Wheel feeder (upstream and downstream). Although the mounting brackets
Assembly and shafts have been designed to be universal, they may need to be
modified to accommodate your transport.

The Nip Roller Wheel Assembly will need to be adjusted during

product changeovers to accommodate different product lengths.
Properly set, the Nip Roller Wheels will capture the product while
¼ - ½ inch of product is still on the transport of the feeder. It will also
provide the best control of the product for placement accuracy.

Encoder Mounting The encoder is designed to be mounted on the “Nip Roller Wheel
Assembly” shaft or on one of the feeder mounting shafts. Location
is dependent upon your type of transport base. When mounted, the
encoder wheel must rotate in the direction labeled on the wheel for
proper operation. If not, this system will not function properly.

Should other mounting methods be required, the desired ratio is 9.5

inches of belt travel per rotation of the encoder.

Once the mounting is complete, the encoder must be calibrated.

Proceed to the calibration step for instructions.

Encoder Calibration The encoder calibration sequence is as follows:

Sequence 1. Start the transport (according to manufacturer instructions)

and set the speed to approximately 3000 inches per minute.
2. Power on the Converge 900 by placing the rocker switch at
the control box to the On ( I ) position. In approximately
20 seconds, the FAULT/RESET lamp will begin to flash.
3. At this time, press and hold the CYCLE and READY/
NO TE
JOG buttons, then press the FAULT/RESET button.
This is only performed during the first power up 4. Calibration is complete. Power Off ( O ) feeder.
reset.

Converge 900 Manual 6

Feeder Setup Initial Start Up
Once all components are mounted and the feeder is properly set up
Information with product, the following steps must be performed:

1. Power on the Converge 900 by placing the rocker switch at

the control box to the On ( I ) position.
2. After approximately 20 seconds, the FAULT/RESET lamp
will begin to flash. Press the FAULT/RESET button to
bring the feeder to “ready” mode. This will be indicated by
a solid green lamp.
3. With the feeder now in “ready” mode, pressing the
READY/JOG button will “jog” product through the feeder
and out onto the transport base. Observe the smooth flow
of product.
4. Start the transport (according to manufacturer instructions)
and run at approximately 3000 inches per minute.
5. Start dispensing the carrier pieces. Verify the triggering
of the feeder each time a carrier piece passes by the flight
sensor.
6. Verify the placement of the tip on piece to the carrier. Fine
tune adjustments can be made with the OFFSET SPEED
NO TE and OFFSET POSITION dials. OFFSET SPEED increases
or decreases the feeder belt speed. This causes the piece to
Note: Due to differing product weights,
characteristics and operating conditions, discharge either faster or slower to hit the target. OFFSET
placement position will need to be readjusted at POSITION either adds or subtracts a delay from the
the start of every run. flight sensor. By doing this, you can move the placement
location forward or backward on the carrier.

7 Converge 900 Manual

3 Preparing for Operation
Once the Converge 900 is installed, you are ready to prepare the

! ! ! machine for operation. You must perform a few adjustments with the
product 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. You will have to
to operation, always make sure you turn Off
perform this procedure for each product you plan to feed.
the main power switch, open the discharge
safety shield (to disengage the interlock), and
disconnect feeder from the electrical power The adjustments you must make (in order) are as follows:
source. Failure to do so can expose you to a 1: Gate assembly adjustment
potential start-up and moving parts which can 2: Side guides setting
cause serious injury.
3: Back wedge setting
Do not attempt to make any adjustments while 4: Hold-down setting
the machine is running. Failure to do so can 5: Photo sensor adjustment
expose you to moving parts which can cause
serious injury. Do not wear loose clothing 6: Manual test to verify
when operating the feeder. Avoid making
adjustments with loose or unsecured parts.
This can potentially damage parts.

STEP 1: Review
The gate assembly provides the curvature to help preshingle product
Gate Assembly and the proper gap to help the feed belts advance product through
Adjustment the gate assembly area — one at a time. The downward pressure (or
weight) of the stack in the hopper will provide the force to help push
the product against the curvature of the gate assembly, and help it
NO TE contact the feed belts. This preshingling will allow the gate assembly
Hopper refers to the space where the product
to separate (and singulate) product as it moves toward the gap.
is stacked (made up of the side guides and gate
plate). To achieve the optimum separation, you have to use the adjustment
knob to either increase (clockwise) or decrease (counterclockwise) the
gap between the gate assembly and the feed belts. Depending upon the
NO TE characteristics of the product you are using, you may have to change
Keep in mind that the gate assembly works with the gate assembly from the factory-set high spring tension to a low
the wedge to provide the proper lift, curvature of
spring tension. See “Changing from Factory Set High-Tension to
the product, and proper belt/product contact to
separate and feed one sheet at a time. Low-Tension” to follow.

Objective
Adjust the gate assembly for minimum gap, with minimum pressure
on the product. Feeding problems will occur with either too much
pressure on the product, or too large a gap between the gate assembly
and the product.

Converge 900 Manual 8

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.
It may be necessary to pull up on the adjustment knob to allow
(continued) the piece to be inserted.
2. Test the piece for clearance. Grasp the product with two hands
! and slide it front-to-back under the gate assembly. A proper
adjustment allows a slight amount of drag on the top of the
Excessive lowering of the gate assembly can
damage product or lead to premature wear of the piece.
O-rings or feed belts. 3. Adjust the knob on the gate assembly until the piece has the
LO
W ER
desired drag. Turn the knob clockwise to increase clearance or
counterclockwise to decrease clearance.
4. Repeat the drag tests and adjust as needed to achieve accept-
able clearance.
If bottom piece of material does not move freely,
then the gate assembly is too tight. This can lead
to premature wear of the O-rings or feed belts. NO TE
Some illustrations may depict other models or optimal
features and are for illustration purposes only.
!
Due to the discharge belt and hold-down
assembly spinning 50% faster than the feed belts, Slip sheet of
excessive gate assembly pressure can cause product under
premature wear to O-rings or feed belts. gate assembly
Pull knob up

TIP
A wider gap between product and belt provides
the highest tolerance for curled and bent edges.

NO TE

Feeding problems will occur with either too Figure 3-1. Lifting Gate Assembly Upward to Insert Product
much material in the hopper, or too large a gap
between the gate assembly and the material.

Move product Turn knob

front to back, counter-
clockwise to
lower (or
test for decrease
slight drag gap)

Figure 3-2. Using One-Piece Thickness of Figure 3-3. Adjusting Gate Assembly for
Product to Set Gap Correct Gap

9 Converge 900 Manual

STEP 1: To adjust the gate for effective material skew control, follow these
Gate Assembly steps:
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
NO TE sides of the piece of material.
3. To compensate for greater drag on one side of the material,
When feeding product with varying thickness
throughout, it may be necessary to turn both turn the opposite adjustment roller counterclockwise 1/8 turn.
adjustment rollers 1-2 full turns counter- Next, turn the other adjustment roller clockwise 1/8 turn.
clockwise to compensate for the differential 4. Repeat drag tests and adjust as needed until equal drag is
thickness. This procedure allows the gate horizon achieved. You may need to repeat this procedure after observ-
to “float.”
ing the feeder cycling (refer to Section 4, How to Operate).

IMPOR TANT
The adjustment knob set screws are pre-set at the
factory to lock the knob to the threaded rod. DO
NOT OVERTIGHTEN! Over-tightening the set
screws may damage the components.

Figure 3-4. Horizon Adjustment Mechanism (shown on

Advancing O-Ring Gate)

Converge 900 Manual 10

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). This works well for most materi-
Low-Tension als, for tall stack height, and helps provide the best performance in
preventing doubles.

If you are feeding a product of irregular thickness, you should change

! to low-tension. This provides the following benefits:
• Allows the gate assembly to adjust to the irregular thickness
Excessive lowering of the gate assembly can
damage product or lead to premature wear of among product pieces.
the O-rings or feed belts.
• Prevents marking on the product by the gate assembly.
• Prevents peeling back the top sheet of a multi-page product.

Procedure
To change the spring from a high to a low spring tension, follow these
steps:
1. Remove the gate assembly from gate plate (lift up on knob
and tip at slight angle to remove).
2. Remove the adjustment knob by turning counterclockwise
(Figure 3-5A).
3. Lift the cylinder off of top of spring (Figure 3-5B).
4. Turn the cylinder around so that the cylinder collar faces up
(Figure 3-5C).
5. Place the cylinder on top of the spring.
6. Replace the adjustment knob (make about 8 revolutions of the
knob before reinstalling gate assembly on gate plate).

A B C

Figure 3-5. Adjusting Gate Assembly for Low-Tension

11 Converge 900 Manual

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
top to bottom, with no drifting or binding. Adjustments are made
horizontally.

Make sure the space between the side guides can accommodate the
size of the product being fed. Consider the following as you adjust the
guides:
• An initial starting point should always be that each guide is of equal
distance from the center point of the machine.
• Each edge of the product should rest equally on belts either side
of gate assembly (or equidistant spacing). There can be certain
instances where guides do not need to be centered due to product
TIP characteristics. This is called offset spacing.
A good “rule-of-thumb” measurement to use is • Adjust both side guides to be as close as possible to either sides of
about 1/16 in. (1.6 mm) between product edge
and side guides (1/8 in. or 3.1 mm overall).
the product without causing binding, curling of edges, or resistance
to movement.

Procedure
To adjust each side guide for proper equidistant horizontal spacing,
follow these steps (Figure 3-6):
1. Place a small stack of product in the hopper.
2. Using the side guides adjustment knob (centrally located be-
tween the two guides), turn in either direction until guides are
located at the recommended distance from the product:
1/16 in. (1.6 mm) for each edge, 1/8 in. (3.1 mm) overall.
3. Visually check both guides for proper spacing from product.

Converge 900 Manual 12

STEP 2: To adjust each side guide for proper offset horizontal spacing, follow
these steps (Figure 3-7):
Side Guides Setting 1. Push down on the side guides adjustment knob to disengage
(continued) guides from gear mechanism.
2. Grasp whichever side you wish to offset first and move into
position.
3. Place a small stack of product in the hopper, with edge of
paper against offset guide.
4. Move the second side guide so that it is located at the recom-
NO TE mended distance from the product: 1/16 in. (1.6 mm) for each
edge, 1/8 in. (3.1 mm) overall.
Some illustrations may depict other models
5. Lift up on the adjustment knob so that the guides lock into
or optimal features and are for illustration
purposes only. place.
6. Visually check both guides for proper spacing from product.

Manually adjust
either side guide
for offset

Horizontal Horizontal
adjustment adjustment
(rotate to (push down to
adjust both adjust either
side guides) side guide)

Figure 3-6. Horizontal Adjustment of Side Figure 3-7. Individual Side Guide Offset
Guides

13 Converge 900 Manual

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
NO TE assembly. Also, it keeps other sheets off the feed belts until proper
Keep in mind the back wedge works with the gate separation of the bottom sheet at the gate assembly has occurred.
assembly to provide the proper lift, curvature of
the product, and proper belt/product contact to Here are some general guidelines that should help you determine
separate and feed one sheet at a time. how the back wedge should be positioned for your particular product
(for illustration purposes, the optional Articulating Roller Wedge is
shown):
• Moving the individual rollers to the outside of the back wedge shaft
(Figure 3-8A) will create a bow in the center. The bow will stiffen
the product to promote better singulation of thinner product.
TIP
• Pivoting the back wedge from its perpendicular to the gate assem-
There are a number of feeding problems which bly (Figure 3-8B) will increase or decrease the amount of drag of
can be solved by simply adjusting the back wedge contact (or traction) on the feed belts for a given side. This can also
to different positions. Some of these problems
include double feeds, skewing, twisting, poor
be used to control twisting or skewing of product as it leaves the
singulation, ink or varnish buildup on the belts, gate assembly area.
and jamming at the gate assembly area.
• If the back wedge is positioned too far backward from the gate as-
sembly (Figure 3-8C), then the belts are driving the product before
the bottom sheet has separated and left the gate assembly area. This
pushes the gate assembly up, creating more pressure on the prod-
uct, O-rings, and feed belts. The result can be premature buildup of
ink or varnish on the belt surfaces. It can also cause more than one
product at a time to be forced under the gate assembly, creating a
double feed.
By moving the back wedge forward, only the bottom product can
make contact with the belt surface. Slippage is reduced, minimizing
NO TE buildup on the belt surface. Double feeding is also reduced.
For more information about optional wedges and
• If the back wedge is positioned too far forward to the gate assembly
their use with various products, see Section 6.
(Figure 3-8D), then a pinch point can be created between the top
NO TE surfaces of the individual rollers and the product. Moving the back
wedge even closer toward the gate assembly can allow product to
Some illustrations may depict other models or
optimal features and are for illustration purposes overhang the wedge, creating too much lift of the product off the
only. feed belts.

A B C D

Figure 3-8. Tips for Proper Back Wedge Adjustment

Converge 900 Manual 14

STEP 3: Objective
Adjust the back wedge for proper support of the product off the table
Back Wedge top, without creating any pinch or stress points.
Adjustment
(continued) Procedure
To adjust the back wedge for initial proper positioning, follow these
steps:
1. Grasp a handful of product, approximately 2 to 2-1/2 in. (5 to
6 cm) thick, and preshingle the edges with your thumb
(Figure 3-9).
2. Place the preshingled material in the hopper so the edges rest
against the curvature of the gate assembly (Figure 3-10).
3. Turn the back wedge wing-nut adjustment counterclockwise
to loosen the wedge (Figure 3-10).

2 to 2-1/2" (5 to 6 mm)

NO TE
This end against
Some illustrations may depict other models gate assembly
or optimal features and are for illustration
purposes only.

Figure 3-9. Preshingling a Small Stack of Material By Hand

Back wedge
adjustment

Figure 3-10. Positioning Product Prior to Loosening Back

Wedge
4. Move the back wedge forward and backward until the bottom
sheet is not touching the table top (Figure 3-11). A good start-
NO TE ing point is to measure about 5/8 in. (16 mm) from the bottom
Moving the back wedge too far forward to the sheet to front edge of table top. Then as you test, you can “fine
gate assembly can create a pinch point between tune” from this point. You can also fine tune back wedge loca-
upper surface of the rollers and the product. If
moving the back wedge in is not effective, then an tion by loosening the roller swivel wing-nut to pivot the rollers
optional wedge may be required. See Section 7 back and forth (Articulating Roller Wedge only (Figure 3-12).
for more information.

15 Converge 900 Manual

STEP 3: NO TE
Back Wedge Some illustrations may depict other models or optimal
Adjustment features and are for illustration purposes only.

(continued)

Loosen wingnut to
swivel forward or
backward

Start with
about 5/8"
(16 mm) lift

Figure 3-11. Adjusting Back Wedge for Figure 3-12. Adjusting Roller Position
Proper Lift

5. Make sure the edge of the back wedge assembly is parallel

with the edge of the product stack (Figure 3-13). Adjust as
required and then tighten wing-nut.
6. Check that individual rollers are evenly spaced to provide
enough support to lift the product off the table top and feed
belts, without any bowing or twisting (Figure 3-14).

Back wedge
parallel to
stack Equal
distance

Figure 3-13. Adjusting Back Wedge for Parallel Figure 3-14. Evenly Adjusting Individual Rollers

Converge 900 Manual 16

STEP 4: Review
The hold-down assembly consists of several self-adjusting rollers
Hold-Down Setting which rest on top of the product as it exits the gate assembly area.
With the correct amount of pressure applied to the product, the dis-
charge belt will have the proper amount of contact and friction needed
! to pull product away from the gate assembly area. No need to adjust.
Due to the discharge belt and hold-down
assembly spinning 50% faster than the feed belts,
excessive gate assembly pressure can cause
premature wear to O-rings or feed belts. Review
Step 1, Gate Assembly Adjustment.

STEP 5: Review
The Flight-Detect photo sensor is mounted on the line to detect a tar-
Photo Sensor get and instruct the feeder to eject a product. The Sheet-Detect photo
Adjustment sensor is mounted in the discharge assembly to detect the leading edge
of a product about to be ejected.

Objective
For the Sheet-Detect photo sensor to be effective, it must be adjusted
within a specified range and angle to the product. It is factory set and
does not need to be changed.

17 Converge 900 Manual

STEP 6: Now that you have made all the necessary adjustments for operation,
it is recommended that you verify the singulation and separation of
Manual Test to Verify product through the gate assembly area. Before you power-up and
run your machine with a full hopper, manually feed several sheets of
product through the gate assembly area.

Prepare your test by loading the hopper with approximately 2 to 2-1/2

in. (5 to 6 cm) of product. Make sure you preshingle the stack so that
product rests against the curvature of the gate assembly.

1. Manually feed several sheets of product slowly through the

gate assembly area. Move the drive belts by pressing your
thumb against the discharge belt.
2. Observe how individual product enters and exits the gate as-
sembly area. Remember, a properly set gap will allow each
NO TE
new sheet to enter at about the centerline of the cylinder while
If the gate assembly is too tight, the feeder will the bottom sheet is exiting the gate assembly area (Figure 3-
have difficulty pulling the product through the 15). Ideally, this means a slight overlap of both the first sheet
gate assembly area. This will cause “missed”
feeds. and the second sheet (1/8 in. or 3 mm) at the gate assembly
area. The overlap occurs as the bottom sheet is exiting, and
the next sheet is entering.
3. If feeding doubles, move the wedge in toward the gate assem-
bly. Test again.
4. If sheets are overlapping excessively or, if the machine is
feeding doubles, reduce the gap slightly by moving the knob
about 1/8 turn counterclockwise. Test again.
5. As product moves through the hold-down area, check for any
NO TE skewing or jamming. Also check for damage to the product.
6. If this or other feeding problems still persist (slipping, skew-
Moving the back wedge too far forward to the
gate assembly can create a pinch point between ing, jamming), review all the adjustment procedures in Sec-
the tip of the wedge and the product. If moving tion 3, Preparing for Operation.
the back wedge in is not effective, then an
optional wedge may be required. See Section 6
for more information.

NO TE
Some illustrations may depict other models or
optimal features and are for illustration purposes Next Bottom
only. sheet sheet

Slight overlap
at mid-point

Figure 3-15. Optimum Overlap and Separation of Product

Converge 900 Manual 18

4 How to Operate
Operational Successful power-up and operation of the feeder is assured if you ap-
ply each of following sets of procedures where needed:
Sequences • Loading product
• Quick setup/cycle sequence
• Accessing the menus for setup
• Starting a cycle
• Stopping the feeder
• Clearing a jam

Loading Product 1. Preshingle a small stack of material and load in hopper with
one end of the stack resting against the gate assembly, and the
other end resting on the back wedge (Figure 4-1).
NO TE 2. Gradually add more product to the hopper. As stack height
Some illustrations may depict other models or will have a preferred minimum and maximum, you will have
optimal features and are for illustration purposes to experiment to determine the effective range of height (Fig-
only.
ure 4-2).
3. As you add product, tap each handful of product with your
hand to make sure it rests evenly against the back plate.
NO TE
Preshingling prevents multiple sheets from
jamming under the gate assembly at start-up.

Add more product;

TIP gently push in
to make sure edges
touch back plate
Stack height affects the downward pressure on
the feed belts. Greater downward pressure can
increase the chances for misfeeds or double
feeds.

Edges should be
against curvature

Figure 4-1. Placing Product Against Gate Figure 4-2. Adding More Product to Fill Hopper
Assembly

19 Converge 900 Manual

Stopping the Feeder The feeder can be stopped either manually or automatically. Press-
ing the STOP button will stop feed cycles and return the feeder to the
“Fault” status.

When a product fails to be staged in a preset amount of time, the feed-

er will automatically timeout or stop. If this occurs, the Fault Lamp
will begin to flash. Determine and resolve the cause of the timeout and
press the FAULT/RESET button to resume feeding.

Clearing a Jam If a jam occurs during operation, follow these steps:

1. Turn power Off.
2. Open the discharge safety shield.
3. Remove jammed product from feeder. While doing so, try to
determine the cause of the jam (see Section 5, Operational
Troubleshooting).
4. Verify whether any adjustments are loose. If so, refer back
to Section 3, Preparing for Operation, for proper adjustment
procedures.
5. Reposition trigger sensor (as required).

Shutdown Should you not be using a the feeder for long periods of time, follow
these steps to ensure a safe and secure storage:
1. Turn power Off.
2. Disconnect feeder from AC power source.
3. If removing the Flight-Detect photo sensor from the produc-
tion line, disconnect cable connector from feeder and coil up
for storage.
4. Cover the feeder with a cloth or plastic tarp to prevent dust
and debris from accumulating.

Converge 900 Manual 20

5 Operational Troubleshooting
Table 5-1 is intended to provide you with quick solutions to the more common day-to-day problems you may
encounter. For additional troubleshooting information, see Section 10, Technical Troubleshooting.

Table 5-1. Quick-Look Troubleshooting

Problem Cause Solution
No AC power to 1. On/Off switch in "Off" (or "O" position). Move switch to "On" (or "_" position).
feeder
2. Power cord loose or not plugged into Check and secure power cord at AC
outlet (or AC power source). outlet.

3. Female end of power cable loose or not Check and secure cord at AC power
plugged into AC power inlet at rear of inlet at rear of machine.
feeder.

Feeding doubles 1. Gate assembly improperly adjusted Review gate adjustment procedure.
(possibly more than one sheet thick-
ness).

2. Back wedge improperly adjusted. Review back wedge adjustment proce-

dure.

3. Worn O-rings (or angled edge). Rotate O-rings (or replace angled
edge). If wear is excessive, consult with
a qualified technician.

4. Material interlocking. Check material and source.

5. Static buildup. Check material and source.

Feed belts are op- 1. Material stack height is too low when Review material loading procedure.
erating, but mate- stack height is down, resulting in reduc-
rial not feeding tion of down pressure.

2. Binding in side guides. Adjust side guides farther apart to allow

freedom of movement between sheets.

3. Slippery feed belts. Consult with a qualified technician.

4. Sheet adhesion or interlocking between Review material loading procedure and

the bottom and next sheet. back wedge adjustment procedure.

5. Gate assembly may be down too tight. Review gate assembly adjustment
procedure.

6. Too much weight in hopper. Remove material from stack. Test

again.

21 Converge 900 Manual

Table 5-1. Quick-Look Troubleshooting (continued)

Problem Cause Solution

Feed belt(s) not 1. Excessive weight in hopper. Reduce weight. Test again.
tracking on rollers
2. Excessive down pressure on gate as- Rotate gate adjustment 1/8 turn to
sembly. increase gap and manually test. Review
gate assembly adjustment procedure.

3. Off-centered product from center point Review side guide setting procedure.
of machine.

4. Belt wear. Review gate assembly adjustment

procedure. Also review inspection and
care procedures. If wear is excessive,
consult with a qualified technician.

Jamming occurs 1. Improperly adjustment in one or more 1. Turn the Power switch to "Off" by
during operation of the following areas: pressing the circle (O).
A. Gate assembly. 2. Remove jammed material from
B. Back wedge. feeder. While doing so, try to deter-
C. Top roller hold-down assembly. mine the cause of the jam.
D. Discharge alignment rails. 3. Verify each adjustment by reviewing
the "Preparing for Operation" section
of the manual.

Material skewing 1. Back wedge not aligned properly. Review back wedge adjustment proce-
dure.
2. Excessive gate pressure on one side. Review gate assembly adjustment
procedure.

Converge 900 Manual 22

6 Inspection and Care
Please read this Section to learn how to:

! ! ! • Visually inspect your machine to detect part problems which may

require adjustment or replacement.
When performing initial adjustments prior
to operation, always make sure you turn Off • Periodically care for your machine to prevent any operational prob-
the main power switch, open the discharge lems.
safety shield (to disengage the interlock), and
disconnect feeder from the electrical power
source. Failure to do so can expose you to a
potential start-up and moving parts which can
cause serious injury.
Do not attempt to make any adjustments while
the machine is running. Failure to do so can
expose you to moving parts which can cause
serious injury. Do not wear loose clothing
when operating the feeder. Avoid making
NO TE
adjustments with loose or unsecured parts. Some illustrations may depict other models or optimal
This can potentially damage parts. features and are for illustration purposes only.

Visual Inspection Checking for Feed and Discharge Belt Wear

Check for visual signs of:
Discharge roller (B) • Walking. Replace as required.
A • Cracking. Replace as required.
A
A
• Thinning. Replace as required.
A B
A
A
A

Feed Belt (A)

Figure 6-1.

Checking for Timing and Drive Belt Wear

Drive belt (C) Check for visual signs of:
C • Fraying. Replace as required.
• Missing teeth. Replace as required.
• Cracking. Replace as required.

D
Timing belt (D)

Figure 6-2.

23 Converge 900 Manual

Visual Inspection Ensuring Proper Feed and Discharge Belt
(continued) Tracking
Check for visual sign of:
• Stretching.
• Improper roller adjustment.
NO TE
Some illustrations may depict other models or
optimal features and are for illustration purposes
only.

Feed belt drift

Discharge belt
Figure 6-3.

Ensuring Proper Timing and Drive Belt

Tracking
Check for visual signs of:
• Misaligned timing pulleys.

Drive Belt

Timing belt drift

Figure 6-4.

Converge 900 Manual 24

Visual Inspection Checking for Gate Assembly Wear
Check for visual signs of wear:
(continued) • Bar gate: Bar material begins to flatten excessively.
• Standard O-ring or advancing O-ring (if applicable):
Flat areas along the O-rings.

See “Preventive Care” to follow.

Bar Gate II Standard Advancing

O-Ring Gate O-Ring Gate

Flattened edge Flattened

(more than 50%) O-rings Flattened
O-rings

Figure 6-5. Figure 6-6. Figure 6-7.

25 Converge 900 Manual

Visual Inspection Replacing Worn Bar Material
To replace a worn bar material:
(continued) 1. Turn Off feeder and remove power cord from outlet.
Bar Gate 2. Remove gate assembly from gate plate.
3. Remove plate (two screws).
4. Use a pliers to grip and remove bar material.
5. Install new bar material by inserting one end and then pushing
in until centered. Do not grip bar material with pliers as this
may cause damage to the edge.
6. Reinstall clamp (two screws).
7. Reinstall gate assembly and restore power.

Remove angled
wedge and replace

Figure 6-8.
Standard Standard O-Ring Gate: Adjusting Worn
O-Ring Gate O-Rings
To adjust worn O-rings on standard O-ring gate:
1. Turn Off feeder and remove power cord from outlet.
2. Remove gate assembly from gate plate.
3. Insert a screwdriver in slot on top of gate assembly and rotate
screwdriver clockwise or counterclockwise 360° to move
worn area of O-ring about 1/8 to 1/4 in. (3 to 6 mm).
1/8 to 1/4"
4. Remove screwdriver and repeat for each ring.
(3 to 6 mm) 5. Reinstall gate assembly and restore power.

Flattened
edge rotated

Figure 6-9.
Gate Advancing Advancing O-Ring Gate: Adjusting Worn
Adjustment
Knob
O-Ring Gate O-Rings
To adjust worn O-rings on advancing O-ring gate:
Cylinder 1. Turn Off feeder and remove power cord from outlet.
Advancing 2. Remove gate assembly from gate plate.
lever
3. Lower advancing lever away from gate adjustment knob.
4. Rotate O-rings by grasping advance knob and pushing toward
gate cylinder about 1/8 to 1/4 in. (3 to 6 mm).
5. Lower advancing lever to resting position away from gate
adjustment knob.
6. Reinstall gate assembly and restore power.
Side plate

Figure 6-10.

Converge 900 Manual 26

Preventive Care Cleaning Feed and Discharge Belts
To clean feed and discharge belts:

!
1. Turn Off feeder and remove power cord from outlet.
2. Remove gate assembly from gate plate for easier access to
Use only isopropyl alcohol (98% concentration). belts.
Other solvents will cause belts to wear 3. Apply a small amount of isopropyl alcohol to a soft cloth.
prematurely, and even total breakdown of 4. Use your hand to move the discharge belt, start with one feed
material.
belt at a time and carefully press the moistened area of the
cloth to the belt. As you rotate the belt, use moderate pres-
sure to wipe across the belt, making sure to wipe in direction
of grooves also. After several rotations of the belt, repeat for
NO TE each belt.
Some illustrations may depict other models or 5. Taking a dry portion of the cloth, go back to the first feed belt
optimal features and are for illustration purposes cleaned and use moderate pressure against the belt for several
only. revolutions to ensure the belt is dried. Repeat for each belt.
6. Repeat steps 3 through 5 for the discharge belt also.
7. Reinstall gate assembly and restore power.

Feed belts Discharge belt

Figure 6-11. Figure 6-12.

27 Converge 900 Manual

Preventive Care Cleaning Gate Assembly
Use only isopropyl alcohol (98% concentration). Do not use any
(continued) other types of solvents. They will cause premature wear of the
belts, or even total breakdown of the material.

To clean gate assemblies:

1. Turn Off feeder and remove power cord from outlet.
2. Remove gate assembly from gate plate.
3. Apply a small amount of isopropyl alcohol to a soft cloth.
4. Wipe across bar material (or O-rings if applicable), first in one
direction, then the other.
5. Taking a dry portion of the cloth, go back and wipe all sur-
faces to ensure they are dried.
6. Reinstall gate assembly and restore power.

Bar Gate Standard Advancing

O-Ring Gate O-Ring Gate

Clean angled wedge Clean all O-rings Clean all O-rings

Figure 6-13. Figure 6-14. Figure 6-15.

Cleaning Photo Sensors

! To clean the photo sensor lenses:
1. Turn Off feeder and remove power cord from outlet.
Do not use any solvents or cleaning agents
when cleaning the photo sensor lenses. This can 2. Open the discharge safety shield (to access sheet-detect sen-
result in surface damage and eventual faulty sor).
performance. 3. Using a soft, dry cloth, wipe across the face of each lens.
4. Recheck the adjustments of both photo sensors to make sure
they are still in alignment to the targets.
5. Close discharge safety shield and restore power.

Converge 900 Manual 28

7 Additional Wedges
NO TE This section provides information about setting up various wedges
which are compatible with the Converge 900.
Some illustrations may depict other models or
optimal features and are for illustration purposes
only.
Now that you are familiar with the basic principles of using a wedge,
it is simply a matter of combining these principles with the informa-
tion provided in this section. This will allow you to get optimum
performance when setting up the standard wedge for your particular
needs.

The following wedges are covered:

• Combination triangle/low-profile
• Separate triangle and low-profile
• Separate articulating roller and low-profile
• Articulating roller
• Extended narrow
• Combination

Combination Triangle/ When to use: For thin product with minimal body requiring minimal
mid-range support.
Low-Profile
Setup guidelines: Adjust so bottom of stack preshingles against the
curvature of gate assembly. Make sure edges of product do not touch
or overhang tip of triangle wedges, as this creates pressure points.
Roller(s) should lift bottom of stack off table top to eliminate friction
and create body. See Figure 7-2.
Side

Preshingled at
No product edge gate assembly
past this point curvature

Top

Mid-range
support

Figure 7-1. Figure 7-2. Triangle/Low-Profile Wedge Setup

29 Converge 900 Manual

Separate Triangle and When to use: If moving combination triangle/low-profile wedge
assembly back from the gate assembly, bottom of stack still touches
Low-Profile table top. This means you need even more mid-range support.

Setup guidelines: Adjust the triangle wedge the same way that you
would the combined triangle/low-profile wedge assembly (see previ-
ous page). Set the low-profile wedge relative to the triangle wedge
so it lifts the bottom of the stack off the table top to eliminate friction
Side and create body. Again, make sure edges of product do not touch or
overhang tips of triangle wedges. See Figure 7-4.

No product edge
past the mid-point
Top

More mid-range
support

Figure 7-3. Figure 7-4. Separate Triangle and Low-Profile Wedge Setup

Separate Articulating When to use: For thicker product with more body requiring medium
mid-range support. Longer product may also benefit.
Roller and Low-Profile
Setup guidelines: Initially adjust articulating wedge so that roller
edges preshingle the bottom of the stack against the curvature of gate
assembly. Make sure edges of product do not extend back more than
mid-point of rollers. Set the low-profile wedge so that roller(s) lift bot-
Side tom of stack off the table top to eliminate friction and create body.

No product edge
past the mid-point
Top

More mid-range
support

Figure 7-5. Figure 7-6. Separate Articulating Roller and Low-Profile

Wedge Setup

Converge 900 Manual 30

Articulating Roller When to use: Effective for very thick and/or ridged product requiring
virtually no mid-range support.

Setup guidelines: Adjust so roller edges preshingle the stack against

the curvature of gate assembly. Again, make sure edges of product
do not extend back more than the mid-point of roller. See Figure 7-8.
NOTE: With some product that tends to bind together (i.e., perforated
Side product), it may be beneficial to separate 4 to 5 sheets of product at
the bottom to provide some air space.

No product edge
past the mid- point
Top

No mid-range
support needed

Figure 7-7.
Figure 7-8. Articulating Roller Wedge Setup

Extended Narrow Setup guidelines: Effective for moving in close to the gate assembly
for supporting very small product. Due to size, no mid-range support
is required.

Ideal setup: Adjust so wedge preshingles the bottom of stack against

the curvature of gate assembly. Make sure edges of product do not
Side extend back more than the mid-point of wedge. See Figure 7-10.

Top
No product edge
past this point

Figure 7-9.

No mid-range
support needed

Figure 7-10. Extended Narrow Wedge Setup

31 Converge 900 Manual

Combination Wedge When to use:

Product Length: 4 in. to 14 in. (10.16 cm to 35.56 cm)

Product Weight: Light to Heavy

Product Body: Flexible or Rigid

Product Friction: Low to High

Sample Products: Envelopes, card stock, and booklets

Setup guidelines:

Adjust the back wedge for proper support of the product off the table
top, without creating any pinch or stress points. The combination
Figure 7-11. wedge is a two piece design that allows the ability to run difficult ma-
terial with a full hopper. The top part of the wedge is designed to hold
the weight of the stack and allows the bottom wedge to support only a
light stack of product.

Figure 7-12. Proper Wedge Adjustment Figure 7-13. Proper Wedge Adjustment
(short product) (long product)

Converge 900 Manual 32

8 Mechanical Components

5 7,8

35 32

30 2

16
17
39
15

6 14
34 18

1
29

25
36 38 35
13
30
28
19
20
4
21 24

35
37
23
22

3
33 31

27
11

11

12 26

Converge 900
Exploded View
Assembly: 14600001

33 Converge 900 Manual

 Converge 900
Assembly: 14600001

Diagram Part
Number Qty. Description Number

1 1 Shell 51460052
2 1 Extended Narrow Wedge Assembly 63311212
3 1 Carriage C900 Assembly 14601101
4 1 Hold down Assembly, C900 14601108
5 1 Adv O-ring Gate Horizontal Adj HDO 87211007
6 1 Flight Sensor Assembly 14601110
7 1 Solid Gate Plate Assembly 70011004
8 1 Side Guide Assembly Kit 1424 64011017
9 1 Control Panel Assembly (Not Shown) 14601109
10 1 Operator Interface Assembly (Not Shown) 14601113
11 1 Knock Down Assembly 14601112
12 1 Encoder Assembly 14601111
13 1 Deflector Assembly 14601118
14 1 Side Cable Block 44947085
15 1 Side Cable Mount, LH 44947084
16 1 Side Adjust Block 44947086
17 1 Side Cable Mount, RH 44947107
18 2 Guard Cover Mount Shaft 44640011
19 2 Hinge Top Cover Mount Block 44640012
20 4 Alignment Block 51460053
21 1 Bulkhead union, Legris 51476005
22 1 Motor Mount 44630011
23 1 Servo Motor 44946005
24 1 Safety Interlock 70011007
25 1 Plug 44500061
26 2 Knock Down Mount 51460082
27 1 Knock Down Shaft 51460083
28 1 Top Protective Cover 51460080
30 2 Feeder Mount 51460081
31 1 Base Plate 51460070
32 1 C900 Cover Plate 51460049
33 1 Pulley 16T (16 x L37 Dia-.500KDFA) 43560097
34 1 Safety Interlock Key 44649010
35 6 Knob 23500092
36 1 Sheet Sensor Harness 14601119
37 4 Mounting Bracket 51460087
38 2 Mounting Shaft, 5/8 Dia 51460084
39 1 Board ST, I/O Distribution 44700021

Converge 900 Manual 34

 Extended Narrow Wedge Assembly: 63311212

Diagram Part
Number Qty. Description Number

2-1 2 Wedge Material Support 33560212

2-2 4 BHCS, 10-32 X 3/8 00002305

2-3 1 Shaft, Belt Tensioner 3/8 43555077

2-4 2 Bracket Extension Narrow Wedge 44633022

2-5 1 T-Nut Round 44633016

2-6 1 Block Hold Down Wedge 44633021

2-7 1 Knob, 3 lobe 10-32 x 5/8 44633033

35 Converge 900 Manual

 Extended Narrow Wedge Assembly: 63311212

Converge 900 Manual 36

 Carriage Assembly: 14601101

Diagram Part
Number Qty. Description Number

3-1 2 Side plate 51330002

3-2 2 Material Support Guide Rail 51460050
3-3 1 Alignment Rail, RH 51460059
3-4 1 Belt Tension Block, Left 51460013
3-5 2 Cup, Bearing R4 44846050
3-6 4 Bearing R4 44582021
3-7 1 Vacuum Lower Discharge Shaft 51460010
3-8 1 Support Bar 51460007
3-9 1 Round Support Shaft 51460011
3-10 1 Alignment Rail, LH 51460051
3-11 1 Belt tension Block, Right 51460012
3-12 1 Hold Down Support Block 51460061
3-13 1 Drive Shaft, ½ SS 23560211
3-14 1 Left Side Carriage Holder 51460069
3-15 2 Vacuum Belt Tension Plate 44485004
3-16 1 Drive Shaft 44700016
3-17 1 Shaft Block Support 51460071
3-18 1 Shaft Belt Support Belt 23500040
3-19 1 Idler Shaft 23560147
3-20 1 Manifold 44947038
3-21 1 Driven Tube 44947041
3-22 1 Right Side Carriage Holder 51460068
3-23 1 Pulley, 25T 51460002
3-24 1 Roller Pulley 51460015
3-25 1 Tensioner Shaft 51460014
3-26 1 Discharge Belt, 240XL150 X 51460072
3-27 6 Bearing R8-2RS 23500094
3-28 2 Bearing R6-2RS 23500095
3-29 2 Belt Tension Shaft 44852098
3-30 1 Pulley, 16T (16xL37 Dia .500KDFA) 43560097
3-31 2 Pulley, 24T (24xL37 Dia .500KA) 43560098
3-32 2 Handle, Ratchet 10-32 x 1/2 43555097
3-33 1 Belt, Feed BlueGum Vac Liner, 2.75Wx9.75 44947037
3-34 1 Timing Belt, 78XL037 Kevlar 23560078
3-35 2 SHCS, 10-32 X 1/2 00002815
3-36 10 SHCS, 10-32 X 3/8 00002810
3-37 2 ¼ Grip ring 00001105
3-38 2 SHCS, 10-32 X 5-16 00002809
3-39 4 FHCS, 10-32 x ½ 00002330
3-40 2 SHCS, 6-32 x 3/8 00003304
3-41 2 SHCS, 6-32 x 5/8 00003303
3-42 2 SHCS, 8-32 x 1 00002303
3-43 2 SHCS, 10-32 x 1 00002335
3-44 3 Woodruf Key, 1/8 x 3/8 00003351
3-45 1 Timing Belt, 160XL037 Kevlar 33560097

37 Converge 900 Manual

 Carriage Assembly: 14601101

Converge 900 Manual 38

 Hold Down Assembly: 14601108

Diagram Part
Number Qty. Description Number

4-1 1 Hold Down Block 51330006

4-2 6 Hold Down Shaft 51277052

4-3 12 Discharge Roller Collar 51277087

4-4 12 Bearing, R6-2RS 23500095

4-5 6 Spring Pin, 1/8 in 51312003

4-6 24 E-Clip, 3/8 00001150

4-7 1 Hold Down Cross Support 51460008

4-8 2 Hold Down Support Block 51460086

4-9 1 SHCS, 10-32 x ¾ 00002325

4-10 1 Sensor Mount 51460004

4-11 1 FHCS 10-32 x ¾ 00002338

4-12 2 Knob, Medium 23500092

4-13 2 Spring, Heavy 51460073

4-14 4 Spring, Hold Down 51328001

4-15 2 SHCS, 10-32 x 1 1/4 00002312

39 Converge 900 Manual

 Hold Down Assembly: 14601108

Converge 900 Manual 40

 Advancing O-Ring Gate with Horizon Adjust, HDO: 87211007

Diagram Part
Number Qty. Description Number

5-1 1 Cylinder Gate Advance 44872004

5-2 2 Adjust Screw 44872005
5-3 2 Roller 44872003
5-4 2 SS 10-32 x 3/8 44872007
5-5 2 Adjuster Side Plate 44872002
5-6 4 Spring Roller Pin 00001161
5-7 1 Gate Lift Shaft Mount 15000001
5-8 1 Gate Compression Spring 23500083
5-9 1 Gate Lift Shaft 23560084
5-10 1 Cylinder Gate Spring Tension 23500019
5-11* 1 Adjust Knob Sleeve 23500037
5-12* 1 SHCS, ¼-28 x 1 00002400
5-13* 1 Knob w/o screw 23500077
5-14* 1 Gate Adjust Knob Label 23500084
5-15 1 Belt Indexer Bracket 44657005
5-16 1 Pin Roll Cam 44657003
5-17 2 O-Ring Take up Roller 44657002
5-18 1 Belt Indexer Shaft 44657008
5-19 1 Belt Indexer Center Hub 44657009
5-20 2 E-Clip ½ 00001155
5-21 1 Belt Indexer Spacer 44657010
5-22 1 BHCS, 8-32 x ½ 00002302
5-23 1 Knob Handle, 10-32 44657007
5-24 2 Shoulder Screw, 3/16 x 1/8 8-32 x 3/16 00003321
5-25 2 Shoulder Screw, 3/16 x 1/4 8-32 x 3/16 00003320
5-26 1 BHCS, 10-32 x 1 00002340
5-27 1 BHCS, 10-32 x ½ 00002334
5-28 12 O-Ring Advance Gate, HDO 44657011

*5-11 thru 5-14 can be ordered as assembly #23511037

41 Converge 900 Manual

 Advancing O-Ring Gate with Horizon Adjust, HDO: 87211007

Converge 900 Manual 42

 Flight Sensor Assembly: 14601110

Diagram Part
Number Qty. Description Number

6-1 1 Sensor Mounting Block 51460065

2 SHCS, 10-32 x ½ 00002815

6-2 1 Scanner Arm 51208166

6-3 1 Fiber Optic Bushing 51460063

6-4 1 Fiber Optic Sensor w/Cable 51460074

6-5 1 Fiber Optic Amplifier 51460075

2 BHCS, 8-32 x ¾ 00003322

6-6 1 Fiber Optic Sensor Mount 51460064

1 SHCS, 8-32 x 3/8 00002813

6-7 1 Clamp, Cable Circular 4 Pin AMP 53500506

6-8 1 Plug, 4 Pin 206429-1 AMP 53500504

6-9 3 Pin, Contact Male, 24-20 AWG AMP 53500502

43 Converge 900 Manual

 Flight Sensor Assembly: 14601110

Converge 900 Manual 44

 Solid Gate Plate: 70011004

Diagram Part
Number Qty. Description Number

7-1 1 Cover Side Guide Adjustment 44700014

4 BHCS, 10-32 x 3/8 00002805

7-2 1 Bar Lower Gate Support 44700011

2 Hook Gate J 15000007
2 SHCS, 8-32 x 5/8 00002215

7-3 2 Rail Side Guide Support 44700012

7-4 2 Side Guide Adjustment Block 44646001

4 Screw Socket Set, ¼-20 x ¼ 00002205

7-5 1 Guide Stationary Block Side 44646002

7-6 4 Rack 44700013

7-7 2 Lower Spacer 44646015

7-8 1 Block Adjustment Reference 44646004

4 BHCS 10-32 x 3/8 00002805

7-9 1 Shaft Pinion Adjustment 44646005

7-10 1 Solid Gate Plate 44700005

7-11 4 Flat Hd Screw, 10-32 x 3/8 00002234

7-12 2 Knob, Plastic, 10-32 44681021

2 Socket Set Screw, 10-32 x 1½ 00003313
2 Upper Spacer 44646016

7-13 1 Knob, 5 lobe 44646009

1 Upper Retainer Spring 44646008
1 Lower Retainer Spring 44646007
1 Compression Spring 44646013

7-14 2 Flat HD Screw, 10-32 x ½ 00002830

45 Converge 900 Manual

 Solid Gate Plate: 70011004

Converge 900 Manual 46

 Side Guide Kit: 64011017

Diagram Part
Number Qty. Description Number

8-1 1 Side Guide Left 1424 44640017

1 Label Warning Belt Pinch Point 44600005

8-2 1 Side Guide Right 1424 44640018

1 Label Warning Belt Pinch Point 44600005

8-3 2 Guard Rear Accordion 44600001

8-4 4 Screw Flat Head 10-32 X 1/2” LG 00002830

47 Converge 900 Manual

 Side Guide Kit: 64011017

Converge 900 Manual 48

 Control Panel Assembly: 14601109
Diagram Part
Number Qty. Description Number

9-1 1 Control Box 51460048

9-2 12 in Din Rail 53500154
2 BHCS, 8-32 x 3/8 00002306
9-3 2 Plate, Anchor End 53500156
9-4 1 Relay, PLC Form C 51241005
9-5 4 Relay, PLC Solid State 51241006
9-6 8 Terminal Block 53500153
1 Bridge Bar 53500157
2 Barrier Plate 53500155
9-7 1 ServoStar SC Drive 6A 51327021
9-8 1 Terminal Block, WAGO Green/Yellow 51327028
1 Terminal Block, WAGO Side Plate 51327009
9-9 1 Power Supply, Switching 24VDC 50 Watt 53500598
9-10 2 Fan Guard 53500281
8 BHCS 8-32 x 3/8 00002306
9-11 1 Harness, Remote Operator Station 14601102
4 BHCS 8-32 x 3/8 00002306
9-12 1 Harness Encoder 14601105
4 BHCS 6-32 x 3/8 00003314
9-13 1 Module, AC Power Entry w/o Fuse 44649034
2 Fuse, 10A 125V Fast GMA 5x20mm 53500455
2 Terminal, female 44649046
9-14 1 Flight Trigger Harness 14131106
4 BHCS 6-32 x 3/8 00003314
9-15 1 System I/O Harness 14131108
4 BHCS 8-32 x 3/8 00002306
9-16 1 Mount, Side Cable, RH 44947107
1 Side Adjust Block 44947086
2 FHMSPHS/S 6-32 x 1 ¾ 00002236
9-17 1 Mount, Side Cable, LH 44947084
1 Block Side Cable 44947085
9-18 1 Bridge, Snap in 51241013
N/S 1 Harness, DC Power 14131111
N/S 1 Harness, AC Power 14601104
N/S 1 Harness, DC Power 14601107
N/S 1 Harness, Power Ground 14601115
N/S 2 Harness, Secondary Ground 14601116
N/S 1 Feeder Interconncet Cable 14601117
N/S 1 Servo Set Kollmergen Cable 44946006
N/S 1 Power Cord, 115 VAC IEC 53500002
N/S 1I/O Cable 64911012

49 Converge 900 Manual

 Control Panel Assembly: 14601109 (continued)

Converge 900 Manual 50

 Operator Interface Assembly: 14601113

Diagram Part
Number Qty. Description Number

10-1 1 Enclosure Remote Operator Box 51460097

10-2 1 Cover, Remote Operator Box 51460099

10-3 4 BHCS, 10-32 x 3/8 00002805

10-4 2 Harness Speed Pot 14131114

10-5 1 Push Button Square, Green 51413006

10-6 2 Knob, Black, .75 x .75 44675030

10-7 1 Push button, Square, Amber 51379089

10-8 1 Push Button, Square, Blue 51379088

10-9 1 Red Push Button Extended 51241012

10-10 1 Cable Remote Operator Station 14601103

10-11 1 Contact Block NC 51327025

N/S 1 Lamp, LED 24V Green 51379092

N/S 1 Lamp, LED 24V Amber 51379093

N/S 1 Graphics set 51460098

51 Converge 900 Manual

 Operator Interface Assembly: 14601113

Converge 900 Manual 52

 Nip Roller Assembly: 14601112

Diagram Part
Number Qty. Description Number

11-1 1 Knock Down Block 51460042

11-2 1 Knock Down Shaft 51460043

11-3 1 Knock Down Roller 51460044

11-4 2 Bearing, R8-2ZZ 51460093

11-5 2 E-clip, ½ 00001155

11-6 2 Dowel Pin 51450005

11-7 1 Handle, Rathchet 10-32x 1/2 43555097

11-8 2 SHCS, 4-40 x 5/16 00003327

11-9 2 Hold Down Spring 51277076

53 Converge 900 Manual

 Nip Roller Assembly: 14601112

Converge 900 Manual 54

 Encoder Assembly: 14601111

Diagram Part
Number Qty. Description Number

12-1 1 Encoder Mount 51460005

12-2 1 Encoder Arm 51460066

2 FHCS, 10-32 x ½ 00002330

12-3 1 Encoder 2048 PPR 51460077

4 SHCS, 6-32 x ½ 00002212

12-4 1 IGUS Bearing Sleeve for 5/8 Dia shaft 44947015

12-5 1 IGUS Bearing Sleeve for 1/2 Dia shaft 51460088

12-6 1 Encoder Wheel 51460067

12-7 1 O-ring, Encoder 51460090

12-8 2 Solid Clamp Collar, 1/2 44635023

12-9 2 Solid Clamp Collar, 5/8 51460089

N/S 1 Encoder Cable 14601106

55 Converge 900 Manual

 Encoder Assembly: 14601111

Converge 900 Manual 56

 Deflector Assembly: 14601118

Diagram Part
Number Qty. Description Number

13-1 1 Deflector Plate Mount 51460091

13-2 1 Deflector Plate 43555078

2 BHCS, 10-32 x 3/16 00003339

13-3 2 Knob, 6-32 x 3/8 435SO269

57 Converge 900 Manual

 Deflector Assembly: 14601118

Converge 900 Manual 58

9 Electrical Components

59 Converge 900 Manual

Converge 900 Manual 60
61 Converge 900 Manual
Sensorless Feed Trigger Connecting to the Trigger Input
Wiring
Objective
The information in this section provides an overview of how to
interface to the Converge 900 trigger input without using an external
photoelectric sensor.

! ! Procedure
This unit operates on 115VAC or 230VAC
electrical power. Bodily contact with these 1. Remove any existing trigger sensor from the control panel.
voltages can result in serious injury or death.
Always disconnect the AC inlet power cord before 2. Connect the sensorless trigger cable to the feeder trigger input.
performing any service activity.
3. Wire the sensorless cable to the host equipment. The host
equipment triggering the feeder to start is to be a dry contact
of a relay. Any other equipment must not power this input.
When the host equipment relay or contacts close the feeder
should trigger.

Host
Control

Figure 9-4. Field Wiring.

Converge 900 Manual 62

I/O Cable Wiring

! !
A qualified service technician should perform the
electrical integration of this equipment to the host
machinery. Always disconnect the AC inlet power
cord before performing any service activity.

External I/O Cable Wiring Table

Pin # Wire Color Function Relay # Relay Type
1 Brown Miss/Double Output (-) 0419 SSR
2 Red Miss/Double Output (+) 24 VDC
3 Orange +24 VDC Supply (150ma. max) -
4 Yellow Done Output (-) 0510 SSR
5 Green Done Output (+) 24 VDC
6 Blue Ready Output (-) 0509 SSR
7 Violet Ready Output (+) 24 VDC
10 Black & Shield DC Supply Ground -
13 Red /Yellow External Trigger Input (-) 0715 SSR
14 Red / Green External Trigger Input (+) 24 VDC

Figure 9-5. External I/O Cable, 649-11-012

63 Converge 900 Manual

AC Power Harness Wiring

Figure 9-6. Harness, AC Power

Encoder Harness Wiring

Figure 9-7. Harness, Encoder

Converge 900 Manual 64

Encoder Cable Wiring

Figure 9-8. Cable, Encoder

DC Power Harness Wiring

Figure 9-9. Harness, DC Power

65 Converge 900 Manual

Feeder Interconnect Cable Wiring

Figure 9-10. Cable, Feeder, Interconnect

Sheet Sensor Harness Wiring

Figure 9-11. Sheet Sensor Harness

Converge 900 Manual 66

Remote Operator Station Cable Wiring

Figure 9-12. Cable, Remote Operator Station

Remote Operator Station Harness Wiring

Figure 9-13. Harness, Remote Operator Station

67 Converge 900 Manual

Power Ground Harness Wiring

Figure 9-14. Harness Power Ground

Secondary Ground Harness Wiring

Figure 9-15. Harness Secondary Ground

Converge 900 Manual 68

Operator Interface Wiring

69 Converge 900 Manual

10 Technical Troubleshooting
The tables that follow are designed to be a “quick lookup” for a problem you may be having. Wiring diagrams also contained in
this manual are provided for reference and component recognition and connection during troubleshooting.

General Troubleshooting Terms

! ! !
Only a qualified technician should perform electrical troubleshooting activities. This unit operates on 115V or 230V electrical
power. Bodily contact with these voltages can result in serious injury or death.

Table 10-1. Quick-Look Troubleshooting

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. Remove power cord from AC input switch module and disconnect the four connec-
tions to AC loads located on the back of the module inside the feeder.

4. Check the two fuses located inside the feeder’s input power module. BOTH fuses
IMPOR TANT must be present and test good. Note: This power module is designed to hold 5mm x
20mm fuses, as well as 1.25" x .25" fuses. The machine ships from Streamfeeder’s
A visual inspection will not facility with 5mm x 20mm fuses.
always be sufficient to determine
fuse integrity. a. Observe the voltage label showing through the window on the fuse housing for
proper orientation when the holder is re-inserted.
b. A small screwdriver inserted under the tab will allow you to pry open the fuse
After power has been applied, housing. Remove the red fuse holder. If the smaller 5mm x 20mm fuse is pres-
allow 20-30 seconds for the ent, verify that the metal tab “finger” is holding the fuse in the forward position
feeder to power up. and has not allowed the fuses to slide back toward the outside of the feeder
and away from where contact with the metal pressure points inside the module
body is made.
c. Use an ohmmeter to test the fuses. If necessary, replace with fuses of the same
rating only.

5. Reconnect power cable and with power switch turned “On,” check for presence of
AC at the output connectors on the back of module.

6. If steady AC power is not measured as in the previous step, the module’s internal
contacts are most likely worn, and the module must be replaced.

Fuses blow on power up 1. Install known good fuses of same rating only.

2. Disconnect all AC loads from the input:

NO TE a. The Servo Amplifier.

b. The DC Supply.
A fuse failure indicates a problem
with the last item connected 3. Reconnect AC loads one item at a time while alternately applying power between
before failure occurs. new connections. Connect each load as follows one at a time to determine the faulty
part:

a. Connect DC Power Supply to the AC input module.

b. Connect Servo Amplifier.

Converge 900 Manual 70

Table 10-1. Quick-Look Troubleshooting (continued)
Problem Solution
Cannot clear fault 1. Make sure the Safety Interlock (located under the front guard) is fully engaged.

2. Make sure DC Power Supply Harness integrity is intact.

3. Jumper J3 pins 1 and 2 on the Breakout Board inside the feeder.

a. If amber light continues flashing after pressing the reset button, check the integ-
rity of cable 14601117 Feeder Interconnect.

b. If amber light turns off after pressing the reset button, check the integrity of har-
ness 70011007 Safety Interlock.

Flight photo sensor 1. Test the integrity of the wiring harness leading to the flight sensor input connector.
does not trigger feeder
a. Measure 24VDC across pins 1 and 3 on the 4-pin circular connector. If
voltage is not present, repair broken wire.
NO TE b. Jumper pin 1 to pin 2. This should trigger a cycle. If not, repair broken
wire.
• Pin 1 is 24VDC.
• Pin 2 is the signal input pin. 2. Connect “flight” sensor to 4-pin circular connector and verify the sensor is getting
• Pin 3 is DC ground. power by checking the status LEDs on the sensor body for illumination. If not, check
• Pins 1 and 3 give life to the sensor leads for integrity.
sensor.
• Pin 2 requires 24VDC to be 3. Test the flight sensor for a switching output. If not present, replace flight sensor.
applied to it when a “flight” is
present and the output of the
sensor is on.

71 Converge 900 Manual

© 2009 Thiele Technologies, Inc. - Streamfeeder
Printed in the USA.