Superior Xtreme Series User manual

Xtreme ™ Series
Touchscreen Manual
Software version 4.2.XX
Why Would You Go Anywhere Else?
Superior PAPER HANDLING SOLUTIONS
Have this information ready when calling in about your equipment:
Model: Serial #:
PLC firmware version: HMI firmware version:
Warranty Start Date:
© Superior Paper Handling Solutions, Inc. All rights reserved.
Illustrations in this guide are for reference only and may depict optional features that are available
at additional costs.
Superior Paper Handling Solutions, Inc.
14414 21st Avenue North
Plymouth, Minnesota 55447 – USA
Tel. [phone]
Fax. [phone]
Email. [email protected]
Web. www.Superior-PHS.com

CONTENTS
SCREEN LAYOUT .......................................................................................................... 3
MECHANICAL PUSH BUTTONS .................................................................................... 4
POWER UP SCREEN ..................................................................................................... 4
RUN SCREEN ................................................................................................................. 5
5_JOB SETUP SCREEN ..................................................................................... 6
1_SETUP 1 SCREEN ...................................................................................................... 7
2_SETUP 2 SCREEN ...................................................................................................... 8
3_SETUP 3 SCREEN ...................................................................................................... 9
4_COUNTERS SCREEN ................................................................................................. 9
6_DROPPER SELECT SCREEN .................................................................................. 10
BD/RD SELECT SCREEN ................................................................................. 10
MDRD SELECT SCREEN ................................................................................ 11
SD DROPPER SELECT SCREEN ................................................................... 12
2 STAGE DROPPER SELECT SCREEN ......................................................... 13
7_INPUTS 1 .................................................................................................................. 14
8_INPUTS 2 .................................................................................................................. 14
9_OUTPUTS 1............................................................................................................... 14
10_OUTPUTS 2............................................................................................................. 14
MESSAGE and ERROR DISPLAYS .............................................................................. 15
OPERATORS NOTE PAGE
page 2

RUN COUNTER DROPPER INPUTS/OUTPUTS SETUP
POWER UP
Brings you to the POWER UP Screen Brings you to the RUN Screen Brings you to the previous numbered Screen Brings you to the next numbered Screen Brings you back to the main numbered Screen you started from
BELOW COMMANDS WORK WITHIN THE
NUMBERED SCREENS 1-10:
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© 2005-2015 Superior-PHS
Superior PAPER HANDLING SOLUTIONS
HMI and PLC firmware versions
HOME [POWER UP SCREEN]
RUN: Takes operator directly to Run Screen
COUNTER: Takes operator directly to 4-Counters Screen
DROPPER: Takes operator directly to 6-Dropper Select Screen
INPUTS/OUTPUTS: Takes operator directly to 7-Inputs 1 Screen
SETUP: Takes operator directly to1-Setup 1 Screen
NOTE: All settings from previous power down will be retained
page 4
Stop/Reset Button If an error occurs this push button will illuminate.
It will also light when the stop is used to stop the feeder. Clear all errors if
present and push this button to move the feeder to a Ready stage.
Cycle Button If the feeder is Ready than this push button will illuminate.
From here pressing the button will command a start cycle.
Jog Button The feeder will advanced when the Jog button is pressed.
The feeder will continuously run when the jog button is activated. This
option is typically used when setting up product in the feeder or clearing
any product under the Separator. While holding down the Jog button, you
can adjust the Separator and feed product until the product feeds consistently.
MECHANICAL FRONT PANEL PUSH BUTTONS

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RUN
JOB SET: Takes operator directly to 5-Job Set Screen
MODE [LOCAL or SYSTEM]: Local Mode is the standard
setting. Push to toggle between System and Local Mode.
To run the feeder in a stand alone operation this
must show Local Mode. (Green displayed)
CONTINUOUS MODE: Display only. If the feeder is in
Continuous Mode this display will appear. (Green displayed)
CYCLE SPEED: Allows user to set feeder speed. 100 is
equal to maximum speed.
RESET COUNT: Pressing this button will reset the Actual Count display. If the feeder has stopped in the
middle of completing a Batch, pressing this reset will start the batch count over.
BATCH SIZE: Pressing this button will allow a user to set the batch size.
[KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ]
ACTUAL COUNT: Display only. Displays the count as the feeder is running. It will count up to your batch
size and reset to zero when the batch is complete. If the feeder errors or stops before the batch cycle
completes, this number will reflect what has been counted. Starting the feeder again will finish the batch.
NOTE: If using the EXT I/O to remotely STOP, RESET and CYCLE the feeder; Upon an error
or remote stop, the Actual Count will always reset to zero and not retain the partial batch. If required to retain
the partial batch, then remotely PAUSE/RESUME the feeder through the EXT I/O.

© 2005-2015 Superior-PHS
Superior PAPER HANDLING SOLUTIONS
page 6
NOTE: When the Job Set is turned on and the Total Count reaches zero a display will appear
stating the Job Set is complete. In order to initiate another batch cycle you must turn the Job Set off.
5 - JOB SET
DROPPER: Takes operator directly to 6-Dropper Select
Screen
TOTAL COUNT: Enter the Job size. [KEYBOARD ENTRY
-MIN/MAX WITHIN KEYBOARD DISPLAY ]
JOB SET ON/OFF: When using the Job Set function, you
will be able to set a Total Count that will stop the feeder
when reached (i.e. while batching 50 piece sets, you only
5000 sheets batched out)
NOTE: If Total Count is at zero when Job Set is turned on
it will display Job Complete. Enter count first
ACTUAL COUNT: Display only. Does not function in Continuous Mode. This will display the Actual Count
where the feeder is at within a batch. Mirrored display to the Actual Count from the Run Screen.
BATCH COUNT: Display Only. Does not function in Continuous Mode. This will display the number of
batches completed by the feeder. The Reset button allows this field to clear to zero when pressed.
NOTE: The Run Screen does not display accumulation of Batch Counts. Because this field doesn’t require
the Job Set to be turned on, acquiring Batch Counts can be retrieved in this 5 - Job Set Screen even when
the Job Set function is not being used. The 4 - Counters Screen also displays the Batch Count field. They
are also mirrored displays and the Reset buttons from either screen will zero it.
COUNT to TOTAL : Display only. Displays the quantity left until the Job Set is complete.S

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1 - SETUP 1
TRIGGER DELAY: Enter the delay time in seconds
[KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD
DISPLAY ] Used only with trigger sensor or external
CYCLE input.
SKIP FLIGHT: Enter the number of skips per trigger.
[KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD
DISPLAY ] Used to skip the feeder from firing every
on every trigger. (i.e every third pocket)
SLOW START or STOP function: The next three functions control the settings with regards to
setting a slower speed when starting or stopping the feeder. At high speeds this will assist
controlling product to stop consistently and also limit the possible skewing of product as the
feeder advances at startup to a high speed.
SLOW STOP COUNT: Set how many pieces at the end of a batch will run at the slow speed.
[KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ]
SLOW START COUNT: Set how many pieces at the beginning of a batch will run at the slow speed.
[KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ]
NOTE: The slow function is turned ON when a value of 1 or greater is recorded at either two of the count
buttons above. In order to not use the slow function, a value of zero must be recorded in those settings.
CONTINUOUS MODE: Set ON/OFF from here. The Run Screen has a display and this button will
illuminate green when the condition is ON.
PAUSE RESUME: Set ON/OFF from here. The Pause/Resume function is used to automatically keep
cycling the feeder with a period of time between batches. This button will illuminate green when the
condition is ON.
PAUSE RESUME TIME: Enter the time value in seconds. This represents the time between the batch
cycles. [KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ]
SLOW SPEED : Set the speed of the feeder when either the Slow Start or Slow Stop is activated.
[KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ] Recommended to be less than half
the speed recorded in Cycle Speed from the Run Screen.

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Superior PAPER HANDLING SOLUTIONS
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2 - SETUP 2
DOUBLE DETECT: Allows user to turn ON/OFF the
Double Detect. Green illumination when ON.
MISS DETECT: Allows user to turn ON/OFF the Miss
Detect. This function monitors that the batch cycle
has completed before receiving another trigger or
remote START. Green illumination when ON
BUSY/DONE VACUUM: Allows user to turn ON/OFF
the Busy/Done or Vacuum function. Read below for
explanation of functions. Green illumination when ON
BUSY/DONE or VACUUM function: There is a particular I/O point in the Ext Interface that will
change its state with regards to whether the motor on the feeder is running or not. Thus a
system controller could monitor the feeder and know when it has completed its batch cycle.
The Vacuum application is considered when an optional venturi vacuum setup is purchased
with the feeder. This allows the vacuum to only operate when the feeder is running. EITHER
one condition or the other is used as a scenario. Both situations use the same I/O point.
TIME OUT function: The next three functions control the settings with regards to setting the
Time Out function. This is used to monitor the sheet sensor for clear and block conditions.
(Feeder empty or Jammed conditions)
TIME OUT EYE CLEAR: Enter the time in seconds. An error will occur if the sheet sensor stays open
the duration of time set. [KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ]
TIME OUT EYE BLOCKED: Enter the time in seconds. An error will occur if the sheet sensor stays
blocked the duration of time set. [KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ]
NOTE: The time set for blocked has to be large enough to allow one piece to advance completely
through the sheet sensor. This may have to set bigger for large product running at slow cycle speeds.
LOW STACK function: The next three functions control the settings with regards to setting the
Low Stack function. This function is only used if the feeder was purchased with a Low Stack eye.
LOW STACK WARN: Set how many pieces once the Low Stack eye clears to when the warning amber
light will flash (Requires purchase of light tower with feeder) [KEYBOARD ENTRY-MIN/MAX WITHIN
KEYBOARD DISPLAY ]
LOW STACK HALT: Set how many pieces once the Low Stack eye clears to when the feeder will stop.
Product must be filled again to cycle the feeder. [KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD
DISPLAY ]
TIME OUT: Allows the user to turn ON/OFF the Time Out function
LOW STACK : Allows the user to turn ON/OFF the Low Stack function. Green illumination when ON
. Green illumination when ON

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3 - SETUP 3
and cycles at the speeds programmed below.
TAMPER RETURN DELAY: Enter the return time in seconds
for the actuator arm. [KEYBOARD ENTRY-MIN/MAX
WITHIN KEYBOARD DISPLAY ]
TAMPER EXTEND DELAY: Enter the extend time in seconds
for the actuator arm. [KEYBOARD ENTRY-MIN/MAX
WITHIN KEYBOARD DISPLAY ]
NOTE: General settings will have these extending and
returning times around .2-.5 seconds, dependent on the
air volume and tamping speed requirements.
MANUAL CYCLE: Manually activates the wedge tamper
WEDGE TAMPING function: This function along with the mechanical assembly will tap the
product while stacked in the hopper. This assists in funneling the product down into the separator
assembly for better performance.
# OF SHEETS BETWEEN TAMPS: Set how many pieces will run between tamping cycles.
[KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ]
TAMPS # OF TIMES : Set how many times the tamper will extend and return during its tamping cycle.
[KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ]
TAMPER DISABLED : Turn the Tamper ON/OFF. Green Illuminate when the function is enabled.
NOTE: If you did not purchase a Wedge Tamper, disregard this setup page and leave it disabled.
4 - COUNTERS
products through the sheet counter. RESET button sets
to zero
BATCH COUNTER: Display only. Counts the number of
batches completed through the sheet counter. RESET
button sets to zero
TOTAL PIECE COUNTER: Display only. Counts the
number of products through the sheet counter.
NOTE: This Display is not resettable. It will reflect the
number of pieces through the feeder at any given time
PIECE COUNTER: Display only. Counts the number of

© 2005-2015 Superior-PHS
Superior PAPER HANDLING SOLUTIONS
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6 - DROPPER SELECT
BD/RD DROPPER: Allows user to turn ON/OFF. Green
illumination when ON.
BD/RD DROPPER SETUP: Takes you to Setup page.
SD DROPPER: Allows user to turn ON/OFF. Green
illumination when ON.
SD DROPPER SETUP: Takes you to Setup page.
MDRD DROPPER: Allows user to turn ON/OFF. Green
illumination when ON.
MDRD SETUP: Takes you to Setup page.
2 STAGE SETUP: Takes you to Setup page.
NOTE: If you did not purchase a dropper, disregard this setup page and leave all OFF.
NOTE: Only one Dropper can be ON at one time.
BD/RD SETUP
BACK: Takes user back to 6 - Dropper Select Screen
DROPPER EXTEND DELAY: Sets the time in seconds
the period the dropper stays open. [KEYBOARD ENTRY
-MIN/MAX WITHIN KEYBOARD DISPLAY ]
FEEDER DELAY: Sets the time in seconds the feeder
will delay before feeding the next batch. [KEYBOARD
ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ]
MANUAL CYCLE: Cycles the dropper once.

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MDRD SETUP
BACK: Takes user back to 6 - Dropper Select Screen
Feeder Start Delay: This delay allows the feeder to pause between receiving a signal and cycling. This
allows the dropper time to return to a closed or near-closed position before feeding into the dropper.
Note: When dropper is “on' and “manual” is selected, the “Extend, Retract, and Cycle” buttons are
shown.
Dropper Auto/Manual Button: Press Auto/Manual button to toggle between dropper being in Auto Mode
and Manual Mode. When in the Auto Mode, when Feeder Cycle Button is pressed or a Trigger Signal is
received, the dropper will retract, then extend, then feeder will feed next batch. When in the Manual Mode
and Dropper is ON, system will not cycle as in Auto Mode. System will ONLY allow operator to press
Dropper Cycle Button. See Section below.
Dropper Cycle and Open/Close Button: When Dropper is ON and Dropper is in Manual Mode, this
button will manually cycle the dropper forks one half of a cycle. If the button is pressed when dropper forks
are fully extended, forks will fully retract into the base. If the button pressed with forks fully retracted into the
base, forks will fully extend out. If the button pressed with forks in between fully retracted and fully
extended, dropper forks will fully retract into base. This button will only activate the dropper forks and it will
not activate the feeder. Note: This feature is active with the cover open if it's in manual mode.
Delay Before Drop: This timing feature allows the
operator to create a delay between when the dropper
receives a signal and when the dropper retracts. This
delay allows the operator to guide where they want the
stack to fall into a pocket of a lugged conveyor.
Dropper Open Dwell: This setting will depend on the
stack height in the dropper. Smaller stacks need less
time to finish exiting the dropper, while taller stacks may
need the dropper to stay open longer to complete the
drop. Increase this delay to keep the dropper open
longer.

© 2005-2015 Superior-PHS
Superior PAPER HANDLING SOLUTIONS
SD DROPPER SETUP
MANUAL CYCLE: Manually activates the dropper sides to
open. If the button is held the sides stay open.
DROPPER EXTEND DELAY: Sets the time in seconds
the period the dropper stays open. [KEYBOARD ENTRY
-MIN/MAX WITHIN KEYBOARD DISPLAY ]
DROPPER DONE DELAY: Sets the time in seconds the
feeder will delay before feeding the next batch. If using
the 2 stage Dropper, this signal is the delay before the
2nd stage begins. [KEYBOARD ENTRY-MIN/MAX
WITHIN KEYBOARD DISPLAY ]
BACK: Takes user back to 6 - Dropper Select Screen
DROPPER TAMPING function: This function along with the mechanical assembly will tap the
product while stacked in the dropper. This assists in jogging the product and squaring the
counted stack before dropping it onto a conveyor line.
TAMPER RETURN DELAY: Enter the return time in seconds for the actuator arm. [KEYBOARD ENTRY
-MIN/MAX WITHIN KEYBOARD DISPLAY ]
TAMPER EXTEND DELAY: Enter the extend time in seconds for the actuator arm. [KEYBOARD ENTRY
-MIN/MAX WITHIN KEYBOARD DISPLAY ]
NOTE: General settings will have these extending and returning times around .2-.5 seconds, dependent
on the air volume and tamping speed requirements.
TAMPS # OF TIMES : Set how many times the tamper will extend and return during its tamping cycle.
[KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ]
TAMPER DISABLED : Turn the Tamper ON/OFF. Green Illuminate when the function is enabled.
NOTE: If you did not purchase a dropper tamper with your SD dropper, disregard the
tamper setup controls on this setup page. Leave Tamper Disabled.
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2nd STAGE DROPPER SETUP
2ND STAGE DROPPER DISABLED: Turn the Dropper
ON/OFF. Green Illuminate when the function is enabled.
RESET 2-STAGE: Resets the 2nd Stage Dropper to
its home position.
1ST STAGE DELAY:
BACK: Takes user back to 6 - Dropper Select Screen
CLOSE Sets the time in seconds
the dropper plate is needed to close before receiving the
next feeder batch. If using the 2 stage Dropper, this signal
is now the trigger delay.
[KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD
DISPLAY ]
TESTING functions: The following functions are used to test the 2nd Stage Dropper. Some
of the testing features require the the dropper to be enabled and some will not.
1ST STAGE DROP OPENED: This function ONLY works when the 2nd Stage Dropper is disabled.
This button will toggle the Dropper plate from open to closed
RAISE: This function ONLY works when the 2nd Stage Dropper is disabled.
Pressing the RAISE button. This will raise the dropper plate location to it’s highest position. This is
considered home.
INDEX DOWN: This function ONLY works when the 2nd Stage Dropper is disabled.
Press the INDEX DOWN button. This will step the dropper plate location ½” from the home position.
Pressing the INDEX HOLD again will move it another ½”. A total of five moves can be stepped
manually. Then the RAISE function must be used to bring it home.
CYCLE: This function ONLY works when the 2nd Stage Dropper is enabled. From the home
position the 2nd Stage dropper will perform 5 INDEX DOWN steps and then RAISE and return Home.
It will place the feeder in a stopped mode while this test runs
1ST STAGE OPEN DELAY: Sets the time in seconds the period the dropper plate stays open.
[KEYBOARD ENTRY-MIN/MAX WITHIN KEYBOARD DISPLAY ]
NOTE: If you did not purchase a 2nd Stage Dropper with your SD dropper, disregard this
setup page. Leave the 2nd Stage Dropper Disabled.
page 13

© 2005-2015 Superior-PHS
Superior PAPER HANDLING SOLUTIONS
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7 - INPUTS 1/8 - INPUTS 2
INPUTS screens: Screens 7 and 8 are used by maintenance to troubleshoot the PLC inputs.
Each line item represents an input on the controller. A positive read is when the indicator
light on screen illuminates next to the item you are troubleshooting. For assistance please
contact the manufacturer.
9 - OUTPUTS 1/10 - OUTPUTS 2
OUTPUTS screens: Screens 9 and 10 are used by maintenance to troubleshoot the PLC
outputs. Each line item represents an output on the controller. To activate, you must turn
ENABLE OUTPUT FORCE ON. The button will illuminate green when on. Here you can
test certain indicator lights and motor commands within the feeder and droppers. For
assistance please contact the manufacturer. ***WARNING***do not leave the ENABLE
OUTPUT FORCE ON for it will affect the feeder performance.

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MESSAGE DISPLAYS
ERROR DISPLAYS
- The Job Set will not work with a dropper attached to the feeder. Turn one off
- You have completed a Job Set, turn it off in Screen #5
- A second trigger was received before the current cycle could finish. Slow down
what is triggering the feeder or turn your feeder up to complete the batch cycle sooner
- The Double Detect determined a Fault. Reset your mechanical setup to pull only
one piece
- The Feeder Servo has faulted. Allow ten seconds and then hit the red reset.
Check mechanically the feeder to verify all moving mechanics are good
- Only one Dropper can be turned on in #6 Screen. With the error on screen
you will have to turn one off. There is no reset
- The Batch count request is too large for the dropper to handle
- A Time Out has occured. Verify your settings in #2 Screen or setup your feeder
better so overlaps and skipped feeds are eliminated
- Low Stack error. Fill the hopper so that the Low Stack eye is covered
- The Dropper was left in manual mode. Correct and enable it to Auto
- Close the Cover on the Dropper
- Within the dropper, the Retract function has faulted. Check mechanically
- Within the dropper, the Extend function has faulted. Check mechanically
- Within the dropper, a fault has occurred. Check mechanically
- Press the Red STOP/RESET mechanical push button
- Feeder is running.
- Waiting for a trigger
- Feeder must always have one piece first under the sheet sensor.
If not the feeder will first stage a piece on its first trigger, then
perform a cycle on the next trigger
- Feeder is waiting for the dropper to drop its stack before it can
initiate another cycle
- Used within the Dual Stage Dropper. When Dropper is full it will
pause feeder and complete the stack on the next trigger
- Servo has faulted. refer to error displays to correct
- Press the Red STOP/RESET mechanical push button
- Low stack Halt, refer to error displays to correct
- Low Stack has approached its warning stage